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"The profitability of special materials for easy-to-process floor heating pipes continues to maintain a high level
.
After more than 8 years of iteration and optimization, Qilu Petrochemical's special material for easy-to-process floor heating pipes has now become a polyethylene product that is widely welcomed by customers
.
Eliminate the design bottleneck of old equipment, develop and put into use anti-static system, and realize high-load production on two lines
Eliminate the design bottleneck of old equipment, develop and put into use anti-static system, and realize high-load production on two linesMany properties of this special material have reached or even exceeded the level of similar imported products.
At the beginning of the market, it has won a high degree of market recognition, and production and sales have continued to grow
.
The low-load operation of the device not only affects the benefit in terms of output, but also the energy consumption and labor cost per unit product output are also high
.
Soon, the first high-skilled talent innovation studio of the plastics factory, Wang Tao's high-skilled talent innovation studio, was established, and 15 studio members including Wang Tao began to tackle key issues around increasing the production load of the device
.
They continued to explore, adjusted the device many times, and consulted a large number of documents, and finally found that the root cause of the inability to increase the production capacity of the device was a design defect, and the problem could be completely solved after the transformation
.
"How to change it"? In order to determine the optimal transformation plan, Wang Tao and others took advantage of work gaps and spare time to collect production data on site, sort out the production process, and check related materials
.
In July 2017, the antistatic system of the polymerization line B was successfully put into use, and the production load of the polymerization line B of the device was increased; after continuous improvement, in August 2018, the production load of the polymerization line B was further increased, realizing high-load production
.
"The high-load production of only one production line is only a staged victory.
It is our ultimate goal to achieve high-load production on both production lines
.
" The high-density polyethylene plant has two production lines of polymerization A and B.
Wang Tao led the studio.
The members completed the adaptive transformation of the polymerization line A to realize the high-load production of double lines
.
Let two sets of hexene refining systems run in "parallel" to solve the problem of increasing hexene consumption, and the smooth operation lays the foundation for expanding the market
Let two sets of hexene refining systems run in "parallel" to solve the problem of increasing hexene consumption, and the smooth operation lays the foundation for expanding the marketHowever, two-line high-load production is not a simple arithmetic problem like "one plus one equals two"
.
Ethylene is the main raw material for the production of this special material, and hexene is the auxiliary production raw material.
After the modification of the device, the consumption of hexene raw material increases greatly, which leads to the production fluctuation of the device
.
"The design capability of the hexene refining system can no longer meet the requirements of hexene refining
.
" Zhang Xiaoxia, a member of the studio and a technician of the refining unit, gave possible reasons for the problem with her rich work experience
.
Wang Tao also paid attention to this problem
.
The operating capacity of the hexene refining system has an upper limit.
If the upper limit is exceeded, the refining effect of the hexene raw material will be greatly reduced, and in severe cases, production fluctuations will be caused
.
So, he began to think about how to improve the operation capacity of the refining system
.
The easiest and most effective way is to transform the refining system, but the transformation takes time and affects the output of the special material
.
Can it be enhanced without shutting down the system? Wang Tao and other studio members repeatedly scrutinized and experimented
.
In the end, they decided to change the operation mode of the two refining systems from the original "one use and one preparation" to "parallel" operation of the two systems, so as to prolong the residence time of the hexene raw material in the refining system and enhance the refining effect
.
The method does not need to be shut down for renovation, and the practical application effect is good.
In the case of "zero" input, the refining effect of the refining system is greatly enhanced
.
In 2019, with the assistance of the company's technical department and chemical sales company, Qilu Petrochemical's production and sales of special materials for easy-to-process floor heating pipes continued to increase, the market share gradually increased, and the economic benefits were good
.
Replace old pipelines, solve the problem of unstable product quality, and carefully "polish" to improve product quality
Replace old pipelines, solve the problem of unstable product quality, and carefully "polish" to improve product quality"Product quality is the key to making products into high-quality products and winning the market and customers
.
" Wang Tao led the studio members to repeatedly scrutinize the quality optimization plan and carefully adjust the index parameters
.
After the quality optimization plan was determined, they also solicited opinions from the front-line team leaders, and revised and improved them according to their opinions
.
In order to ensure that the optimization plan received the expected results, Wang Tao and others taught the front-line employees of the high-density polyethylene workshop, and combined with the actual production conditions of the employees during their shifts to explain the specific operations, accident handling and application of new technologies
.
At the same time, the studio members formed a team of two to guide the front-line employees to stabilize and optimize production parameters, finely control the production process, and solve problems in the production process
.
In March 2019, the quality of the special material was unstable.
The studio immediately searched for information and instructed the team to adjust parameters such as water temperature
.
"The effect of precipitation and temperature is not ideal, and the load adjustment is not very effective.
" After eliminating the reasons for water temperature and load, they decided to replace the stainless steel granulation conveying pipeline of polymerization line
A.
The granulation and conveying pipeline of polymerization line A is an old pipeline that has been used for more than 20 years.
The existing pipelines are densely packed, and it is very difficult to replace and construct
.
To this end, studio member Dong Qibin and equipment technician Zhou Yankai went to the site to investigate and adjust the construction plan according to the actual situation; studio member Li Ziying coordinated the production department to strive for a short stop time for the granulation line to create conditions for pipeline installation; workshop safety officer Chi Jianming According to the construction plan, check the safety risks that may be encountered on site, and implement safety measures.
.
.
On April 26, 2019, they completed the pipeline replacement in only 8 hours
.
After the new pipeline was put into use, the problem of unstable quality of the special material was solved
.
