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In recent years, the development of Guizhou tires has entered a rational track of “structure, quality, brand, and benefitsâ€. In order to achieve a more stable and rapid development on the path of scientific development, and to successfully implement the transformation of the tire industry in Guizhou and the adjustment of product structure, the company has increased the efficiency of energy use, reduced emissions of waste gas, waste water, and waste, and increased recycling. Put in an important position in green development. Among them, the application of a number of new technologies and new processes has enabled the energy consumption of Guizhou Tire's industrial added value to be greatly reduced. In May 2012, a Tire Series GL283AL.ET truck tire from Guizhou Tire passed the US Environmental Protection Agency (EPA) Smartway certification and was confirmed to meet Smartway requirements for low rolling resistance tires.
Low-temperature gel refining method: purification environment
The rubber mixing process is the highest energy consumption of the tire production process. Since 2010, the company has invested 26 million yuan in the introduction of two OMS low-temperature mixing process production lines, put into production in March 2011, into the plastic, loop, cooling, sulfur, mixing, breaking, rubber row The production process is fully automated at one time. In May 2012, the company's third low-temperature one-step process was started.
The tire rubber refining process in Guizhou successfully developed a low-temperature one-step refining process. This technology changes the traditional multi-stage mixing to one-time mixing, that is, the compound is cooled by the first open mill after high-temperature smelting by the mixer, and then distributed symmetrically to the surrounding multi-platform through the central delivery system. The mixer performs continuous low-temperature mixing to directly obtain the final rubber. The entire process enhances the mixing of the auxiliary machine, and the entire process is automatically controlled. The new process has reduced the intermediate transfer link of the rubber compound, thereby reducing the amount of space occupied by the rotary rubber compound, shortening the space occupied by 1/2 hour to 30 minutes, and greatly reducing the cost of raw materials; achieving about 20% reduction in electricity consumption per ton of plastic and increasing More than twice the production efficiency.
Due to the low temperature, no compound flue gas will be produced, no abnormal quality such as glue burning will occur, fresh air will be produced at the production site, and energy saving and emission reduction will be conducted, the ecological environment will be purified, the employee's labor health protection will be eliminated, scorch will be eliminated, and the rubber compound will be qualified. Rates and other aspects will be completely changed.
Nitrogen vulcanization technology: low-carbon economy
The 700,000 high-performance all-steel radial truck tire production project put into operation in July 2011 has become one of the major highlights of Guizhou's tire energy-saving and emission reduction. Previously, the heat required to use superheated water during the vulcanization process was absorbed only by a small part of the tire, and a large amount of hot water was inefficiently circulated. Nitrogen is used instead of hot water as the internal pressure medium for vulcanization. It is more advanced than the existing over-hot water vulcanization process in terms of production efficiency, product quality, production cost, and energy consumption. On June 17, 2012, the daily output of this production line has exceeded 2,000 tires, reached 2005, and the production capacity has reached full production.
The project is characterized by advanced products, advanced technology and advanced production technology. It guarantees technical upgrading of the product structure. The tires produced are tireless, high-grade (M-class), flat and high-tech high performance. The all-steel radial tires have the advantages of low rolling resistance, good fuel economy, and good safety and comfort. They are the development direction of product upgrading and are in line with national industrial policies and low-carbon economic requirements.
Since the tires of this project are high-performance energy-saving products, the weight of the tires, the inner tubes and the cushions that are reduced compared with the inner tire products of the same specifications can reduce the weight by 13.9%, and can also reduce the weight of the rim by 15%. The tires are light in weight, low in rolling resistance, and 1% in fuel economy. The use of nitrogen vulcanization technology saves steam and shortens curing time, saves energy consumption by 30%, and recycles water resources to achieve zero emissions. The project has adopted various items. Effective energy-saving measures, energy consumption is lower than the norms of the industry norms.
Removable snap button insulation technology: energy saving cooling
The all-steel radial tire vulcanization production line equipment branches, valves, and molds have been exposed for a long time, and the heat dissipation area has increased the temperature at the vulcanization site, which in turn has caused hidden safety hazards of scalding. The space for energy saving and improving the production environment is large.
From January to March 2012, the company had fully insulated the 50 vulcanizer branches of the production line with a detachable snap closure. The detachable snap closure is a kind of inner layer made of two layers of glass fiber needled felt + one layer of high temperature centrifugal glass wool felt; the outer layer is silicon rubber coated high temperature resistant alkali-free glass fiber cloth which can withstand 280°C. The fixing device is a fire-retardant velcro. The principle of heat preservation is: blocking the convection of hot air and cold air and preventing heat conduction and heat radiation. Its biggest advantage is that it can be disassembled and used repeatedly. The construction can be installed without downtime, and it is safe and environmentally friendly. Human stimulation is small. After 50 sets of vulcanizing machines after thermal insulation, the average daily steam savings per day were 0.56 tons, a total of 28 tons of steam was saved, and the energy saving effect was obvious.
Steam energy-saving heating system: reduce coal consumption
In order to reduce energy consumption and pollutant emissions of enterprises, in 2007, Guizhou Tire proposed the implementation of energy optimization and reform projects for steam heating systems, and technical measures such as the use of steam pressure differential waste heat power generation and reverse osmosis desalination technology to reform boiler softened water treatment systems. Realize energy saving and emission reduction. After two years of transformation and construction, in April 2009, the steam energy-saving heating unit used in Guizhou Tire successfully started its full and effective operation.
In the project, a 1×6MW back pressure heat supply generator set is used to generate power using the pressure difference between the boiler steam pressure and the company’s terminal steam load. The annual power generation reaches 3009×104 kilowatt hours, and the annual power supply can reach 2949×104. Kilowatt-hours; for three years, the unit was operating normally, alleviating the strain on power supply. The project uses the reverse osmosis desalination technology to transform the boiler softening water treatment system to reduce the boiler's effluent rate to 5%, to reduce the loss of heat from the sewage discharge by 1.12×1011 kJ, and to reduce boiler coal consumption by 0.5102 million tons of standard coal. In addition, the project also implements the use of hot plate vulcanization technology, which can reduce 48 kilograms of steam consumption for each tire produced. With an annual output of 1.6 million tires, it can save 76,800 tons of steam and save 2.046×1011 kilojoules of energy throughout the year. Save 9320 tons of standard coal.
According to statistics, the technical renovation project of the Guizhou Tire Steam Energy-Saving Heating System has been successfully operated, saving a total of 21,186,000 tons of standard coal annually.
20 tons of sewage treatment technology transformation: to achieve zero emissions
In April 2012, Guizhou Tire put into use the 20-ton sewage treatment technology transformation project implemented on the high-performance truck radial tire production line, which enabled the domestic sewage of the production line and the inner tire production line to be recycled after treatment, and realized “zero emissionâ€.
The sewage treatment process adopts the current advanced biochemical treatment method with a treatment volume of 20m3/h. The treated water quality was tested by the Guiyang Municipal Bureau of Quality and Technical Supervision and met the national second-class water quality standard. After the system is put into use, the produced water can completely guarantee the ground washing of the branch company's factory and the need for replenishing water in the low temperature circulation pool. In May 2012, under the condition of self-usage, the three carriers of radial trucks provided 50 tons of medium water to the circulating pool of the Power Company's power company through the pipeline every day, reducing the amount of fresh water in the circulating pool.
Awareness, management focus: green development
In addition to the breakthroughs in new technology, Guizhou Tire also promoted the in-depth development of the green development of the wheel. The first is to establish the concept of scientific development, to realize the importance of energy saving and consumption reduction for companies to become stronger and stronger, and secondly to gradually Adopt advanced production technology and new technology; Third, through the certification of quality management system and military product certification, formulate tire process management specifications and green tire specifications to promote the development of Guizhou's green tire industry; fourth is to use green additives, special carbon black, steel New materials such as cords; Fifthly, in order to strengthen the on-site material cost control, scientifically verify the consumption quotas of various production processes and strictly implement the consumption quota management; through optimizing the product structure and formula design, including reducing the weight of tires, expanding reclaimed rubber and synthetic rubber The dosage, the application of new substitute materials, and other measures to effectively reduce product design costs and minimize resource consumption.
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