In July, the monthly production of ferrochrome at PT Qingfeng Ferrochrome Indonesia (QFF) in the Morowali Industrial Park, Indonesia, surged to 90,000 mt, with comprehensive electricity consumption steadily controlled within 3,150 kWh/mt, setting a new performance record in a stepped-up manner. This milestone achievement was inseparable from the continuous breakthroughs at key periods earlier: in March, production first exceeded 87,000 mt, setting a new high since the plant's establishment and laying a solid foundation for capacity enhancement; in June, the company's physical inventory and specific electricity consumption for smelting both dropped below 3,000 kWh/mt, achieving a historic breakthrough.
The core driving force behind these successive breakthroughs lies in the continuous innovation and optimization of four key processes: first, accurately calculating the input power of electric furnaces and increasing the power factor to 0.94, effectively enhancing the efficiency of active power output; second, optimizing the types and particle size ratios of reducing agents to accelerate in-furnace reduction reactions and expand the molten pool, simultaneously increasing the output per furnace and the number of operating furnaces; third, improving the pellet roasting process by adding combustion-supporting agents to enhance shaft furnace capacity, significantly increasing the proportion of hot-charged pellets into electric furnaces, and reducing electricity consumption fluctuations caused by cold material charging from the source; fourth, adopting magnetic separation technology to recover slag ferrochrome, achieving an industry-leading metal recovery rate and reducing annual repeated processing energy consumption by over 10 million kWh.
At the management system level, QFF has taken process innovation as a starting point, simultaneously deepening the lean management principle of "full participation, continuous improvement, waste reduction, and value creation," and establishing a long-term mechanism for the coordinated development of safety, environmental protection, and production. The company has accelerated the optimization of talent team construction, continuously reduced inventory and consumption of idle materials, and created a new pattern of safe production through the "three-two-one" safety management concept, providing systematic guarantees for the implementation of process innovation.
Qin Huaxiang, General Manager of QFF, pointed out that since its commissioning, the company has always adhered to the development concept of "efficiency, energy conservation, and environmental protection," achieving excellent results of "zero accidents" in safety, environmental protection, and public security in Q2 2025. On the basis of strictly controlling quality and risk thresholds, the significant leap in management level has laid a solid foundation for production breakthroughs.
The achievement of this series of results is the inevitable outcome of the deep synergy between lean management and process innovation. QFF has distilled efficient operation models from practical experience, providing not only a referable and promotable technical and management path for Tsingshan's high-carbon ferrochrome smelting units but also setting a benchmark for "green smelting + lean management."
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