Intelligent H-beam production line – Industry 4.0 customized production demonstration project

1. Fujian Longgang Intelligent Iron and Steel Industry 4.0 Customized Production Demonstration Project


Intelligent H-beam production line


Fujian Longgang New Materials Co., Ltd. has relocated to different places through capacity replacement, building an iron-making capacity of 1.20286 million tons per year, a steel-making capacity of 1.21 million tons per year, and an annual output of 1.128 million tons of H-shaped rolled steel. The construction content includes the main project, public and auxiliary projects, etc.

Main project: 1 set of 300 square meters sintering machine (supporting 1 set of waste heat generating set), 1 1.2 million tons/year grate machine-rotary kiln pellet production line, 1 1320 cubic meter blast furnace (supporting pulverized coal injection device, Dust removal device, residual pressure power generation device), 1 106-ton converter (supporting 1 argon blowing wire feeding station, 1 LF refining furnace, 1 8-machine 8-stream rectangular billet continuous casting machine, and gas recovery, steel slag hot stuffy crushing processing system, dust removal device), 1 H-shaped steel rolling production line.

Supporting construction content: 2 B-type closed environmental protection material yards, 2 double-bore lime kilns with a daily output of 600 tons, 1 40,000 cubic meter oxygen generator, 1 65 MWh gas generator set, steel billet raw material and finished product warehouse, 1 One 165,000 cubic blast furnace gas cabinet, one 80,000 cubic converter gas cabinet and other supporting public and auxiliary facilities.

After the project construction and production strictly implement the various ecological environment protection, environmental risk prevention measures and main pollutant area reduction measures proposed in the report, and adopt the most stringent environmental management system and environmental monitoring measures, the pollutants can reach the standard discharge, and the main pollution The discharge of pollutants complies with the total control requirements, and the environmental risks are controllable.


2. Intelligent H-beam production Project design, construction and operation


1) In accordance with the target positioning of “environmental protection priority, green development” and the concept of ultra-low emission throughout the whole process, based on the construction of an international leading iron and steel joint production enterprise, further optimize the overall layout, process route and design plan, and select high-quality Raw and auxiliary materials adopt international advanced technology, technology and equipment, benchmark the advanced energy efficiency level of the same industry at home and abroad, strengthen the energy saving, consumption reduction and emission reduction measures of each device, and ensure that the enterprise’s clean production continues to improve on the basis of reaching the first level, from Reduce the generation of pollutants and carbon emissions at the source.


H-beam production line


2) Ecological and environmental protection measures


(1) Prevention and control of air pollution.

Strictly implement the policy requirements and the air pollution prevention and control measures proposed in the report, and simultaneously construct high-efficiency desulfurization, denitrification, and dust removal facilities. The processing capacity and efficiency of each treatment facility should meet the needs. Desulfurization; flue gas bypass shall not be set up, and the height of the exhaust pipe shall meet the requirements of the environmental impact assessment and comply with relevant regulations; comprehensively strengthen the control of unorganized emissions during material storage, transportation and production processes, and adopt effective control measures such as airtightness and sealing to effectively improve waste gas collection rate, dust production points and workshops must not have visible smoke and dust escaping.

Implement the clean transportation requirements for bulk materials and products. Blocky or powdery materials such as ores should be transported in a sealed manner from the Jitai Railway Station to the factory by using a tubular belt conveyor; if they really need to be transported by car, they should all be transported by new energy vehicles or reach Vehicles with National VI emission standards should use closed compartments or tightly covered with thatch for massive or powdery materials, and humidification and other dust suppression measures should be taken when loading and unloading vehicles.


Organized waste gas pollution prevention and control measures:


a. Material preparation process: Unloading waste gas, waste gas from mixing tank, coal bunker and coke bin waste gas, and transfer dedusting waste gas are collected by the gas collection hood and then treated by bag filter with film-coated material.

b. Sintering process: the flue gas of the sintering head adopts the treatment technology of “flue gas circulation technology + four electric field dust collector + circulating fluidized bed desulfurization + bag dust removal (using film-coated filter material) + SCR denitrification”; the sintering mixed waste gas adopts High-efficiency wet dust collector treatment; fuel flux crushing and screening waste gas, sintering batching waste gas, sintering machine tail waste gas, whole grain screening waste gas, sintering product transfer waste gas, finished product mine tank waste gas, etc. are all treated by film-coated filter bag type dust collectors.

c. Pelletizing process: The bag-type dedusting (film-coated filter material) treatment technology is adopted for pelletizing, batching, drying and preheating waste gas. Pellet preheating and roasting flue gas are purified by “tubular dust collector + SCR denitrification in return air section + double chamber four electric field dust collector + circulating fluidized bed absorption tower + bag dust collector”.

d. Ironmaking process: Blast furnace ore coke trough top distribution, under trough sieve distribution, raw coal storage and transportation, coal powder preparation and drying, injection tank pressure relief, powder bin exhaust gas all adopt film-coated filter material bag filter Treatment; cast iron machine exhaust gas is removed by bag filter; blast furnace gas is finely desulfurized by “gravity filter + bag filter + molecular material adsorption system”; blast furnace hot blast stove uses purified blast furnace gas as fuel + low nitrogen combustion process.

e. Steelmaking process: the primary flue gas of the converter is treated by the LHG dry dust removal device, the waste gas of bulk steelmaking and ferroalloy material transfer and feeding, the secondary flue gas of the converter (including the waste gas of the argon blowing and wire feeding station), and the tertiary flue gas Gas (containing molten iron pretreatment waste gas), LF refining furnace and feeding system, and steel slag crushing and magnetic separation waste gas are all treated by film-coated filter material bag filter; converter steel slag treatment roll crushing waste gas (including cast iron machine waste gas) is treated by wet electrostatic precipitator craft.

f. Steel rolling process: the heating furnace uses purified blast furnace gas as fuel + low-nitrogen combustion process; rough rolling waste gas and finishing rolling waste gas are treated by a plastic burning plate dust collector.

g. Lime ash process: raw material unloading, screening, transfer of waste gas and finished product blanking, transfer, and screening of waste gas are all treated with bag-type dust removal (film-coated filter material). The waste gas of the lime kiln body system is treated by “bag dust removal (using film-coated filter material) + new low-nitrogen combustion”.

h. 65MW coal gas power generation process: Purified blast furnace gas and converter gas are used as fuel + SCR denitrification treatment.


The organized and unorganized emission of air pollutants in the whole plant must meet the defined requirements; the flue gas of some of the equipment should also implement stricter ultra-low emission limit standards in accordance with the company’s commitment and the requirements confirmed by the Longyan Ecological Environment Bureau: sintering machine The emission concentration limit of particulate matter, sulfur dioxide, and nitrogen oxides in machine head flue gas and pellet roasting flue gas is 8 mg/m3, 28 mg/m3, and 40 mg/m3; blast furnace hot blast stove flue gas and steel rolling heating furnace The emission concentration limit of nitrogen oxides in flue gas is 80 mg/m3, and the emission concentration limit of sulfur dioxide and nitrogen oxides in the main system of the lime kiln is 15 mg/m3 and 40 mg/m3.

Fluoride and dioxin emissions from the sintering machine head and pellet roasting flue gas are stricter than the air pollutant emission limit requirements of newly-built enterprises, and the emission concentration limits are 1.8 mg/m3 and 0.4TEQ nanograms/m3 respectively; The concentration of particulate matter at the factory boundary is subject to the concentration limit of fugitive emission monitoring (the highest concentration point outside the perimeter is 1.0 mg/m3). The above-mentioned limits are used as the basis for the completion of the project’s environmental protection acceptance and daily environmental supervision and law enforcement.

Strengthen the construction of automatic monitoring, process monitoring and video monitoring facilities, and the pollution control facilities at pollution sources should install distributed control systems.

The sintering machine head, machine tail, pellet roasting, blast furnace ore coke chute, blast furnace cast house, converter secondary and tertiary flue gas, lime kiln body system, gas generator set exhaust pipe should be equipped with automatic monitoring facilities, and Network with the ecological environment department.

High-definition video monitoring facilities should be installed at the entrance and exit of the stockyard, the sintering ring cooling area, the blast furnace trough and furnace roof area, and the top of the steelmaking workshop, which are prone to dust production. Air quality monitoring micro-sites are arranged around the main dust production points and on both sides of the transportation road in the factory area. Establish a centralized control system for fugitive emission control facilities throughout the plant, and record the monitoring, monitoring and control facility operation near all fugitive emission sources, as well as the air quality monitoring micro-station monitoring data.

Environmental protection zones are set up within the enveloping range of 50m outside the sintering workshop, 50m outside the pelletizing workshop, 50m outside the ironmaking workshop, 50m outside the steelmaking workshop, 50m outside the raw material field, 300m outside the steel rolling workshop, and 450m outside the gas cabinet unit. Environmentally sensitive targets such as residential areas, schools, hospitals, administrative offices, and scientific research must not be located in the above-mentioned environmental protection zones. While meeting the environmental protection distance required by the report, the project should also meet the relevant health protection requirements.

(2) Water pollution prevention and control.

In accordance with the principle of “separation of rain and sewage, separation of clean and sewage, quality-based treatment, and multiple uses of one water”, a complete sewage and rainwater collection, treatment and reuse system has been built, and the production wastewater and domestic sewage of the whole plant will be reused after treatment and will not be discharged outside.

The pressure pipeline for conveying sewage shall be laid on the ground as much as possible, and the rainwater outlet shall be equipped with an automatic shut-off valve. To strengthen the control of thallium pollution, low-thallium raw materials should be selected, the detection and analysis of thallium components in ore raw materials and production waste should be strengthened, and a ledger of thallium-related raw materials and thallium-related waste should be established.

Strengthen the water quality monitoring of rainwater outlets, implement online monitoring of water quality and regular monitoring of thallium content in rainwater outlets in accordance with the requirements of environmental impact assessment, and strengthen the tracking and monitoring of water quality in Zhangping City Railway Water Plant drinking water surface water source protection area.

When the project draws water from the river, the scale of water intake must be controlled in accordance with the management requirements of the water conservancy department to ensure the domestic water, ecological water, and agricultural water needs of the downstream basin.

(3) Prevention and control of soil and groundwater pollution.

Strictly implement the zonal anti-seepage measures proposed in the report, and strengthen the daily maintenance of anti-seepage facilities to prevent soil and groundwater pollution. Establish a complete soil and groundwater monitoring system, reasonably set up monitoring points in accordance with the requirements of environmental impact assessment and relevant technical specifications, carry out regular soil and groundwater monitoring, focus on monitoring the soil and groundwater in areas with potential pollution hazards and around facilities, and strengthen monitoring of surrounding agricultural land. Tracking and monitoring of soil and village groundwater environment. In the event of soil or groundwater pollution, emergency plans and emergency measures should be initiated immediately to reduce adverse impacts on soil and groundwater.

(4) Prevention and control of solid waste pollution.

In accordance with the principle of “reduction, harmlessness, and recycling”, solid wastes are collected, stored, treated, and disposed of in a classified manner, solid waste management accounts are established in a standardized manner, and standardized management throughout the process is strengthened to ensure that no secondary pollution is caused.

All general industrial solid waste should be comprehensively utilized.

General industrial solid waste such as steel slag, refining slag, casting slag, iron oxide scale, rolling waste, turbid ring water treatment iron-containing sludge, dust removal ash of each process (except for light dust removal ash of sintering head) and other general industrial solid wastes are returned to the sintering system for comprehensive utilization;

Steel slag processed in the steel slag treatment workshop is reused in the steelmaking workshop; desulfurization ash, blast furnace slag, tailings with low iron content, and waste refractory materials are sold outside the sintering and pelletizing process; waste desulfurization agent for fine desulfurization of blast furnace gas, Waste molecular sieves, waste reverse osmosis membranes, waste dust bags (except sintering head, blast furnace gas dust removal and other processes) are recycled by the manufacturer. Sludge and household garbage from the facilities in the domestic sewage treatment shall be sent to the designated place of the local environmental sanitation department for disposal.

Hazardous waste such as waste denitrification catalysts, waste paint barrels, waste oil barrels, and waste engine oil should be collected and stored in a standardized manner, and qualified units should be entrusted for disposal or recycling.

The sintering head, blast furnace gas waste dust bag, sintering headlight dust and blast furnace gas ash should be identified for their hazardous characteristics and should be disposed of according to the identification results. Before identification, they should be managed as hazardous waste.

(5) Implement noise pollution prevention and control measures.

Optimize the layout of high-noise equipment, give priority to low-noise equipment, and take measures such as noise reduction, sound insulation, and shock absorption to reduce noise and reduce noise. The noise at the factory boundary must meet the standard requirements to ensure that the acoustic environment quality of environmentally sensitive points meets the standard and prevent noise from disturbing residents.

(6) Environmental risk prevention.

Strengthen project intrinsic safety management, and strengthen environmental risk prevention and emergency measures. Install gas leakage automatic detection and alarm devices in the storage, transportation and use areas of coal gas, ammonia water and natural gas to ensure timely detection and effective disposal of toxic and harmful gas leakage accidents;

Set up an underground emergency pool for environmental accidents with sufficient volume, equipped with complete accident wastewater diversion facilities, to ensure the effective transportation and storage of accident wastewater; production wastewater treatment facilities, ammonia tank area cofferdam, rain (sewage) water pipe ditch, initial rainwater Environmental risk facilities and prevention and control links such as collection pools and rainwater discharge outlets must be equipped with switching valves and connected to emergency pools to ensure that emergency treatment wastewater is not discharged outside.

Before the project is put into operation, the construction of the public accident emergency pool and supporting diversion system in the park will be completed, and the public accident emergency pool in the park will be interconnected with the accident pool of this project.

Formulate emergency plans for environmental emergencies and connect them with the plans of the park, the government and relevant departments, reserve sufficient environmental emergency materials and emergency equipment, conduct regular environmental emergency drills, and improve emergency response capabilities for sudden environmental risk accidents.

(7) Environmental monitoring.

Formulate and strictly implement self-monitoring plans for various pollution sources and the ecological environment during the construction and operation periods, and disclose the monitoring results to the public in accordance with regulations; strengthen forecasting, early warning and forecasting, and take effective measures to resolve abnormalities in monitoring data immediately.

Implement the construction of automatic monitoring facilities for exhaust pipes of major air pollution sources, automatic monitoring stations for the atmospheric environment in Suilin Village, and online monitoring facilities for water quality at rainwater discharge outlets, and do a good job in networking with the ecological environment department. After the project was completed and operated stably for one month, the ultra-low emission assessment and monitoring of iron and steel enterprises were carried out in a timely manner, and the assessment and monitoring report was submitted to the Longyan Ecological Environment Bureau.

(8) Environmental management.

Strengthen the building of corporate environmental management capabilities, and strictly implement the “three simultaneous” system of environmental protection. Strengthen environmental protection management during the construction period, and entrust a third party to carry out environmental supervision during the construction period. Proactively disclose corporate environmental information in a timely manner as required, and consciously accept social supervision; strengthen publicity and communication, establish smooth channels and platforms for public participation, and meet the public’s reasonable demands for environmental protection.

(9) Carbon emission management.

Implement the requirements of the National Development and Reform Commission and other departments, and implement the province’s energy consumption dual control goals and tasks and follow-up policies such as the carbon peak action plan for relevant regions, strengthen energy conservation and consumption reduction, optimize pollution reduction measures, and ensure that the energy efficiency of enterprises reaches the industry benchmark level. Strictly control the energy consumption and carbon emission intensity per unit of product, reserve space and interfaces for additional carbon emission reduction measures, and realize coordinated control of pollution and carbon reduction.

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