What is the best way for ceramic enterprises to break through the difficult survival under the high-pressure of "governing qi"?

Release time: 2018-06-06 17:56

【Summary Description】 Following the implementation of the "strictest ever" Air Pollution Prevention and Control Law on January 1, 2016, the environmental pressure on China's Jiantao production areas continues to increase:

Following the implementation of the "strictest ever" Air Pollution Prevention and Control Law on January 1, 2016, the environmental pressure on China's Jiantao production areas continues to increase:

In March 2016, Shandong Zibo took the lead in ushering in the "most stringent" environmental protection, only one month, more than 20 Zibo pottery enterprises were issued a notice to stop production, 14 enterprises were even directly ordered to stop production for 6 months.

Subsequently, in order to cooperate with the G20 Summit, many ceramic enterprises in Zibo, Linyi and Hebei Province were limited or stopped production;

July 14, the central environmental protection inspection group has entered Inner Mongolia, Heilongjiang, Jiangsu, Jiangxi, Henan and other eight provinces (autonomous regions) to carry out environmental protection inspection work, Henan, Jiangxi and other places to build pottery production areas have been ordered to stop production of the news, causing great concern in the industry.

On September 19, Zibo, Shandong Province issued the "Shandong Province Regional Comprehensive Emission Standards for Air Pollution", which proposed more stringent standards for pollutant emissions - particulate matter 10 mg/m3, sulfur dioxide 50 mg/m3, nitrogen oxides 100 mg/m3, and the benchmark oxygen content of 8.6%.


"At present, the most urgent need for ceramic enterprises to solve the problem of dust and NOx standards." Some insiders said in an interview that for the heavily polluting ceramic industry, in addition to the relatively mature and widely used wastewater treatment technology, waste gas and waste residue have always been a problem plaguing ceramic enterprises. Especially with the gradual increase of the national efforts to control air pollution, the pollution control task of pottery enterprises is becoming more and more urgent.

"However, the current situation is that in the current ceramic production areas, except for a few enterprises' environmental governance work has achieved some results, most enterprises are far from meeting the emission standards." The relevant person in charge of an environmental protection equipment company in Foshan admitted that it is not because the pollution control technology is not good, the most critical thing is that ceramic enterprises need to be improved for cost and other considerations.

Respondents said that in 2017, the new revision of the National Ceramic Industry Pollutant Emission Standards is expected to be issued, and its standards will be more stringent than the current standards. "In 2017, the environmental pressure of ceramic enterprises only increased, so we must be ready to meet a new round of challenges in advance."

Single management measure

At present, the treatment measures of atmospheric pollutants in the ceramic industry are relatively simple: for dust removal, the main use of cyclone dust collection, cloth bag dust removal or water bath dust removal; For denitration management, many enterprises have not adopted denitration measures, and only a small number of enterprises have carried out simple SNCR(ammonia or urea) denitration.

For desulfurization treatment, according to the form of desulfurizer, it can be divided into wet method (90%), dry method and semi-dry method. Wet method is divided into lime method, sodium alkali method, double alkali method, ammonia method and so on. At present, the ceramic industry mainly uses the double alkali method for desulfurization, and a small number of enterprises use the lime-gypsum method. The kiln adopts sodium-alkali method (or sodium-calcium double-alkali method) desulfurization dust removal scrubber, and the denitrification part adopts SNCR in the furnace or dry powder with potassium permanganate as the main component.

According to reports, the principle of the double alkali method uses NaOH as a starting absorber to absorb SO2, and then Na2SO3 or NaHSO4 is replaced by Ca(OH)2. This method has low investment, fast results, and can achieve ideal results when it is first put into use.

Lime - gypsum method uses lime as desulfurizer, the final product is calcium sulfate, which is easy to filter and no secondary pollution; Hollow cone atomizing nozzle, gas liquid contact is sufficient, high desulfurization efficiency; The slurry in the system closed circulation, no odor volatilization, small footprint; The main tower has no packing, the system resistance is small, and it is not easy to scale.

The semi-dry rule refers to a reaction state that does not produce waste water, after mixing the desulfurizer and the powder of the spray tower in a dry state, the pollutants in the flue gas are absorbed to the surface of the particulate matter in the reactor, and then the reaction is carried out by the bag dust collector, so that the final discharge is only the dry gas, and no waste water is produced.

Huang Jianqi, chairman of Guangdong Saiindi Technology Co., LTD., said that at present, most enterprises in the ceramic industry have adopted the "double alkali method", because the equipment investment is small, the maintenance cost is also low, and it is easy to be accepted by most pottery enterprises. The lime (stone) -gypsum method was borrowed from the power industry earlier, and in order to adapt to the ceramic industry, the equipment structure and the setting of the link have also been adjusted, and some links have been removed, and only a few ceramic enterprises in the industry use this equipment.

Comparison of advantages and disadvantages of double alkali method and lime (stone) -gypsum method

Yin Haibin, director of the Building Materials Environmental Protection Research Institute of Jiangsu Kehang Environmental Protection Technology Co., LTD., pointed out that at present, the company uses lime (stone) -gypsum desulfurization, high efficiency bag dust wet decongestator, hot blast stove SNCR, low-temperature SCR in the kiln, and gives priority to using a reasonable flue gas summary program, through the combination of the above technologies, can meet the current domestic lowest local standards.

The choice of lime (stone) -gypsum desulfurization is mainly based on the consideration of long-term comprehensive cost. The ceramic industry generally uses the double alkali method mainly because of its early equipment investment is low, before some ceramics factories integrate the double alkali method desulfurization on hundreds of thousands of investment, and the later operating costs are relatively low, but its failure rate is high, often blockage.

Huang Jianqi also expressed the same point of view, in the actual environmental control, the treatment of waste gas is relatively easy, sewage treatment is second, and polluted soil is the most difficult to control.

He introduced that the double alkali method is very feasible in theory, but the exchange reaction can not guarantee that the material reaction is complete, in the laboratory, calcium hydroxide and sodium sulfate can fully react completely, but in the practical application of pottery enterprises, it needs to be carried out in a large pool, unable to fully stir, so sodium sulfate crystals will be produced, and the crystals will adhere to the tube wall. It's hard to deal with after a while. "When companies are draining water, it's quite a pollution transfer."

In addition, in the application process of the double alkali method, because most of the intermediate products have a large number of Na2SO4 did not participate in the replacement reaction, the content continues to accumulate, and the desulfurization efficiency continues to decline. At the same time, under the condition of strong alkaline, the dissolution characteristics of calcium sulfate change, easy to scale, plug the pipeline; In order to avoid calcium sulfate entering the absorption tower, ceramic enterprises are generally equipped with a sizeable sedimentation tank, which covers a large area, and the exposure of the pool causes a lot of water to evaporate, and some of the harmful gases such as SO2 and HCl that have not been removed will also overflow.

Most environmental technologies, including the two-alkali process, have low automation, and the desulphurization system is prone to blockage and high cost. At the same time, the flue gas discharged after treatment is unstable and easy to exceed the standard. In addition, the site environment of equipment operation and the working environment of employees also need to be further improved.

"But even so, most pottery enterprises still choose the double alkali method based on cost considerations." The reason is that the double-alkali method is relatively simple to operate, and the cost is low, the equipment control requirements are relatively low, and the flue gas treatment of some small pottery enterprises is more reasonable." Said Zhu Tingzhen, general manager of Foshan Chuangqing Environmental Engineering Co., LTD.

Technology upgrade, a variety of pollutants can be coordinated treatment

Yin Haibin introduced that Kexin Environmental protection has fully investigated the environmental protection situation of the ceramic industry since 2014, and successfully implemented the first ultra-low emission dust removal project in China - Guangdong Mona Lisa Ceramic denitrification ultra-low emission project in 2015, and quickly formed a complete set of technical solutions with automation, high efficiency and low operating costs.

It is reported that the construction by the Kexing Environmental Protection Institute, located in the Mona Lisa Xixia plant area of a variety of pollutants ultra-low emission project has been successfully operated for more than a few months, the project on the basis of existing environmental protection equipment, hot blast furnace using SNCR denitrification technology, reduce NOx hot blast furnace flue gas and kiln flue gas summary into the wet deconsolizer for deep removal, Further reduce the discharge of various pollutants such as dust and heavy metals.

After testing by the testing unit designated by the Ministry of Environmental Protection, the dust emission at the discharge outlet is 4.9mg/Nm3, the S02 emission is 16mg/Nm3, the NOx emission is 42.4mg/Nm3, the ammonia escape is less than 1ppm, the removal rate of heavy metals and their compounds (mainly lead, cadmium, nickel) is >40%, and the removal rate of fluoride and chloride is >50%. The indicators are far lower than the "ceramic industry air pollutant emission standards" 2014 amendment, and successfully built the first ultra-low emission demonstration project of various pollutants in China's ceramic industry.

The project of "Collaborative Control Technology and Equipment for various pollutants in the flue gas of Ceramic Industry" has overcome many technical difficulties. In view of the large fluctuation of nitrogen oxides in ceramic hot blast furnaces, "dual dual control" ammonia injection control and refined measurement and control technology of ammonia water are adopted to achieve timely and accurate adjustment of ammonia injection volume along with NOx fluctuations, improve ammonia utilization rate and reduce ammonia escape. On-line spray monitoring and classification compensation technology is used to realize real-time detection and on-line monitoring of gun running status, and timely cleaning of scale on the surface of the distribution plate, with simple structure and reduced water consumption.

For some companies concerned about whether the denitration will have an impact on product quality after the problem, Mona Lisa responsible person pointed out that Mona Lisa from antique, polishing glaze, porcelain pieces, small floor tiles to the sheet covered by the product structure is more complex, the past use of simple SNCR denitration technology, will obviously see pinholes, holes and other phenomena, The equipment used today controls ammonia escape better and has no impact on product quality.

Industry voice: More important than the improvement of technology is the improvement of environmental awareness of Tao enterprises

Many respondents said that the current domestic environmental protection technology and equipment can meet the national environmental protection requirements. The key is also the awareness of pottery enterprises, because it involves the input cost of equipment and the later use cost. Wan Xingbo, general manager of Foshan Huaqing Zhiye Environmental Protection Technology Co., LTD., said that the same is a large building materials industry, cement, glass, ceramic glass and cement have required ultra-net emissions, ceramic industry pollution emission standards are relatively loose, there is room for strict repair, the future situation is not good environmental protection, there is no way to survive.

Of course, the upgrading of environmental protection facilities does not happen overnight. "In terms of investment in environmental protection equipment, Tao enterprises should invest less, and the operation can meet the standard continuously, so we are also making some updates, both in terms of technology and equipment itself." Huang Jianjian said that environmental protection is a process, the original is "barbaric dry", in the cost structure of the ceramic factory, basically no input cost for environmental protection such equipment, and later gradually added this item, but when everyone has this cost, it is a relatively fair competitive environment, and ultimately the user pays for the protection of the environment.

At the same time, in Zhu Tingzhen's view, the industry's environmental protection equipment enterprises do not have a unified standard, only in accordance with the relevant national emission standards, for private enterprises such as ceramic enterprises, there is no third-party agent bidding situation, no gatekeeping, most business owners are based on price pricing.

"The environmental governance of the ceramic industry has just begun." Zhu Tingzhen said that some time ago, he visited Guangdong ceramics factory more concentrated Qingyuan, Enping, Zhaoqing, Yunfu, Gaoming and other places, in addition to individual pottery enterprises, most of the environmental protection facilities of pottery enterprises did not operate in place, the use of old technology and equipment more than ten years ago, there is no perfect system of desulfurization and dust removal equipment.

Most pottery enterprises think that environmental protection is a one-time investment, in fact, environmental protection is a long-term arduous task, in the face of more stringent environmental standards in the future, but also to carry out corresponding transformation, rectification, and even to a third party contracted operation, cost control.

After all, most pottery companies still have not raised their environmental awareness to the level of social responsibility and social feedback.

Yin Haibin said that the environmental protection transformation technology path of different enterprises is not the same, and it is necessary to make a reasonable choice according to the current environmental protection treatment measures and status quo of the enterprise, the owner's investment planning and environmental protection indicators. Under the current environmental protection situation, enterprises need to adopt an overall plan, consider the application of environmental protection technology as a whole, reduce unnecessary duplication of investment, and adopt a one-time or step-by-step implementation plan to implement transformation.

■ Related links

Environmental dynamics of major pottery producing areas in 2016

Shandong (Province)

On February 6, the government of Shuangyang Town, Zichuan District, Zibo City, Shandong Province urgently issued a notice: the town building pottery enterprises shall not start production without authorization after the Spring Festival, must improve environmental protection management and safety production measures, submit a written acceptance application to the town safety supervision station, and then the town government submitted an acceptance application to the district government, and the environmental protection, safety supervision and other departments can resume production after acceptance.

On February 24, the Party and government office of Shuangyang Town, Zichuan District, once again issued an emergency notice: the pollution control facilities and online monitoring facilities of enterprises in the area, including all ceramic enterprises, are suspended.

In March, Zibo City government issued the Special Action Plan for Air quality Improvement in Key areas of Environmental Governance in Zibo City, proposing that the construction of pottery enterprises should support the construction of DCS system, ammonia escape monitoring system and pollutant online monitoring system, and enterprises engaged in the processing and storage of powdered materials must complete the dust removal and spray dust reduction facilities. Pollution control facilities are not perfect, environmental supervision found that the enterprise excessive pollution discharge, immediately stop production control.

In October, Shandong Province issued a special renovation action plan for kilns, classifying and renovating all kinds of kilns and furnaces that are not compatible with pollution control facilities and do not meet the requirements of environmental protection, and promoting the continuous improvement of atmospheric environmental quality.

On October 13, the leading Group for Air Pollution Prevention and Control of Linyi City issued the Notice on Issuing the Implementation Plan for Winter Peak Production of key industry Enterprises in Linyi City, which formulated the scope of peak production, peak production schedule, peak production requirements, organizational security and the list of peak production enterprises. Among them, the key pollutant discharge units, including coking, construction pottery, page brick and other key industry enterprises that discharge air pollutants.

In November, the "Zichuan District construction ceramics industry precision transfer Implementation Plan" was officially introduced, determine the list of local upgrade enterprises, require local upgrade enterprises unified gas, unified powder, environmental protection one vote rejected. Enterprises retiring from the city and entering the park should achieve the lowest emission of pollutants in the country, adopt the domestic leading furnace energy-saving equipment process and flue gas treatment facilities, and install an online monitoring system connected with the municipal Environmental Protection Bureau.

Jiangxi (Province)

In late July, Gao 'an City, the direct organ of Jiangxi Province, decided to implement an environmental protection "online monitoring" policy for ceramic enterprises, to monitor the equipment emissions of ceramic enterprises and the use of environmental protection facilities online, and to carry out environmental supervision "zero action", and to stop production for rectification of enterprises with problems.


On March 31, the Sichuan Provincial Government website published the Notice of the General Office of the Provincial Government on Issuing the 2015 Implementation Plan of the Implementation Rules of the Sichuan Provincial Air Pollution Prevention and Control Action Plan, proposing that key industrial industries will speed up the construction and transformation of desulfurization, denitrification and dust removal facilities, and continue to eliminate small coal-fired boilers. We will accelerate the construction of central heating, coal-to-gas and coal-to-electricity projects in built-up urban areas.

In November, Danliang County held a work to clean up and rectify illegal environmental protection construction projects, arrange and deploy the cleanup and rectification work of illegal environmental protection construction projects in the county, and require all domestic enterprises to fully complete the environmental protection remediation task before November 30.

Hebei (Province)

On November 7, the Hebei Atmosphere Office issued No. 1 air pollution prevention and control "dispatch order" to implement production control measures for key industries such as cement, casting, steel, thermal power, coking and coal-fired boilers, requiring most enterprises to stop production at the peak of the heating season. On November 16, the 2nd dispatch order was issued again, requiring the ceramic industry in Gaoyi and Zan Huang to

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