Recently, after two months of hard work, Shaanxi Iron and Steel Group Longgang Company completed the intermediate repair of the 450㎡ sintering system electrostatic precipitator successfully passed the test run and entered normal operation with good results. It has become a successful example of the company's technological innovation to help the development of the enterprise.

The 450㎡ sintering system electrostatic precipitator is one of the important components of the 450㎡ sintering desulfurization and denitrification system of Shaanxi Steel Group Longgang Company, and is also the front-end equipment facility of the company's environmental protection system. In just 60 days, cadres and workers worked day and night through repairs, independent innovation, and technological transformation, which not only extended the service life of equipment and reached the five-year guaranteed operation standard, but also significantly reduced maintenance costs.

Practice innovation, precise positioning and cost reduction

450 kilo sintering machine is equipped with two double-chamber four-electric field electrostatic precipitators, which were put into operation in 2014. after nearly 10 years of continuous operation, the electrostatic precipitator body and ash bucket steel plate have been thinned by high temperature flue gas corrosion, which can no longer meet the current safety requirements of the company. Through cost analysis, they organically combined maintenance with spare parts replacement, independently produced 144 welded roofs, 235 tons of consumables, 28 anode manholes, part of cathode incubator manholes, 28 top electric field manholes, replaced 288 sets of box girder heating and cathode incubator heating, replaced 256 sets of internal cathode system and accessories, 176 groups of anode system and accessories. Especially in the maintenance of four-node control cabinets, they put their heads together, adhered to the principle of "can be repaired and resolutely not replaced", and repaired 8 cabinets by using the dismantled waste materials. through transformation, it not only avoids the extension of the construction period caused by slow return due to rain and snow, reduces the procurement cost, but also thoroughly breaks through the technical bottleneck of the electrostatic precipitator system, and prolongs the service life of the precipitator. The stable operation of sintering main exhaust fan and desulphurization and denitrification system is ensured. "through independent maintenance, tackling key problems with professional skills, and fighting around the clock, it will be impossible for us to become possible." On the 450 kilo sinter electrostatic precipitator platform, Yan Junjie, director of the environmental protection operation area, looked proud of the fruitful results in the past two months.

Technological innovation, excellence and efficiency increase

Liu Xin, the chief of the company's environmental protection operation area, did not wait and took the initiative. He worked with the technicians to find a solution. After consulting the data, combining the process operation and the actual situation on site, he proposed to implement the H-shaped column, the manhole door attachment plate and the ash bucket. Structural optimization is carried out. On the one hand, the H-shaped column at 2 meters around the anode manhole is reinforced, and segmented welding is used to add ribs to ensure that the column is firm; On the other hand, move the outer sealing plate of the manhole backwards, and take out the channel from the middle after installation. After the renovation, not only did the stability of the column increase, but also the manhole side plate move inward, preventing direct contact between flue gas and the H-shaped column and extending the service life of the dust remover frame.

"Through structural optimization, the column can be used stably for 3 years without increasing maintenance costs." Liu Xin said,"After 7 days of continuous fighting, we have renovated a total of 40 columns and 80 sides, laying a solid foundation for the stable operation of the equipment."

Extreme innovation, careful calculation and deep tapping potential

Faced with the impact of tight time, heavy tasks, multiple projects and severe weather, maintenance squad leaders Yan Gangqiang, Xiao Hui and other technical backbones led tongs and welders to seek benefits from repairing old ones. By making every piece of equipment, every valve, and every cable,"Every penny must be calculated", achieving a "big problem" of reducing costs and increasing efficiency. According to statistics, a total of 25 groups of anode plate suspension beams, 12 groups of anode rapping rods, more than 1000 meters of power cables, and an efficiency of more than 30,000 yuan were recycled during this mid-scale repair. Hydraulic shears were used to cut and hand over the recycled waste steel materials, saving time and labor. Seeking benefits from technological innovation, we independently modified the grate to filter the accumulated ash in the ash hopper, and installed 24 dust remover ash hopper extension plates to solve the problem of difficulty in cleaning up accumulated ash and impurities in one fell swoop and ensure the safe operation of the equipment... These small technical changes have not only greatly reduced the work intensity of personnel and saved maintenance time, but also achieved considerable benefits, making everyone a promoter and practitioner of reducing costs and increasing efficiency, helping the company move towards extreme efficiency, extremely low costs, and extreme energy efficiency. The goal continues to move forward.

author| Li Hao Xu Weiping

edit| Hao Shuhui

audit| Liu Jiajun

planning| Chen Xiaoli