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Taurus potash is one of the few companies in China that uses ion membrane technology to produce high-quality potassium hydroxide. In August of last year, the company's second-phase improvement project made the annual production capacity of potassium hydroxide the second in the country, and its products rapidly expanded both at home and abroad.
However, as the market expands, goods exported overseas have been transported by sea for a long time. The damaged packaging bags have caused the products to become damp and agglomerate, and domestic customers have also reflected the occurrence of sundries and black alkali. This led to the attention of the leaders of Jinniu Potash. Huang Zhijie, general manager of the company, said in pain at the product quality analysis meeting: “The output has increased and the management cannot relax. There is a quality problem. The compensation is small, which damages the reputation of the company and loses the product market. Big. Losing the market means shutting down production and closing down!†On the one hand, they are actively organizing exchanges, discounts, and compensation, changing the package size to avoid friction and damage during transportation; on the other hand, strengthening internal quality management and improving quality, Consolidate the brand's activities.
A campaign to enhance product quality through QC event team technology innovations was launched in Taurus Potash. The QC department and the technical department of the company jointly established 16 QC activity teams for each intermediate link that could easily cause product quality problems. Through technical innovation and technological innovation, the company made raw materials into the factory, production processes and intermediate processes, and product inspections. All links are always under control.
In the production of potassium hydroxide, they reduced the number of opening and stopping operations and kept the equipment operating stably. In response to problems in the production of packaging scales and caustic burners that often fail, they set up a QC activity group to reduce the number of failures of protokali packing scales and reduce the number of stoppages in the combustion furnace. Through the research, they changed the materials, air circuits and circuits of the packaging scales, which reduced the number and the processing time of the packaging scales significantly. They also modified the connection between the flame detector and the burner, fundamentally eliminated the furnace failure caused by the false alarm of the flame detector, and stopped the furnace from stopping to produce the unqualified alkali.
According to Lu Qingmei, vice minister of quality inspection, the high chlorate content in the system will also affect product quality. During the operation of the system, if this indicator is not lowered, closed-circuit circulation will increase the concentration of chlorate in the salt water, which will eventually lead to excessive levels of chlorate in the caustic product and excessive caustic soda chloride, which will not meet the industry requirements. Standards and user requirements. Reducing the chlorate content in the liquid caustic soda, the QC team took on the task of solving this problem. They conducted a small test in the laboratory to simulate the actual production environment, temperature and conditions, and finally found the chlorate decomposition process parameters and applied them to The effect of actual production is obvious, and the content of potassium chlorate in the 48% liquid caustic soda has been reduced to 0.002%, which has reached the domestic leading level.
The QC team responsible for reducing the high chlor-alkali base and increasing the qualification rate led the reuse of the high-chlorine alkali produced as a defective product from the past stop-and-stop to the intermediate process of the system, which reduced the number of unqualified products and also reduced the corrosion of the equipment.
Control of sugar concentration to improve the quality of protopine QC group through the exploration and practice, to determine a reasonable ratio of sugar, improve the clarity of protopine solution and protopine products quality, eliminate the production of black alkali. In addition, the equipment failure rate has also been reduced from the original 1% to 0.2%, bringing direct and indirect economic benefits to the company of more than 2 million yuan.
The QC team, which improves the qualified rate of refined brine, improves the brine concentration control qualification rate, and shortens the downtime of the circulating water pump, all through technological innovations, so that all indicators of the production process are in the best controllable state.
After more than half a year's efforts, the pass rates of Tauren Protopine and Liquor-alkaline products both increased by 2%, and thousands of tons of substandard bases were reduced, creating profits of more than 300,000 yuan. At present, the R&D project of the Taurus Potassium QC Activity Group is more about the new requirements put forward by some special users and high-end users on product indicators. The efforts of the QC team have continuously improved the quality of the company's products and created a new situation in which innovation improves quality and establishes a brand image.
Hit the quality upgrade of potassium hydroxide
Right now, Suizhong Energy Xingkuang Group is the busiest quality inspection department in the Taurus Potash Branch. A staff member of the department told the reporter: “We have to go to the workshop every hour to take a sample, and after we come back, we will transmit the detected data to the central control room. The central control room will then direct the whole production process of the whole plant based on these data. In this way, product quality can be guaranteed most effectively."