Merrill Lynch: Overturn the tradition and promote the healthy development of the industry
Since 2014, a new round of elimination competition has swept Ningguo, Anhui Province, which is known as the "capital of wear-resistant castings". In 2009, there were more than 130 wear-resistant material enterprises registered in industry and commerce in Ningguo City, and now there are less than 20. In addition, the cement market of the major consumer of wear-resistant steel balls has dropped sharply,
Since 2014, a new round of elimination competition has swept Ningguo, Anhui Province, which is known as the "capital of wear-resistant castings". In 2009, there were more than 130 wear-resistant material enterprises registered in industry and commerce in Ningguo City, and now there are less than 20. In addition, the cement market of the major consumer of wear-resistant steel balls has dropped sharply, and ceramic abrasives have come out, so it seems that there is no way out for wear-resistant steel balls. In this environment, Hubei Merrill Lynch Technology Co., Ltd. (hereinafter referred to as "Merrill Lynch") invested 1 billion to enter the wear-resistant steel ball industry, which is somewhat "incredible" to outsiders.
Fully automatic intelligent batching system
"We just put into the market in October last year, and the sales volume rose sharply in just a few months. There was a rare situation that the supply could not meet the demand. We were recognized by a number of large cement groups, such as Jinyu (372.5 yuan/ton, 0%), Jidong (318 yuan/ton, 0%), Huaxin (355 yuan/ton, 0%), Guangdong Tapai, Jianfeng Cement, etc. As of February 2017, we had provided products and services to more than 60 cement enterprises, and gained good market reputation." Zou Libing said. "It needs to be hard to strike iron", and such gratifying achievements can be achieved at the beginning of entering the market. In addition to the overall stable and rebounding environment of the cement industry in 2016, this is closely related to Merrill Lynch's new understanding of the production of wear-resistant steel balls. "At the beginning, a new process was developed, and the European steel ball production process was introduced. From raw material batching to heat treatment system, intelligent assembly line production was realized. In terms of quality, Merrill Lynch fully automated batching system and 6t medium frequency furnace achieved 100% qualification of molten iron. The sand box formed by the DISA molding line imported from Denmark has high accuracy and good performance. The German heat treatment system, with 24 zone temperature control, has an accuracy of ± 5 ℃, and each steel ball is heated evenly and has good quality Exactly the same. In terms of energy efficiency, the capacity of a steel ball production line with an annual output of 80000 tons of Merrill Lynch is 8 times that of the general domestic production line, while the number of workers is only one third. The unit power consumption has decreased by 50%, and the qualification rate has increased to 99.95%. "
German Intelligent Control Heat Treatment System
The introduction of heat treatment system and motion simulation software has further improved the stability of steel balls and ball mills. The input of heat treatment system has reduced the ball consumption by more than 10% and the crushing rate by less than 1 ‰. Reducing the ball consumption and crushing rate means reducing the amount of balls added and the number of shutdowns. With the application of motion simulation software, Merrill Lynch can calculate and simulate the working conditions of the ball mill, provide customers with a better grading scheme, and make the ball mill reach a better working condition.
DISA fully automatic modeling line
Most traditional steel ball enterprises are unable to overcome the noise pollution during production, which gives the impression of heavy pollution and high energy consumption. In response to such a persistent problem, Zou Libing said that all dust raising points of the Merrill Lynch steel ball production line were equipped with filter cartridge dust collectors imported from the United States, which met the EU emission standards. In particular, the two dedusting devices of the intermediate frequency furnace were the first to install an online monitoring system in the foundry industry to monitor emission data in real time, so as to truly achieve green casting.
As for the future casting steel ball industry, Zou Libing believes that as a consumable of cement enterprises, the demand for casting steel balls has been declining year by year in the last ten years due to the large use of roller presses and vertical mills. By 2014, the transformation of roller presses and vertical mills had been basically completed, and the downward trend had slowed down, and it began to stabilize in 2016. In the case of stable market demand, competition will continue to intensify, environmental protection requirements will become stricter, and some steel ball enterprises with poor quality, high energy consumption and heavy pollution will be gradually eliminated from the market, ultimately promoting the self revolution of steel ball manufacturers.
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