Ruitai Monment-Guided by the concept of "five modernizations" and centered on digital transformation

Zhengzhou Ruitai Refractory Magerials Technology Co., LTD. (hereinafter referred to as Zhengzhou Ruitai) belongs to Ruitai Materials Technology Co., LTD., a subsidiary of China National Building Materials Group(CNBM Group), which was founded in 1984 and is located in Xinmi City, Henan Province, which is known as the "town of refractory materials". Zhengzhou Ruitai registered capital of 105 million RMB, covers an area of 260 acres, the existing staff of 220 people, is a building materials, non-ferrous, new energy and carbon power industry high-temperature furnace to provide a variety of refractory services manufacturing enterprises, but also research and development, production, sales, international trade and technical services in one of the science and technology enterprises.

Zhengzhou Ruitai mainly produces high-temperature refractory new materials for industrial kilns in nonferrous, cement and other industries, with an annual production capacity of 110,000 tons. At the same time, it provides supporting refractory materials and personalized services such as construction and installation for thermal kilns. Zhengzhou Ruitai production capacity, scientific and technological innovation, product quality, service level and other comprehensive strength are in the leading position in the industry.

Zhengzhou Ruitai to "build a domestic first-class, internationally renowned high temperature new material supplier" as a strategic positioning, to promote products towards high-end, green. Integrate green development into the whole process of Zhengzhou Ruitai production, practice green manufacturing from the aspects of system construction, product research and development, factory transformation, and strive to achieve a virtuous cycle of ecosystem and economic system, and realize the organic unity of economic benefits, ecological benefits and social benefits. Based on the quality, ecology, environment, energy, occupational health and safety system, we build a strict management system, improve the management structure, and benchmark international and domestic standards in all aspects of production management. In August 2017, Zhengzhou Ruitai was among the first batch of national green factory demonstration units in the refractory industry of the Ministry of Industry and Information Technology, and is the first green factory in the refractory industry of the country. At the same time, it has won the honorary titles of Henan Province Green Leading Enterprise, environmental protection performance A-level enterprise, Henan Province energy conservation and environmental Protection Demonstration Enterprise, Henan Province Green Development Advanced Enterprise, Henan Province carbon Management Demonstration Enterprise, Henan Province carbon asset Management Demonstration enterprise and so on.

In recent years, Zhengzhou Ruitai around the "five" concept of "organized ultra-low emission, unorganized emission systematization, clean transportation mode, plant environment forest, product green energy saving", green action continues to make efforts, through the "management, control, treatment, reform, use" multiple measures, has achieved the whole process of ultra-low emission of air pollutants, enterprise green and low-carbon development has achieved remarkable results.

Organized emission ultralow

Since 2018, Zhengzhou Ruitai has invested more than 50 million RMB in environmental protection, and finally determined the flue gas treatment process of "dry desulfurization, bag dust removal, and SCR denitrification" according to the combustion process characteristics of tunnel kiln. Desulfurization and denitrification dust removal equipment is designed for 100,000 air volume to meet the treatment needs of 4 tunnel kilns, and the flue gas is collected through the equipment for centralized treatment, entering the desulfurization tower, and the reaction with the baking soda emitted in the tower, so as to eliminate the sulfur dioxide in the flue gas. Then the flue gas enters the dust removal equipment, the flue gas after bag dust removal enters the denitration tower, and is catalyzed by the catalyst in the denitration tower to achieve the purpose of denitration, and finally reach the ultra-low emission standard of flue gas, that is, nitrogen oxide ≤50mg/m3, sulfur dioxide ≤35mg/m3, and particulate matter ≤10mg/m3.

At the same time, Zhengzhou Ruitai invested more than 600,000 RMB to purchase imported ultra-low emission monitoring equipment to monitor emissions data in real time and ensure stable standards. Treatment process does not produce new hazardous waste, no secondary pollution, chimney does not produce white plume phenomenon; All automatic control equipment, at any time according to the flue gas content, automatically adjust the amount of material injected, saving labor costs, to ensure ultra-low and stable emissions.

Systematization of disorganized emissions

Zhengzhou Ruitai takes the initiative to tackle hard problems, and has formulated unorganized control measures for comprehensive monitoring and system management in view of the characteristics of unorganized emission points, wide coverage and difficult control. Built more than 6,000 square meters of closed raw materials warehouse, all raw materials stored in the warehouse. It is equipped with 69 pulse-cylinder dust collectors, 5 vehicle-mounted mobile dust collectors, 1 set of high pressure spray equipment, and two mobile high pressure dust and fog cannons. At the same time, the construction of unorganized PM2.5, PM10 particulate matter factory environmental monitoring points, as well as production workshops without dead Angle monitoring, environmental protection dust removal equipment chain control procedures, to replace human management, online monitoring of all emissions data, to achieve the automatic operation of environmental protection system, unorganized emissions normal control. Green development cannot be separated from the support of "wisdom", which is not only reflected in the main production links, but also reflected in the green and intelligent life cycle.

Clean transportation mode

In the process of refractory production, a large amount of dust will be generated in the transfer of raw material ingredients, which has the risk of harming human health. Through the "5G+ autonomous batching" program, Zhengzhou Ruitai uses 5G highly reliable network and positioning capability to achieve millimeter positioning docking of batching transfer, batching raw materials do not leak, and the workshop is dust-free and unmanned, and the equipment operation rate is increased by 12.5%. It provides strong support for high-quality production of enterprises.

Zhengzhou Ruitai construction access control system and video surveillance system, monitor and record transport vehicles in and out of the factory, the use of license plate recognition technology, automatically record vehicle information in and out of the factory, including license plate number, vehicle type, etc.; Combined with vehicle emission stage information (such as national V, national VI emission standards), make a preliminary judgment on vehicle emissions, and intercept vehicles that do not meet the requirements; Install high-definition cameras to monitor the entire process of vehicles entering and leaving the factory to ensure that there is evidence; Statistical analysis of the collected data is conducted to provide data support for environmental management and safety decisions. Vehicles that do not meet the requirements are prohibited from entering and leaving the factory, and the proportion of bulk materials and products entering and leaving the factory shall reach 100% by clean transportation.

Environment of our plant?is forested

A good factory environment and a high green rate can not only maintain a good ecology in the factory, improve air quality, but also reduce noise diffusion, which is an important sign of a green factory.

"Can green never hardening" is the ecological construction concept that Zhengzhou Ruitai has always adhered to. In order to beautify the ecology of the factory area, realize the "forest" of the factory environment, and "full greening" of the bare land, Zhengzhou Ruitai invested 3.5 million yuan to plant more than 20 varieties of trees such as cinnamomum camphor, osmanthus, ginkgo, all kinds of shrub balls, hedges, lawns, and achieved "three seasons of flowers, four seasons of evergreen", with a green rate of 30%. Now entering Zhengzhou Ruitai factory, the trees are shaded, the flowers are blooming, the fragrance is rich, the insects are singing and the birds are singing, just like being in a garden.

Green and Energy-saving Products

To build a domestic first-class, internationally renowned high temperature new material supplier, Zhengzhou Ruitai knows the importance of high-end products, green, energy saving. This requires the integration of green development into the whole process of production, starting from the aspects of system construction, product research and development, factory transformation, etc., the whole process of green manufacturing, and strive to achieve a virtuous cycle of the ecosystem and economic system, and realize the organic unity of economic benefits, ecological benefits and social benefits.

According to the new requirements of relevant management departments for the synergistic efficiency of pollution reduction and carbon reduction, energy saving and carbon reduction is a top priority for production enterprises. The high-temperature new material industry should not only accelerate the transformation of ultra-low emissions, but also transform and leap in the transformation of development, and fundamentally move towards the road of high-quality development.

After unremitting efforts, Zhengzhou Ruitai obtained two major inventions: magnesia-ferri-aluminum (chromium-free) spinel brick and low thermal conductivity multi-layer composite mullite brick.

As an environmentally friendly alkaline refractory material for cement kilns, magnesia-ferrium-aluminum (chromium-free) spinel brick replaces the traditional magnesia-chromium brick, completely eliminates the harm of hexavalent chromium ions to the environment and human body, and has obtained 4 national invention patents.

Independent R&D?low thermal conductivity multi-layer composite mullite brick is an environmentally friendly "energy-saving product", this product is used in large cement rotary kiln, kiln body temperature can be reduced by 100℃. Each ton of cement clinker produced can reduce the standard coal consumption by 1.5kg. Taking the cement rotary kiln with a daily output of 5000 tons as an example, the use of this product can save 7 tons of standard coal per day, and a cement kiln can save about 2300 tons to 3300 tons of standard coal per year; Reduce carbon dioxide emissions by 5880 tons, reduce sulfur dioxide emissions by 184 tons, reduce nitrogen oxide emissions by 253 tons, reduce other dust and harmful gas emissions by 460 tons. Low thermal conductivity composite brick not only reduces the production cost for cement enterprises, but also contributes to the control of air pollution.

While adhering to the concept of "five modernizations", Zhengzhou Ruitai focuses on intelligence and digitalization to help green and low-carbon development. In recent years, under the strategic guidance of China Building Materials General Institute and Ruitai Technology, Zhengzhou Ruitai focuses on the digital strategic planning of the General Institute, takes "industrial digital transformation" as the core, and fully implements the work of "intelligent transformation and number transformation" of production enterprises. In the transformation work, adhere to the result-oriented, focus on industrial pain points, combined with the concept of "digital value enhancement" of the General Institute, deeply promote the "refresh" of the industry, and realize the reprocessing and upgrading of accumulated data. In accordance with the strategic goal of building a "digital General Institute", we will vigorously develop the digital economy and promote the transformation and upgrading of traditional industries.

The 5G smart factory built by Zhengzhou Ruitai has built a "1+1+N" smart factory architecture, deployed a 5G private network, and developed an industrial Internet platform and "N" application scenarios. Through the construction of system hardware and software, the system can realize the information integration with ERP and automated production line, and realize the collection, management and feedback of man-machine material method information in the production process. Based on the 5G public network architecture, through the 5G network dedicated channel, the use of 5G+MEC to open up the data connection of the whole business process, and through the combination of 5G+ data collection and industrial Internet data, the intelligent multi-scenario management and control of the whole process such as planning, production, quality, equipment, barcode traceability, inventory, energy, safety and environmental protection is realized.

At present, Zhengzhou Ruitai intelligent factory management and control system has realized all the digital management and control in the refractory manufacturing process, including production planning, job assignment, inventory management, equipment networking, automatic real-time data collection, industrial big data analysis and on-site Kanban display. In the production process, from crushing, batching, molding, firing to testing, packaging process to fully realize automation, digital, networked, intelligent.

Through industrial Internet integration and innovation, Zhengzhou Ruitai has won the national intelligent manufacturing demonstration factory unit, the national intelligent manufacturing pilot demonstration excellent scene, the national specialized special new small giant enterprise, the national new generation of information technology and manufacturing integration development demonstration enterprise, the national industrial Internet pilot demonstration enterprise, the national intellectual property advantage enterprise, Henan Province smart factory, Henan Province's first batch of "5G. "+ Smart Factory", Henan Province's first batch of 5G application scenario demonstration enterprises, Henan Province's new generation of information technology integration application new model demonstration enterprises, Henan Province quality benchmarking enterprises and other titles.

Refractories are the foundation of the traditional manufacturing industry, in the face of high-quality development requirements and the realization of the "double carbon" goal, the traditional refractories industry is facing unprecedented challenges. In terms of product quality, we should continue to pursue longevity and high efficiency, energy saving and consumption reduction, green environmental protection; In terms of production, it must meet the requirements of safety, environmental protection and occupational health regulations, and constantly innovate green, intelligent, efficient and other production modes. In the next step, Zhengzhou Ruitai will continue to improve the green and intelligent level in production and operation, and continue to improve operational efficiency. On this basis, we are committed to promoting the green and intelligent innovative production mode in the industry, and contribute to the green and intelligent high-quality development of the national refractory industry.

Published in China Environment News, page 6, September 24, 2024