(1) Project overview
In order to improve production efficiency, the company plans to carry out intelligent technical transformation of the original F10 glass fiber pool kiln drawing production line in the company's longevity plant. After the completion of the technical transformation, the design capacity of the production line was increased to 150,000 tons, and all the products were wind power yarn. The production line to be technically renovated in this project has been in continuous operation for more than 10 years since the initial ignition in October 2010, and the service life of the pool kiln has exceeded the design service life, the main process equipment is aging and the level of automation is not high, so it is necessary to carry out the cold repair of the pool kiln and the technical upgrading of the production line.
After the completion of the project, the manufacturing process and technical level of the production line will reach the leading level in the industry, and the production efficiency and product quality will be greatly improvedAt that time, the company's total production capacity of wind power yarn will increase by 50,000 tons, which can better meet the market's needs for high-end products and personalized varieties, and lay a solid foundation for the realization of the company's strategic goals.
The construction period of this project is 12 months;The total investment of the project is 56,413450,000 yuan, of which 50,892 was spent on the project300,000 yuan, other construction costs of 627450,000 yuan, 1,803 reserve fees190,000 yuan, laying the bottom of the working capital of 3,090510,000 yuan. After the project is fully put into production, it is expected to achieve an annual output value of 47 billion yuan, the annual investment profit margin of the project operation is 1721% with an internal rate of return of 1688%。
(2) The necessity of project implementation
Grasp market development opportunities, consolidate and enhance the company's market position
In recent years, with the rapid development of clean energy industries such as wind power and solar energy, the scale of wind turbine assembly machines has continued to grow. In the face of the explosive growth of the downstream market, domestic and foreign glass fiber manufacturers are actively building new wind power yarn production lines or carrying out cold repair technical transformation of the original production line to expand the scale.
With years of investment and accumulation in the field of wind power yarn, the company has achieved advantages in product technology, sales channels, customer resources, and advanced chains. In the face of the continuous growth of the market space and fierce market competition in the future, it is necessary for the company to increase investment in production, expand production scale and improve production capacity to consolidate and enhance the company's market position.
Optimize the product structure to meet the diversified and differentiated needs of customers
The application of glass fiber in wind turbines is mainly blades, nacelles and shrouds, of which the amount of wind turbine blades is larger. Wind turbine blades are mainly composed of matrix resin, reinforcing materials, sandwich materials, structural adhesives and surface coatings. At present, most wind turbine blades are made of glass fiber reinforced polyester resin or glass fiber reinforced epoxy resin. The blade is one of the main components of the wind turbine, because the blade directly obtains wind energy, it is required to have a reasonable structure, suitable materials and processes to make the blade reliably bear the wind force and self-weight centrifugal force to give the blade various bending moments and tensile forces.
The blade structure is composed of girders, shells, and webs, and different structural parts have different requirements for the performance of glass fibers, resulting in the manufacture of the same blade requiring multiple types of glass fibers. The company's existing high-modulus wind power yarn production line products are mainly used in the manufacture of wind turbine blade girders and large-scale pultrusion profiles and other markets, and the wind power yarn products of this project are mainly used in wind turbine blade shells, webs, blade roots and other components, which complement the existing products and can meet the diversified and differentiated needs of customers.
Carry out the expansion and intelligent transformation of the production line to improve production efficiency
This project redesigns the main workshops such as the batching system, pool kiln system, combustion system, fiber molding system, and logistics system of the original production line, optimizes the key points that affect the life of the pool kiln, designs the combustion mode for energy saving, optimizes the distribution of the electric flux matrix, and improves the energy conversion rate. Through the introduction of advanced wire drawing and winding, automatic yarn loading, yarn unloading, automatic logistics and other equipment, the implementation of intelligent transformation, to achieve efficiency improvement, reduce energy consumption and employee labor intensity, help to enhance the comprehensive competitiveness of the company's products.
Use existing assets to improve asset utilization efficiency
The fiberglass manufacturing industry is capital and technology intensive. A new production line requires a large amount of investment, and the main investment includes construction costs (plant, foundation, public works construction, etc.) and equipment purchase costs. The original plant, part of the foundation, public works and part of the original equipment of the production line to be renovated and renovated in this project can be utilized. Through the technical transformation of the existing production line, the project investment can be greatly reduced, which is conducive to the company's optimization of resource allocation and improvement of asset efficiency.
(3) Feasibility of project implementation
The demand for downstream applications of wind power yarn has grown steadily
The International Energy Agency (IEA) released the 2019 edition of "Offshore WindOutlook 2019", which believes that the next 20 years will be a period of rapid development of the global wind power industry, which will bring a trillion-dollar market to global investors. In September 2020, at the 75th session of the United Nations General Assembly, the world solemnly declared that it would increase its nationally determined contributions, adopt stronger policies and measures, strive to peak carbon dioxide emissions before 2030, and strive to achieve carbon neutrality before 2060.
In response to the national strategy to address climate change, on October 14, 2020, more than 400 wind energy companies from around the world jointly issued the "Beijing Declaration on Wind Energy", which requires the 14th Five-Year Plan to set up a development space for wind power that is compatible with the national strategy of carbon neutrality: to ensure that the average annual installed capacity is more than 50GW, and the average annual new installed capacity after 2025 is not less than 60GW, by 2030** the capacity will reach 800GW, and by 2060 at least 3,000GW. With the rapid development of the wind power industry, the demand for wind power yarn will continue to grow in the future.
The company has the design capabilities and production operation management experience required to implement the project
After years of exploration and development, the company has become a world-class glass fiber manufacturer. In terms of the construction of glass fiber production line, it has experienced the stage of introduction, digestion and absorption, and independent research and development from abroad, and can now independently design the technical scheme, equipment scheme and engineering scheme of the production line. The construction of this project is the technical transformation and capacity upgrading of the company's existing production line, and the company's experience in wind power yarn research and development, production, operation and management accumulated over the years can be used for reference and application.
In terms of engineering design, the company can make a reasonable layout of the batching system, pool kiln, sizing preparation, wire drawing, drying, packaging and other processes and public works according to experience, from raw material input, product manufacturing, to the packaging and delivery of finished products, and optimize the material flow and product flowThe space required for personnel, materials and equipment is appropriately allocated and effectively combined.
In terms of equipment configuration, with many years of experience, the company can configure the production line with stable, safe and reliable, energy-saving and environmentally friendly, cost-effective equipment, including batching equipment, pool kiln intelligent control system, combustion system equipment, wire drawing equipment, sizing configuration equipment, loading and unloading robots, transportation robots and other major equipment.
In terms of process technology, the company can independently carry out core process design such as batching system, pool kiln system, combustion system, fiber molding, sizing coating, etc., combined with its own successful experience over the years and advanced technology and advanced indicators of actual operation, the designed process technology route is stable, reliable and advanced, and the overall technology has reached the international advanced level.
In terms of production management, the company has a mature production line of glass fiber and products, with mature manufacturing technology and complete product categories. At present, the company has more than 10 pool kiln production lines, with rich experience in glass fiber production line management and sufficient production line management and operation personnel, and has the ability to efficiently operate new production lines.
The company has a high brand influence and reliable product quality in the wind power industry
The company has entered the field of wind power for more than ten years, is one of the first to enter the field of wind power domestic glass fiber manufacturers, through independent research and development of glass fiber formula and wind power sizing formula, with excellent performance and stable quality has been widely recognized by customers, quickly in the domestic and foreign wind power market occupies a large market share. With the development of the global wind power industry, especially the rise of the domestic wind power industry, the company has always regarded wind power as the key market of the company's development plan, continued to increase investment, established stable cooperative relations with domestic and foreign industry leaders, and established the company's brand in the wind power industry with stable product quality and perfect service system.
It has leading glass R&D and sizing R&D capabilities
The company's wind power products are based on new product research and development, closely combined with the needs of downstream customers of wind power for product development, and have successively launched a series of formula products such as ECT glass, high-modulus TM glass, improved high-modulus TM+ glass, ultra-high-modulus TMII glass and so on, which provide strong support for the wind power industry chain to achieve longer blades, higher efficiency and lower weight through the improvement of basic material performanceIn terms of sizing development, epoxy wind power yarn, unsaturated polyester wind power yarn, polyurethane resin wind power yarn, vinyl resin wind power yarn and other products have been developed for different resin application needs, and the formula has been continuously upgraded to meet the new blade design needs. At present, the company has achieved a cumulative sales volume of more than 1 million tons in the field of wind power, with a market share of more than 25%, and the product performance and quality stability have been widely recognized by the market.
The company has a perfect sales system and high-quality customer resources
The company implements the gauze integration strategy, has 3 glass fiber production bases in Chongqing, Bahrain and Brazil and a number of wind power fabric production bases in Changzhou, Xiangtan, Morocco, North America, etc., and its sales network radiates to Asia, Europe, America and other areas with strong demand for wind power, leading customer needs through the continuous development and upgrading of new products and new processes, and forming long-term cooperative development relationships with customers to achieve a win-win situation.
The company's wind power yarn is mainly sold to China, Asia, Europe, America and other countries and regions, and has established stable cooperative relations with well-known wind power blade manufacturers at home and abroad, such as Zhuzhou Times, Sinoma Science and Technology, Tianshun Wind Power, Zhongke Yuneng, Guodian United Power, LM, Vestas, SGRE, TPI, etc. Over the years, the company has been able to provide customers with complete sets of product solutions through the research and development of downstream composite materials, thereby increasing the stickiness of customers.
Wind power yarn downstream wind turbine blade manufacturers usually carry out strict quality certification for material manufacturers, involving production management, production scale, control system and other standards, the certification cycle is long, and higher qualifications are required to obtain product certification and business certification, the company's subsidiary Hongfa New Materials has obtained the certification of almost all mainstream wind turbine blade customers in the world. At the same time, this kind of large customers pay more attention to the stability of the first business, and in the case of the existing first-class system working well, it will generally not be replaced frequently.
(4) Project investment
The total investment of the project is 56,413450,000 yuan.
(5) Project construction plan
This project plans to use the existing F10 plant in the company's Changshou plant to carry out cold repair and technical transformation of the pool kiln of the F10 glass fiber production line. After the completion of the technical transformation, the design capacity of wind power yarn will increase to 150,000 tons, and the total production capacity of the company's wind power yarn will increase by 50,000 tons, which can better meet the needs of the market for high-end products and personalized varieties, and lay a solid foundation for the realization of the company's strategic goals.
(6) Project implementation progress
The construction period of this project is 1 year (12 months), and the operation period is 2 years old. The project is planned to be implemented in four stages, including: project establishment, planning, design, determination of the plan, construction of the plant, equipment purchase, equipment assembly, commissioning, production line construction, staff recruitment, training, and trial production.
(7) Project environmental protection
Exhaust gases
The melting of glass liquid in the pool kiln of this project adopts the method of "pure oxygen combustion + electric fluxing", and the exhaust gas emission is significantly reduced compared with the traditional air combustion process, and the waste gas treatment adopts the mature "SNCR denitrification + wet fluoride and desulfurization" process, and the supporting waste gas treatment device is transformed to ensure that the air pollutants are discharged up to the standard. The batching process of this project adopts closed conveying and dust collection treatment to reduce dust emission.
Wastewater
During the production process of the project, sewage will be generated for the cleaning of the sizing preparation system, the cleaning of the wire drawing partition and the cleaning of the floor. At present, there are two sets of sewage treatment facilities using "physicochemical + biochemical" treatment process in the factory area, and the surplus capacity of the sewage treatment station can meet the new sewage treatment needs of the project. At the same time, the project plans to change the process of the biochemical section of the first phase of the sewage treatment station from the traditional activated sludge method using surface aeration to the biological contact oxidation process with filler, so as to further improve the treatment efficiency of the biochemical section.
The wire drawing workshop adopts water-saving measures such as improving the efficiency of sizing coating and reducing clean water to effectively reduce the amount and concentration of sewage, and the sewage treatment is discharged into the sewage treatment plant of the park relying on the pretreatment of the existing sewage treatment station in the plant to meet the comprehensive discharge standard.
Noise
The project will produce noise from pool kiln fans, wire drawing machines, refrigeration stations, water supply station pumps, screw air presses, cooling towers and other equipment, and the project will reduce the noise impact by means of vibration reduction, installation of mufflers, and building sound insulation.
Solid waste
The solid waste generated by the production line of this project mainly includes waste glass fiber filament and sewage treatment sludge. The waste glass fiber filament of this project is intended to be processed into waste filament powder for reproduction or provided to other glass and ceramic manufacturers as raw materials. At present, the factory is equipped with waste silk powder processing facilities, and the waste silk powder produced is disposed of by reuse or takeaway to other manufacturers. The sludge from the sewage treatment station is handed over to the landfill for disposal.
Environmental protection investment budget estimate and governance effect
The company adheres to the concept of "green development", and all pollution indicators can be controlled within the national standards. The project plans to transform the original waste gas treatment device with an investment of 4.25 million yuan. The waste gas, waste water, solid waste and noise generated during the production period of this project can be discharged up to the standard after reasonable and effective treatment measures are taken, and the impact on the surrounding environment is small.