I. The goals and tasks of the transformation and upgrading of the heat treatment industry
Heat treatment is the basic process to improve the performance and reliability of equipment in the mechanical manufacturing process, avoid major accidents, and ensure the quality of products. It is also a traditional industry with a long history. The heat treatment affects the performance, reliability and life level of our equipment, which not only leads to the lack of international competitiveness, but also causes considerable material and energy waste due to short product life. “Do a good job of heat treatment, a few parts of the topâ€, indicating that the heat treatment can obtain several times the energy-saving material effect by increasing the service life of the parts.Heat treatment is also a major energy consumer in the machinery industry. In large and medium-sized automobiles, tractor manufacturing, standard fasteners, bearings and machine tool manufacturing enterprises, the heat treatment workshop consumes more than a quarter of the electricity consumption of the entire enterprise. The heat treatment energy consumption of tool and die manufacturing and auto parts production accounts for more than one-half of the total electricity consumption. This reminds us that the energy saving potential in the heat treatment production process is quite large.
It can be seen that energy-saving and emission-reducing clean production is the key to the transformation and upgrading of the heat treatment industry. There is a long way to go to achieve this goal. First, improve product quality, indirectly achieve energy-saving materials by extending the life cycle of parts, and energy saving in the heat treatment process. material. Therefore, the construction of “specialized, precise and special†heat treatment process centers will accelerate the application demonstration and promotion of advanced processes and equipment in the production process, improve the technological level through technological transformation, and realize energy conservation, consumption reduction and emission reduction in the heat treatment production process. The fundamental task of heat treatment industry transformation.
Second, do a good job in basic work, and clarify the key points of transformation and upgrading
1. In-depth investigation and research to explore ways to save energy and reduce emissions
Under the organization of the China Machinery Industry Federation, the China Thermal Association has launched the “Pathway and Policy Research for Heat Treatment Industry to Promote Energy Saving and Emission Reduction Workâ€. The three main ways of energy saving and emission reduction in the heat treatment industry have been clarified. One is to speed up technological transformation, the other is to improve management level, and the third is to strive for policy promotion. The main technical transformation measures proposed include: enterprises should choose heat treatment electric heating equipment reasonably, should choose continuous heat treatment furnace as much as possible; increase the range of induction heating heat treatment; limit the use of salt bath furnace; promote vacuum and controllable atmosphere heating equipment and microcomputer precision control 9 items such as system. In terms of improving management level, it is proposed to strengthen the promotion of energy-saving and emission-reducing heat treatment technologies and equipment, forcibly eliminate obsolete high-energy-consuming heating equipment, strictly implement national standards, and strictly prohibit the production of high-energy-consuming products; standardize production management and increase energy-saving emission reduction Work management efforts to limit the low-level redundant construction of heat treatment enterprises and effectively eliminate high energy-consuming production capacity.
2. Formulate the “12th Five-Year†energy conservation plan for the heat treatment industry
In order to do a good job in energy saving and emission reduction in the heat treatment industry, in addition to the preparation of the “12th Five-Year†development plan for the heat treatment industry, the China Heat Association has also specially prepared the “12th Five-Year†heat treatment industry energy conservation plan. In view of the basic status quo of China's heat treatment industry, it is proposed that the heat treatment industry strives to reduce energy consumption per unit heat treatment by 30% during the “Twelfth Five-Year Plan†period, and reduce the total discharge of three wastes by 15%. The backbone heat treatment enterprises strive to achieve zero pollution and save energy and reduce emissions. Objective: Requires the average unit energy consumption of the heat treatment enterprises above the scale of the 12th Five-Year Plan to be reduced from the current 600 kWh/ton to 450 kWh/ton; the heat treatment fuel furnace has a specific gravity of 15% and the average thermal efficiency reaches 55%, 80%. The fuel furnace is preheated by air, the preheating temperature is guaranteed above 300 °C; more than 50% of the heat treatment resistance furnace is lining with ceramic fiber, the comprehensive thermal efficiency is up to 30%; the heat treatment production electric energy fuel consumption is reduced to less than 20% of the production cost; Life expectancy is more than 20 years. The plan also proposes specific introduction and promotion of project content and management of energy conservation measures.
In the “Twelfth Five-Year Development Plan for Mechanical Basic Components, Key Special Materials and Basic Manufacturing Process†organized by the Equipment Department of the Ministry of Industry and Information Technology, the China Thermal Association proposed based on the actual situation of the industry, taking energy conservation and emission reduction as the basic starting point. The main points of heat treatment basic process development are: chemical heat treatment and infiltration process, precision control heating and quenching process, precision controllable heat treatment process of gears and bearings, vacuum heat treatment process for super large parts, induction hardening heat treatment process for large shaft and pipe parts, large scale Fiber furnace lining without tray controllable atmosphere continuous heating furnace heat treatment process, continuous vacuum heat treatment process, large-scale thin plate part pressure quenching heat treatment process, cryogenic heat treatment process.
3. Formulate the implementation plan for clean production in the heat treatment industry and the evaluation standard for the clean production level of heat treatment enterprises
In order to achieve the goal of energy-saving and emission-reducing clean production on the basis of ensuring product quality and safe production, the China Thermal Association organized experts and key enterprises, and under the organization of China National Machinery Association, China Thermal Association completed the "heat treatment industry clean production implementation plan" and Preparation of the "Evaluation Standards for Cleaner Production Levels in Heat Treatment Industry". In the implementation plan of the clean production technology of 17 key industries including the heat treatment industry released by the Ministry of Industry and Information Technology in March this year, the overall goal of cleaner production in the heat treatment industry was clarified: by the end of 2012, the whole industry saved 3.4 million tons of standard coal; Reduced by 45 million cubic meters; wastewater discharge reduced by 150,000 tons; waste salt slag emissions decreased by 6 million tons. Listed nine clean production technologies highlighted in the heat treatment industry, including: (1) vacuum heat treatment technology; (2) controlled atmosphere heat treatment technology; (3) heating furnace full fiber lining technology; (4) energy efficient air exchange (5) IGBT transistor induction heating technology; (6) computer precision control technology; (7) chemical heat treatment and percolation technology; (8) multi-function quenching cooling system; (9) vacuum cleaning technology. These nine technologies have pointed the way for the technical transformation of the heat treatment industry to promote cleaner production.
The main technical contents of the "Evaluation Standard for Cleaner Production Level of Heat Treatment Industry" compiled include: heat treatment enterprise safety production and environmental protection, enterprise management and product quality assurance, energy consumption index of heat treatment process, energy efficiency index of heat treatment heating equipment, heat treatment salt bath furnace Use and use of salt management, heat treatment processing enterprise market access conditions, supervision and management methods. This standard serves as the market access conditions for new heat treatment production and processing enterprises and the evaluation of the clean production level of existing heat treatment enterprises to prevent enterprises from high energy consumption and low level of repeated construction, effectively reduce environmental pollution and prevent unsafe factors, and accelerate the transformation and Eliminating outdated old traditional crafts and equipment, promoting the scientific development of the heat treatment industry, can also make heat treatment enterprises better meet the requirements of national and regional industrial development planning, regional environmental functions and industrial structure adjustment, so that enterprises can accelerate the direction of intensification and specialization. development of.
4. Formulate an industry access system and propose the “Entry Requirements for China's Heat Treatment Industryâ€
In accordance with relevant national regulations and policies, the “Entry Requirements for China's Heat Treatment Industry†was formulated to promote clean production, technological advancement, product upgrading and structural adjustment in the heat treatment industry, and to enhance the overall competitiveness of the industry, and to ensure the quality of products and the basis of safe production. Promote cleaner production, promote energy conservation and emission reduction, prevent redundant construction of high energy consumption and low level heat treatment enterprises, reduce environmental pollution and prevent unsafe factors, and accelerate the implementation of the “equipment manufacturing adjustment and revitalization plan†Innovative investment in technological transformation, promotion of advanced manufacturing technologies and clean production methods, improvement of material utilization rate and production efficiency, reduction of energy consumption, reduction of pollutant emissions, etc., so that heat treatment enterprises are better in line with national and regional industrial development plans, The requirements of regional environmental function and industrial structure adjustment have prompted heat treatment enterprises to accelerate the scientific development towards intensification and specialization. The main research contents of this subject include: (1) the scope of application of “heat treatment industry access conditionsâ€; (2) the enterprise layout of heat treatment industry and the construction conditions of heat treatment enterprises; (3) the process equipment of heat treatment enterprises; ) on heat treatment energy consumption and comprehensive utilization of resources; (5) environmental protection requirements for heat treatment industry; (6) requirements for quality of heat treatment products; (7) internal management of heat treatment enterprises; (8) safety and health requirements and society of heat treatment enterprises Responsibility; (9) Industry supervision and management.
Third, focus on the work, solid and effective promotion
1. Recommend key energy-saving products and technologies
In order to accelerate the promotion of advanced technologies for clean production in the heat treatment industry, promote industrial technology upgrading, improve industrial technology level, and adapt to the development of low-carbon economy, China Thermal Association will implement the Ministry of Industry and Information Technology's “On the development of energy-saving and high-energy-consuming backward mechanical and electrical equipment (products). The Notice of the Recommended Work of the Directory, organized the screening and recommendation of advanced technology equipment for energy conservation and emission reduction in the heat treatment industry. This work aims to screen and recommend advanced and applicable technical equipment, eliminate high-energy-consuming backward equipment, and give full play to technical support. In 2010, after the expert meeting, the heat treatment industry recommended vacuum high pressure gas quenching furnace, pre-vacuum heat treatment production line, vacuum controlled atmosphere nitriding furnace, large controlled atmosphere well type carburizing furnace, controlled atmosphere hood type nitriding furnace 12 energy-saving technical equipments were included in the “Recommended Catalogue of Energy-saving Electromechanical Equipment (Products) of the Ministry of Industry and Information Technology (Second Batch)†(Announcement of the Ministry of Industry and Information Technology of the People's Republic of China, Gongjie [2010] No. 112) . In 2011, we recommended 9 technologies (equipment) to the Ministry of Industry and Information Technology (the second batch of catalogues), including: composite heat pipe heat exchanger, vacuum cleaner, closed cooling tower, bottom loading vertical multi-purpose furnace production line, intelligent vacuum infiltration Carbon quenching furnace, induction heat treatment machining center, intelligent water-based quenching and cooling system, precision control and controllable atmosphere box type multi-purpose furnace and precision control controllable atmosphere box type nitriding furnace.
2. Carry out clean production demonstration projects and set benchmarks
In order to speed up the promotion and application of advanced technologies for heat treatment and energy saving and emission reduction, and achieve the goal of energy conservation and emission reduction and clean production in the “12th Five-Year Plan†of the heat treatment industry, refer to the “Clean up of 17 key industries such as printing and printing PVC, including heat treatment†issued by the Ministry of Industry and Energy Conservation. Notice on the Implementation Plan of Production Technology (Ministry of Industry and Trade [2010] No. 104), through the research of the Standing Committee of the China Thermal Association, formulated a demonstration work plan for the promotion of advanced technologies for clean production in the heat treatment industry, and carried out “key energy-saving technology promotion projects†and “cleaning†The production of advanced technology demonstration projects, guide the heat treatment enterprises to learn advanced, using advanced energy-saving new technology, new technology and new equipment. Application of vacuum heat treatment technology, controlled atmosphere heat treatment technology, heating furnace full fiber lining technology, energy efficient air heat exchanger, IGBT transistor induction heating technology, computer precision control technology, chemical heat treatment and osmosis technology, multi-functional quenching cooling system And member companies with significant energy saving and emission reduction effects in vacuum cleaning technology set a benchmark in the industry and lead the progress. So far, 21 heat treatment enterprises have been selected as “exercise enterprises for advanced technology of heat treatment and clean productionâ€. This activity has received strong support from relevant departments and has been positively responded by heat treatment enterprises with obvious results.
3. Integration of two technologies promotes high-level technological transformation
Information management and advanced automation control technology have 10~15% energy saving potential in the heat treatment industry. The integration of the two processes in China's heat treatment industry has just started. After several years of overseas study and development, the microcomputer automatic control technology has been maturely applied. Enterprise information management has taken shape, but there is still a considerable gap with advanced foreign telematics control. To this end, in addition to promoting and promoting the process of heat treatment integration, the China Heat Association is actively seeking the introduction and development of advanced information technology suitable for heat treatment.
4. Supervise the progress of energy conservation work in enterprises
In order to standardize the production management of heat treatment enterprises, promote enterprises to strictly implement the national laws and regulations on environmental protection and safe production, consciously adopt relevant national standards, comprehensively improve the technical level and scientific management level of heat treatment enterprises, ensure the quality of heat treatment products, and help enterprises to do energy conservation. In the work of reducing emissions, the China Thermal Association has formulated the “Measures for the Examination and Management of Excellent Enterprises for Heat Treatment Standards and Quality Management Enterprisesâ€, and insisted on the examination and approval of heat treatment standards. Strictly require enterprises to conscientiously implement the ISO14000 series of standards, establish, implement and maintain an environmental management system; environmental indicators meet the national (or industry) relevant standards; to meet the mandatory standard GB15735 "metal heat treatment production process safety and health requirements." The company is required to have no major quality, equipment, casualties, fires and explosions for three consecutive years; the use and storage of plant structures and chemicals meet safety and fire protection requirements. The China Thermal Association conducts necessary supervision and dispatch supervision on the enterprises that have been examined and approved as “heat treatment standard enterprisesâ€. This work has played a significant role in promoting clean energy production and emission reduction.
4. Achievements in heat treatment in accordance with new technologies:
Through the above activities, it has seen obvious results in the past few years. The speed of technological transformation of heat treatment enterprises can reach 30%/year, and the equipment renewal rate of key enterprises reaches over 70%. At present, the heat treatment industry has less than 60% of the oxidation heat treatment heat treatment; the products of the backbone heat treatment equipment manufacturer have all used ceramic fiber insulation materials to manufacture energy-saving heating equipment, and the full fiber furnace lining has accounted for 80% of the standard heat treatment enterprises; The management enterprise has seen the prototype, the proportion of precision control equipment has increased significantly; the water-soluble quenching medium has been accepted by the majority of heat treatment enterprises, and has begun to be promoted relatively quickly; the heat treatment enterprises have achieved remarkable results in energy conservation and emission reduction, and the energy consumption level of key key enterprises has basically reached the national standard. At the level of the “Twelfth Five-Year Planâ€, the energy conservation work started smoothly. The average level of heat treatment energy consumption has dropped by 10% from the end of the “11th Five-Year Planâ€. The advanced level is close to the “Twelfth Five-Year Plan†target.
V. Heat treatment work plan implementation:
1. Continue to carry out “Key Energy-saving Technology Promotion Project†and “Clean Production Advanced Technology Demonstration Projectâ€, accelerate the technical transformation of the heat treatment industry and the construction of the “specialized, precise and special†heat treatment basic technology production center, and save energy for the “Twelfth Five-Year Planâ€. The goal is to achieve increased momentum.
2. Accelerate the deep integration of the two processes in the heat treatment industry, approach the international high-end heat treatment level, and accelerate the pace of transformation and upgrading by improving the technology and management level of the enterprise.
3. According to the “Entry Requirements for China's Heat Treatment Industry†(to be approved), explore the basic conditions and promotion methods applicable to the transformation and upgrading of the industry.
During the “Eleventh Five-Year Plan†and the “Twelfth Five-Year Planâ€, the heat treatment industry has made remarkable progress in transforming and upgrading and promoting clean production of energy conservation and emission reduction. These achievements have contributed to the National Development and Reform Commission, the Ministry of Industry and Information Technology, and the China National Machinery Association. The China Thermal Association expressed its heartfelt thanks to the guidance and support of the superior leadership. In the new year, under the leadership and guidance of the higher authorities, the China Thermal Association will organize and lead the heat treatment industry to thoroughly implement the scientific development concept, thoroughly implement the “Twelfth Five-Year Planâ€, and accelerate the economic restructuring of the heat treatment industry. Transforming the development mode, strengthening the "two-type" industrial construction, and taking energy-saving and emission-reducing clean production as an important strategy for the development of the industry, so that the whole industry can further recognize that energy-saving and emission-reduction clean production is the key to transformation and upgrading, and continuously promote energy-saving and emission reduction. And clean production to improve product quality, reduce energy consumption, material consumption, reduce emissions in the production process, accelerate the pace of transformation and upgrading of the heat treatment industry, and make new contributions to energy saving and emission reduction in equipment manufacturing.
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