Zhuye Nonferrous opens a new chapter in the development of high quality

SMM News: Zhuye Nonferrous to Zhuye Group transferred to Hengyang Changning 300000 tons of zinc project as the platform, completed and put into production in one year, reached production and efficiency in one year, and become a beautiful landscape for the transformation and upgrading of non-ferrous smelting enterprises and green development.

Time bears witness to history, and history needs to be agitated and remembered.

Hunan Zhuye Nonferrous Metals Co., Ltd. (hereinafter referred to as "Zhuye Nonferrous Metals") has been established on the platform of the 300000-ton zinc project of the copper-lead-zinc industrial base, guided by Xi Jinping's thought of socialism with Chinese characteristics in the new era. We will vigorously implement the new development concept of "innovation, coordination, green, openness, and sharing", and firmly cling to the theme of high-quality development. The enterprise spirit of "do not slack off for a day" strives courageously, constantly writing history and witnessing miracles.

In 2020, Zhuye Nonferrous, on the basis of 230000 tons of zinc precipitated in the first three quarters, achieved the feasibility target of zinc full cost in September, which is about 20% lower than the industry average, laying a solid foundation for returning to the industry benchmark position. This is the answer that Zhuye Nonferrous has handed over again in the journey of high-quality development after it was completed and put into production in 2018 and put into production in 2019.

Wastewater to maximize the utilization of zero-discharge resources

"Green water and green mountains are Jinshan and Silver Mountains." This is the most vivid and intuitive display of Xi Jinping's ecological civilization thought in the new era.

In the process of construction and operation of Zhuzhou smelter Nonferrous, eco-environmental protection is not only a solemn commitment, but also an endogenous driving force to maximize the utilization of resources.

Under the guidance of China Minmetals and Hunan Nonferrous, the 300000 ton zinc project transferred by Zhuzhou smelter to the copper-lead-zinc base is designed in accordance with the strictest domestic environmental protection standards: zero discharge of industrial wastewater, the first domestic non-ferrous enterprises; waste gas SO2 according to 80mg/Nm3 design, 1/5 of the national emission standard; waste residue design using Wells method to achieve valuable metal recovery and harmless comprehensive utilization of tailings. In the process of implementation, a series of core technologies with advanced level in the world are adopted: the largest 152m2 boiling roaster in the world, the largest single series 300000 ton leaching system in the world, the deep purification system of OTC solution, the largest oxygen-rich volatile rotary kiln in the industry, the direct extraction of indium from zinc and indium, and the unique acid treatment technology to ensure zero discharge of industrial wastewater.

Today, there is no industrial wastewater outlet in Zhuzhou smelter's non-ferrous plant of more than 1800 mu. All industrial wastewater is treated by special acid treatment technology and returned to production for reuse. At the same time, rain and sewage diversion is carried out at the non-ferrous production site of Zhuzhou smelter, and through quality treatment and reuse, Rain Water in the initial stage and Rain Water in the later stage can replace the production water for reuse. The almost stringent comprehensive utilization of water resources has helped Zhuye Nonferrous to achieve zero discharge of industrial waste water. 300000 tons of zinc hydrometallurgy uses an average of about 7000 tons of new water per day, all of which are recycled internally. The production water consumption of the system is controlled to the best level in the industry.

The volatilization kiln for the purpose of extracting valuable metals from zinc leaching residue is known as "cash cow" in Zhuye. This year, Zhuye non-ferrous volatilization kiln area boldly implemented oxygen-rich smelting and air compressor technical reform program, arranged for special personnel to constantly explore pre-proportioning methods, and strive to improve the proportion of low-cost fuel structure, through a series of effective measures, so that the main indicators of this year's volatilization kiln exceed the advanced level of their peers. In the first three quarters, the average zinc content in kiln slag is 1.96%. In recent months, the kiln slag contains 1.5% zinc, and the cost has been reduced by more than 90 yuan. At the same time, the equipment operation rate has increased steadily, and the average operation rate has reached 98% since the beginning of this year, realizing the green smelting of volatile kiln slag treatment, and the tail gas qualified rate is 100%.

Sulphuric acid production from flue gas and waste heat power generation are remarkable signs of green smelting. Since the beginning of this year, the quality of non-ferrous sulfuric acid in Zhuzhou smelter has been greatly improved by tackling key technical problems. In September, it produced 1 batch of high-grade products, 9 batches of first-class products, with a rate of 100% of first-class products, and effectively reduced the inventory of Under the leadership of Li Weidong, a pacesetter of the company and a member of the Communist Party, the post of waste heat power generation in Zhuye Nonferrous Zinc roasting Plant aims at its own characteristics, fine operation, strict control of process parameters, stable steam output and quality of waste heat boiler, strengthen equipment inspection, and carry out stable operation of the roaster-acid system. In September, the waste heat power generation reached a record high of 6.57 million kilowatt hours.

Focus on reducing cost and increasing efficiency to open up the "barrier lake" with stable and high yield

The copper-lead-zinc industrial base is an important part of the development mission of China's Minmetals to ensure the supply of national metal resources and the development strategy of Hunan non-ferrous "one base and seven industries". Based on reducing cost and increasing efficiency, achieving stable and high yield is the key to show Zhuzhou smelter's non-ferrous mission and industry benchmarking level.

Since the beginning of this year, Zhuye Nonferrous has fully implemented the overall deployment of the Group and Hunan Nonferrous, actively responded to the challenges of the epidemic, strengthened its goals and confidence, deeply promoted fine management and technical problems, and found the right way to reduce costs and increase efficiency. Seven key measures have been formulated, such as metal input, volume control, acid and root balance, key technical indicators, comprehensive recovery, equipment guarantee, and work-in-process control, which are led by the production Technology Department. The implementation of weekly meetings, daily scheduling to ensure the accurate landing of key projects, effective.

Zinc electrolysis production is the bottleneck of Zhuzhou smelter's non-ferrous production capacity in the first half of this year, the power consumption can not be raised, the output can not be raised, and the morale of workers is relatively low. The company attaches great importance to this, first of all, boost the morale of the staff and workers, start with the optimization of human resources, timely supplement the new forces to enrich the workforce, carry out all-round skills upgrading and ideological and political work, and introduce positive incentive measures. greatly enhance the spirit of the team. The second is to support electrolytic production with the efforts of the whole company. Led by the head of the company every day, organize all relevant units to meet in the morning and sum up in the evening, perform their respective duties, carry out round-the-clock "wallchart" operations, and implement the measures formulated at the daily meeting one by one. Since June, electrolysis production has increased steadily, from less than 800 tons per day to 920 tons per day, with a sharp drop in power consumption compared with the same period last year.

In May and June, due to the influence of the original mineral phase and reagent, the output and recovery of flotation silver were not ideal. Under the guidance of the relevant departments of the company, the zinc wet smelter carried out key reagent tests and creatively carried out the raw ore vulcanization process. Silver flotation production standard operation card was established in the silver flotation post to standardize the operation of the staff. Through the implementation of various key measures, all the indicators of flotation silver achieved a breakthrough in July. In September, the comprehensive recovery rate of silver flotation reached 77%, a record high, making a positive contribution to reducing costs and increasing efficiency.

"the whole staff of cost management, the standardization of cost system, the quantification of cost index, the specialization of cost control, the rigidity of cost realization and the informationization of cost monitoring" are the core contents of fine cost management in Zhuzhou smelter this year. According to the requirements of the fine cost management of the "six modernizations", the financial and securities department of the company has taken the lead to actively carry out fine cost management training in various departments and units, with a coverage rate of 100%, which has effectively promoted the promotion of cost awareness of all employees. Supervise all second-tier units to establish cost management systems, accounts, measures, inspection systems, assessment systems, etc., to achieve 100% coverage of the cost management and control system, and 100% of the cost indicators. To improve the information level of cost management, all cost consumption and cost data are managed daily through the MES system, which shortens the time difference between the front-end operation and the back-end results, ensures the timely and accurate statistics and cost data, and realizes the timely early warning of the cost data to the operation.

Build an intelligent factory to ignite a new engine of innovation and development

"only the reformers advance, but the innovators are strong, but the reformers and innovators win."

Zhuye Nonferrous plays an innovation-driven role, promotes the development of the industry in the direction of high-end, green, intelligent and integration, innovates and practices to build intelligent factory benchmarking enterprises in the non-ferrous metals industry, and ignites a new engine of innovation and development.

The company invested tens of millions of yuan to start the intelligent factory construction project in September 2018. In the process of intelligent factory construction, under the major principles of innovation, integration and development, overall planning and key breakthroughs, the company follows the requirements of data sharing, information visualization, standard internationalization and system flexibility, and uses big data, artificial intelligence and safety technology to build an intelligent factory system platform covering DCS, MES and ERP, so as to realize green, safe and efficient production of non-ferrous metallurgy. The overall acceptance of the project was carried out on September 21, 2020, marking the full operation of the project.

The six main business lines of intelligent factory construction, namely, the integration of industry and property, supply chain system, process control, equipment management, response mechanism and environmental protection index monitoring, have achieved a series of results: the efficiency of dealing with abnormal situations in the process of production and operation has been greatly improved; the implementation of the integration of industry and property has accelerated the business settlement process; the internal risk control of the company has been strengthened; The multi-dimensional presentation and analysis of production and operation data improves the ability of data decision-making. In particular, the application of the intelligent system reduces the number of data input and data analysts, the patrol with the general control room as the core replaces the fixed post management mode, and through automatic means such as unmanned inspection, robots and other automatic means, instead of manual operation, the number of managers and operators has been greatly reduced. Compared with the domestic zinc smelting enterprises of the same scale (300000 tons / year), the personnel has been reduced by more than 1000, the benefit of personnel reduction is obvious, and the labor productivity has quadrupled compared with that before the transfer of smelting capacity.

After the construction goal of Zhuye Nonferrous Intelligent Factory is fully realized, it will become another commanding height for the innovation and development of the industry.

Adhere to the leadership of party building and lay a solid political foundation

"only when the grass-roots organizations of the party become stronger, the ranks of party members become stronger, and the work of the party become stronger, can we gather the strength to move forward in pursuit of dreams." Zhuye Nonferrous attaches great importance to the deep integration of party building and production and management, so that the advantages of party building are fully reflected in various specific production work, leading to high-quality development.

In view of the grim situation of the prevention and control of COVID-19 's epidemic situation in the first half of the year, Zhuye strictly implemented the arrangements of higher-level organizations, and party commandos were set up in all grass-roots party organizations to carry out epidemic prevention and control on the one hand and production and operation on the other to ensure that there were no suspected and confirmed cases throughout the company, laying a solid foundation for achieving more than half of the time and more than half of the tasks in the first half of the year.

At the beginning of August, the party committee of Zhuye issued the activity plan of "leading, fine management and striving for five excellence" among the grass-roots party organizations, all party members and employees of the company. actively explore the effective ways and ways of the integration of party building and production and management. In the important campaign of overcoming the non-ferrous processing cost of Zhuzhou smelter to achieve the goal of feasibility research, Zhuye Nonferrous Metallurgical Party branches, party groups, and team groups "strive for five excellence" combined with the theme of Party Day, "Party Flag fluttering, Party Emblem shining" and other carriers, party building and production and management are deeply integrated, and the fighting fortress role of party organizations and the vanguard and exemplary role of party members are brought into full play. To ensure fine management and various key activities to grasp iron marks, foot disease and stability.

Zhao Zhishun, secretary of the Hunan Nonferrous Party Committee and chairman of the board, the party branch of Zhuye Nonferrous Zinc roasting Plant, closely centering on the goal of "leading party building, fine management and striving to create five excellence", conscientiously implement the promotion plan and ensure the deep integration of party building and production and management. In order to strengthen the construction of work style, the party branch requires the management technicians to go to the scene for not less than three hours a day, and the party members' backbone to claim key equipment for pairing activities in August. The claiming personnel check the claimed equipment according to the standard card of fine equipment management Kanban every day, and rectify the problem points to form closed-loop management, and report the status of the equipment to the branch every week. At the same time, we should improve ideological files, establish an ideological work information network with party branches, party groups, party members and workers as the basic organizational form, through heart-to-heart talks covered by the whole staff, go deep into one-on-one communication and timely understand and grasp the ideological situation of workers, discuss and analyze various tendentious and budding problems that affect the enthusiasm of workers and the stability of enterprises, solve the problems in the bud, and create a harmonious environment for the development of enterprises. In September this year, the operating rates of the roasting furnace and the roaster of Zhuzhou smelter's non-ferrous zinc roasting plant reached 96.87% and 99.79% respectively, ensuring that the metal input of the system met the requirements of full-load production.

Although Zhuye Nonferrous achieves the feasibility research goal at full cost in September, there is no limit to the struggle. Next, Zhuye Nonferrous will make a more in-depth and detailed analysis and judgment on the various factors that affect the cost, and make overall arrangements, consolidate and upgrade, so as to ensure the sustainability of the completion of the target tasks. to lay a solid foundation for the establishment of a world-class benchmark enterprise in the zinc industry.