2万吨铝加工项目方案.doc

2万吨铝加工项目方案1.0 总论1.1 基本原则 投资少、见效快、追求高性能价格比 立足于中高档产品厚铝箔，不介入低端铝板市场 分期投入，逐步做大、做强1.2 工程目标本工程是在长期以来对加工行业人士和研究基础上，结合现有条件作为重大投资项目提出的。工程分2期逐步投入，稳扎稳打，追求投资效益。 1期工程：10000吨年。主要满足对电缆箔、空调箱、PS板、装饰板卷登场品的市场需要，为下一步发展奠定良好的基础。 2期工程：20000吨年。扩大规模，追求规模效应。1.3 工程设计范围及原则1.3.1 设计范围：本工程设计范围为新建一家最终年产2万吨，涵盖铝及铝合金板材、带材、箔材的现代化铝加工企业。设计涉及建筑工程、工艺设备、工艺技术、相关设施，同时也为以后铝材深加工留有发展余地。1.3.2 设计原则：1）产品导向的原则；经过市场调研和预测确定企业主导产品，同时考虑到市场出现变化时应该有较大的适应性，即建设一个从厚铝箔生产到双零铝箔生产的全能综合性铝加工集团。2）生产技术高起点原则：从企业长期发展观点出发，必须提高企业的核心竞争能力，因此在关键设备的选型上，必须坚持高水平、高精度、高速度。工艺配置也必须采用最成熟、最先进的。3）节约投资的原则：以最合理的投资获得最可能的回报。4）合理布局的原则：以铸轧为代表的初级加工尽可能靠近电解铝厂，以单双零铝箔为代表的深加工能力尽可能靠近市场。5）物流合理性原则：各作业单位之间符合最优化的工艺流程，做到物流的顺畅。6）节能环保原则；节约能源，保护环境。7）注重EHS原则：注重“环境健康安全”，改善员工劳动条件。8）可持续发展原则：为今后向更大规模发展留有必要的空间。1.4 建设方案1.4.1 生产方案：本项目拟采取逐步投入，尽快形成生产能力的方式： 1期工程：15000吨年。 Ø6801600铸轧机 2台 Ø380/8001450冷轧机 1台Ø8001400拉弯矫直机 2台1400厚箔剪 1台20吨退火炉 2台MK848050轧辊磨床 1台投资总额：7,220万（含基础设施及流动资金） 2期工程：20000吨年。 Ø6801600铸轧机 1台 Ø380/8001450冷轧机 1台Ø8001400拉弯矫直机 1台1400厚箔剪 1台20吨退火炉 2台MK846350轧辊磨床 1台投资总额：约10,480万（含基础设施及流动资金）1.4.2 产品方案经过市场调研、确定产品方案。详见下表：序号合金牌号产品状态产品名称规格范围(mm)计算规格(mm)年产量(t)11000 3003 H14 H18 H22 H24 O铝卷0.201.00(7001280) (10004000)0.30120020001000021000 3003 H18 O厚铝箔0.100.20(6001280)0.151200200010000合计：200001.4.3 项目实施方案本项目建设周期定为12个月。项目起始时间：2003年4月18日。主要设备交货期（不含设计）序号设备名称交货期安装调试期总时间1铸轧机5.01.06.02冷轧机10.02.012.03铝箔轧机8.01.59.54拉弯矫直机5.01.06.05厚箔剪1.01.05.06分卷机4.51.05.57退火炉4.00.54.52.4 生产工艺2.4.1 铝加工工艺流程图铸轧重卷冷轧冷轧中间退火重卷拉伸弯曲矫直纵切纵切中间退火中间退火坯料退火退火退火冷轧冷轧粗中轧横切纵切检查检查剪切中轧退火包装包装精轧粗/中轧退火入库入库分切剪切剪切退火退火检查检查检查包装待添加的隐藏文字内容2包装包装入库入库入库板带卷产品铝箔产品2.4.2 连铸连轧冷轧生产线：1） 配料：根据生产的合金成分要求，按规定配料计算，为转炉准备炉料。2） 装炉：将准备好的炉料依次装入熔化炉内，加料顺序是先碎料后大块料，先废料后注入电解铝液。3） 熔化，炉料装完后升温熔化，熔炼温度按不同合金一般为700750。4） 搅料、扒渣：炉料全部熔化后，对铝液进行充分搅拌，已促进成分和温度均匀，然后扒去表面炉渣。5） 取样分析：经搅拌均匀后，取样分析其化学成分，当成分不合格时，需补充中间合金或加铝锭以达到规定的要求。6） 转炉：当铝液经分析化学成分合格后，转注到电阻保温炉内保温，转炉温度为710750。7） 静置：铝液到保温炉后再扒去表面炉渣，然后静置不少于30分钟。8） 精练过滤：铸造时将铝液由保温炉放流口放出，经过在线精炼过滤装置进行连续精练过滤，以除去铝液中的氢气和杂质。在精练过滤出口处取样，测氢含量。9） 铝熔液经精练过滤以后直接进连铸连轧，成品铸轧卷作为冷轧坯料。10） 铝板生产：铸轧卷经冷轧机进行轧制而达到成品厚度。对板形要求高的产品需要经过拉弯矫直机，一部分半硬产品，送到退火炉退火，出炉冷却后，再通过冷轧机轧制，由横剪机组开卷、矫直剪成定尺长度的成品板，经检查包装后入库。一部分要求硬态直接检验包装入库。软态经退火炉退火后，冷却到室温后，然后检验包装入库。11） 铝板带生产：铸轧卷送经冷轧机进行轧制，经多道次轧制后达到成品厚度。然后送到纵剪机剪成成品卷，硬态产品直接经检查包装入库。软态经退火炉退火后，冷却到室温后，然后检验包装入库。3.0 主要设备选择本项目分2期逐步投入，2个阶段的目标分别为： 1期：10000吨年 2期：20000吨年设备配置表序号设备名称规格阶段数量备注1期2期合计1铸轧机Ø68016002132冷轧机Ø380/80014501123厚箔剪14001124退火炉20t2245拉弯矫直机Ø80014002136轧辊磨床MK8410060101铸轧辊、支承辊、冷轧机工作辊MK846350011工作辊专用7辅助磨床11用于磨胶辊、导辊等3.1 熔炼及铸造车间1）15吨熔炼炉 3台2）15吨保温炉 3台3）在线精炼装置 3套4）Ø6801600连铸连轧机 3台最大卷重7吨，最大宽度1400mm3.2 冷轧车间1）Ø3808001450四辊不可逆状高速冷轧机 2台最大轧制速度：600mpm成品最小厚度：0.1mm 最大卷重7吨2）20吨退火炉 2台电加热、专用装料车3）轧辊磨床 2台最大磨削直径1000mm MK8410050磨床 1台最大磨削直径630mm MK846350磨床 1台5）拉弯矫直机 3台规格：Ø80014006）1400厚箔剪且机 2台剪切厚度：0.050.5mm剪切条数：20条成品宽度：351320mm工作进度：300m/min4.0 工厂建筑与结构1）铸轧车间：铸轧车间厂房为轻钢结构形式熔铸跨尺寸为建筑面积5040平方米2)冷轧车间:冷轧车间厂房为轻钢结构形式设计为(2428+12)300m建筑面积19200平方米3)机修车间:机修车间厂房为轻钢结构形式车间为18m单跨，长度为72m建筑面积1296平方米4): 110V变电所110V变电所安装2台110KV、3150KVA降压变压器。110KV变电所为两层框架结构变电所长度为50m，宽度为18m，建筑面积1802平方米5）：压缩空气与氮气站：站内设有VW227型无油润滑空气压缩机1台站内设BGPN39-11型碳分子筛制氮机1台DCZD-10氮气纯化装置2台压缩空气与氮气站厂房为单层排架结构站长54m，站宽18m，建筑面积972平方米7）循环水泵站：给水系统设有净循环、浊循环、生活消防桑额系统。厂区系统分为生活污水和雨排水两个系统。净循环系统设有热水泵、冷水泵各2台。热水池一座，尺寸为1254.5（m），有效容积为90立方米；冷水池1座，尺寸883（m），有效容积160立方米。冷却塔1台，型号为10BNG-500。RFC-3工业废水处理机1套。泵房为框架结构，宽20m，长48m，建筑面积960平方米8）轧制油及添加剂储存库：主要供2台冷轧机冷轧机（油箱总量约为100130吨），用油量大，如果采用200升油桶存放成本过高，故采用油罐集中存储，通过管道供油的方法加以解决。供货方油罐车直接卸油到油罐。7.0 投资概算7.1 设备投资估算（单位：万元）阶段序号设备名称规格数量单价安装费材料费总价1变电所3150KVA1115.015.030.0160.0制氮站125.025.0循环水148.048.0空压站150.050.0中心实验室理化分析设备1110.0110.02水平式铸轧机Ø68016002236.010.025.0542.0熔炼炉15t2100.020.015.0270.0静置炉15t270.05.010.0170.03冷轧机Ø380/800145011150.035.0125.01310.0厚箔剪14001150.08.010.0168.04拉弯矫直机Ø68014001530.020.030.0580.05退火炉20t2110.06.011.0254.0三维料车130.02.03.035.06轧辊磨床Ø850MK8480501400.0400.0合计基础设施投资：1608.8 设备投资：4022.0公共设施投资： 402.2本期固定资产投资：6033.01变电所3150KVA190.010.018.0118.0制氮站125.025.0循环水148.048.0空压站150.050.0水平式铸轧机Ø68016001236.010.025.0271.0熔炼炉15t1100.020.015.0135.0静置炉15t170.05.010.085.03冷轧机Ø380/800145011150.035.0125.01310.04拉弯矫直机Ø80014001430.020.030.0480.05厚箔剪14001150.08.010.0168.06退火炉20t1110.06.011.0254.07轧辊磨床Ø630MK8463501290.0290.0合计基础设施投资：1293.6 设备投资：3234.0公共设施投资： 323.4本期固定资产投资：4851.07.2 总投资估算7.2.1 项目总投资项目总投资包括固定资产投资和流动资金，经计算见下表（万元）：序号项目1期2期2万吨总投资1设备费用4022.03234.07256.02基础设施投资1608.81293.62902.43公共设施投资402.2323.4725.64固定资产投资6033.04851.010884.05其它不可预测费用459.6529.61089.26流动资金需求2300.04680.0本期流动资金投入2300.02380.04680.07项目投资8892.67760.616653.2Editor's note: Judson Jones is a meteorologist, journalist and photographer. He has freelanced with CNN for four years, covering severe weather from tornadoes to typhoons. Follow him on Twitter: jnjonesjr (CNN) - I will always wonder what it was like to huddle around a shortwave radio and through the crackling static from space hear the faint beeps of the world's first satellite - Sputnik. I also missed watching Neil Armstrong step foot on the moon and the first space shuttle take off for the stars. Those events were way before my time.As a kid, I was fascinated with what goes on in the sky, and when NASA pulled the plug on the shuttle program I was heartbroken. Yet the privatized space race has renewed my childhood dreams to reach for the stars.As a meteorologist, I've still seen many important weather and space events, but right now, if you were sitting next to me, you'd hear my foot tapping rapidly under my desk. I'm anxious for the next one: a space capsule hanging from a crane in the New Mexico desert.It's like the set for a George Lucas movie floating to the edge of space.You and I will have the chance to watch a man take a leap into an unimaginable free fall from the edge of space - live.The (lack of) air up there Watch man jump from 96,000 feet Tuesday, I sat at work glued to the live stream of the Red Bull Stratos Mission. I watched the balloons positioned at different altitudes in the sky to test the winds, knowing that if they would just line up in a vertical straight line "we" would be go for launch.I feel this mission was created for me because I am also a journalist and a photographer, but above all I live for taking a leap of faith - the feeling of pushing the envelope into uncharted territory.The guy who is going to do this, Felix Baumgartner, must have that same feeling, at a level I will never reach. However, it did not stop me from feeling his pain when a gust of swirling wind kicked up and twisted the partially filled balloon that would take him to the upper end of our atmosphere. As soon as the 40-acre balloon, with skin no thicker than a dry cleaning bag, scraped the ground I knew it was over.How claustrophobia almost grounded supersonic skydiverWith each twist, you could see the wrinkles of disappointment on the face of the current record holder and "capcom" (capsule communications), Col. Joe Kittinger. He hung his head low in mission control as he told Baumgartner the disappointing news: Mission aborted.The supersonic descent could happen as early as Sunday.The weather plays an important role in this mission. Starting at the ground, conditions have to be very calm - winds less than 2 mph, with no precipitation or humidity and limited cloud cover. The balloon, with capsule attached, will move through the lower level of the atmosphere (the troposphere) where our day-to-day weather lives. It will climb higher than the tip of Mount Everest (5.5 miles/8.85 kilometers), drifting even higher than the cruising altitude of commercial airliners (5.6 miles/9.17 kilometers) and into the stratosphere. As he crosses the boundary layer (called the tropopause), he can expect a lot of turbulence.The balloon will slowly drift to the edge of space at 120,000 feet (22.7 miles/36.53 kilometers). Here, "Fearless Felix" will unclip. He will roll back the door.Then, I would assume, he will slowly step out onto something resembling an Olympic diving platform.Below, the Earth becomes the concrete bottom of a swimming pool that he wants to land on, but not too hard. Still, he'll be traveling fast, so despite the distance, it will not be like diving into the deep end of a pool. It will be like he is diving into the shallow end.Skydiver preps for the big jumpWhen he jumps, he is expected to reach the speed of sound - 690 mph (1,110 kph) - in less than 40 seconds. Like hitting the top of the water, he will begin to slow as he approaches the more dense air closer to Earth. But this will not be enough to stop him completely.If he goes too fast or spins out of control, he has a stabilization parachute that can be deployed to slow him down. His team hopes it's not needed. Instead, he plans to deploy his 270-square-foot (25-square-meter) main chute at an altitude of around 5,000 feet (1,524 meters).In order to deploy this chute successfully, he will have to slow to 172 mph (277 kph). He will have a reserve parachute that will open automatically if he loses consciousness at mach speeds.Even if everything goes as planned, it won't. Baumgartner still will free fall at a speed that would cause you and me to pass out, and no parachute is guaranteed to work higher than 25,000 feet (7,620 meters).It might not be the moon, but Kittinger free fell from 102,800 feet in 1960 - at the dawn of an infamous space race that captured the hearts of many. Baumgartner will attempt to break that record, a feat that boggles the mind. This is one of those monumental moments I will always remember, because there is no way I'd miss this.