As National Energy Conservation Week this week, the charge for energy conservation and emission reduction is sounded again. Under the dual pressure of dual carbon targets and economic transformation, ceramic production companies are facing huge impacts and challenges. How to break through such a difficult situation? How to achieve a balance between energy consumption and high product quality?
The questionnaire of the times is waiting for us to write
Industry consensus in ceramic production: different product thicknesses, different water absorption rates, different raw material systems, different body oxidation requirements, and different gas calorific values, these factors will affect energy consumption.
The article "Implementation Guidelines for Energy Saving and Carbon Reduction Renovation and Upgrades in Key Areas of High Energy-Consumption Industries (2022 Edition)" clearly states: Due to differences in firing processes and product specifications, the production energy consumption of different construction and sanitary ceramic enterprises in my country The level and carbon emission level are quite different, and the comprehensive energy consumption per unit product is quite different.
In the initial stage of coal-to-gas conversion in 2019, the energy consumption of ordinary glazed bricks in the industry was generally in the range of 1.9-2.5Nm³/square brick, and the coal consumption was 3.5kg-4.9kg coal/square brick. After just three years of exploration, Zhongpeng Company has customized kilns in different production areas, optimized the ratio of the three belts, introduced high-efficiency heat exchangers and other measures, so that the energy consumption can reach 1.5-1.6Nm³/square brick of natural gas, and the formula can be adapted to Fast-burning ceramics can even achieve 1.0Nm³/square brick.
Take the Guangdong production area as an example. The pursuit of quality is a common requirement in this production area, and the products mainly have double-zero water absorption rates.
In early May 2020, Zhongpeng built a double-zero water absorption glazed brick production line for Xinruncheng Group, producing 600×1200×10mm specifications, setting a record for the lowest natural gas energy consumption of 1.25Nm³/square brick. At the same time, electricity The consumption is also reduced by 20% compared with the old kiln;
In Mona Lisa, Xiqiao, Zhongpeng built a slate production line for it in October 2020. It mainly burns 900*2600*9mm large-size slates. The current gas consumption The level is 1.56Nm³/square brick. In 2019, Guangzhou Simone Lisa 800×800mm double zero water absorption full glaze polishing production line, the comprehensive natural gas energy consumption of the entire line was maintained at 1.55-1.6Nm³/square brick, becoming the only production line in the workshop at that time that allowed multi-layer rapid drying without firing a gun. ".
In February this year, Zhongpeng Thermal Energy’s new “Intelligent Energy Saving Firing Production Line” wide-body kiln was successfully put into operation at the Romantic Heyuan base. The main production specifications are 750*1500mm, 800*800mm and other specifications of glazed tiles. The designed output Up to 20000m²/day.
Compared with the previous old kiln, under the premise of the same fuel calorific value, production process and firing curve, coal consumption has been saved by more than 1kg of coal/square brick. According to calculations, coal consumption alone can save nearly 10 million in energy costs. It is precisely because of such excellent energy consumption and power consumption levels that when the market is almost shrinking and most ceramic companies are trapped in energy consumption costs, Romantic can continue to produce as steadily as possible.
In the industrial upgrading of "Yuhui Enterprise", the entire factory is equipped with Zhongpeng thermal energy burning equipment, scientific layout, detailed construction plan, precise construction, leading design, energy consumption and power consumption data after put into production has been vividly reflected. Compared with the old equipment of the same period, there is a leap-forward improvement, and the coal consumption is directly reduced by 1.2 kg of coal/square meter of bricks on the original basis.
Fujian factory, in 2020, Zhongpeng Thermal Energy renovated a 300×600×7.5mm medium plate production line for Fujian Haoshan Enterprise, achieving natural gas energy consumption as low as 0.96Nm³/square brick;
In the production areas of India, Zhongpeng Thermal Energy has achieved 1.23Nm³/square brick as early as 2012. Of course, this is due to the fact that the calorific value of local natural gas is higher than that in China. The thickness of the bricks is mostly 9.8mm, which is higher than that of polished glazed bricks in China. The bricks must be thin. At the same time, India has unique raw material advantages that are suitable for low temperature and fast burning. These factors are accumulated together, and combined with Zhongpeng Thermal's excellent thermal equipment, it is not surprising to achieve ultra-low energy consumption indicators.
At a seminar, Mr. Wan from Zhongpeng proposed that "thin ceramic tiles will definitely be the future development direction. This will not only achieve excellent energy-saving effects, but also save resources. Can domestic ceramic companies learn from India?" Production areas, through the innovative features of thin-plate products, have achieved significant results in energy saving and consumption reduction, and are looking for low-temperature and fast-burning formula systems to achieve the purpose of reducing consumption. "It can be seen from production practice and theoretical analysis that thin plates have considerable advantages in energy saving. , but considering market acceptance, it is unlikely to quickly replace thick plate products. The demand for thin and thick plates will coexist for a long time.
As a practitioner of energy conservation and carbon reduction in the ceramic industry, Zhongpeng believes that low energy consumption is an important goal for the development of the ceramic industry, but it is not the only indicator to measure the quality of ceramic firing technology. The quality of ceramic tiles should also be considered.
Director of Mona Lisa GroupMr. Zhang Qikang, who is also the secretary of the board of directors, also expressed his views on ceramic enterprises' rational thinking on energy conservation and consumption reduction in relevant reports, "The ceramic industry is relatively complex, and enterprises cannot be evaluated purely from the perspective of energy consumption. High-quality ceramics can only be produced when the heat is high." Products. Enterprises that provide high-quality products and have a high degree of automation will definitely consume more energy than low-end enterprises. If they are judged only by energy consumption, they are not in line with the high-quality development of the industry advocated by the country. ”
Zhongpeng Company has been committed to helping outstanding ceramic companies pursue energy conservation and consumption reduction in high-quality production, and has always explored how to achieve the dual goals of low energy consumption and high product quality from a rational and scientific perspective, so as to enable customers to transform from energy conservation to to truly make profits and lead the entire ceramic industry to develop in the right direction.
Zhongpeng Thermal Energy's "cloud-controlled streamlined covered energy-saving roller kiln" was selected into the recommended catalog of energy-saving technology and equipment by the Ministry of Industry and Information Technology as early as 2019. In that year's selection, Zhongpeng Thermal Energy's in-depth cooperation with ceramic companies, through the layout of the factory, the fine coordination of upstream and downstream supporting equipment, combined with the customer's production technology, and Zhongpeng Thermal Energy's various debugging methods, were the first to launch a complete set of energy saving and emission reduction Solution; At the same time, the excellent energy consumption indicators in major ceramic production areas finally won this honor. This was also the first time that the only ceramic kiln company in the industry was selected into the recommended directory.
Assist ceramic enterprises and never forget their original aspirations. Zhongpeng Thermal Energy will always be on the road of energy conservation, environmental protection and innovation. Empower ceramic enterprises in adversity, provide new ideas for high-quality development of the industry, and be a pioneer in the green and energy-saving era.
