New Dongyue Group Co., Ltd. Cleaner Production Audit Publicity

1.Enterprise basic information

New Dongyue Group Co., Ltd. is a subsidiary of New Dongyue Group with tire manufacturing and sales as its main business. The original site of New Dongyue Group Co., Ltd. is located in Dongping County. Due to urban development, in 2005 Year 7 The month plans to relocate. After the relocation, the company's address is located in the industrial park of Dongping County Economic Development Zone, with a registered capital 5000 Ten thousand yuan. New Dongyue Group Co., Ltd. Annual Production1500The EIA report of the relocation project of 10,000 sets of bionic meridian motorcycle tires has been completed.2009Year7Month1It was approved by Dongping County Environmental Protection Bureau on the 1st, with the approval number: Donghuanfa.[2009]56No. The project has been2009Year7The construction started in January, and the construction has been completed. The main works, auxiliary works and other structures are consistent with the construction content approved by the original EIA. However, due to the large changes in the equipment in the workshop compared with the initial planning, the actual production capacity is only700Ten thousand sets/Year bionic meridian motorcycle tires.

New Dongyue Group is located in the well-known western foot of Mount Tai, scenic Dongping Lake, Jihe Expressway and105 national highway interchange, convenient transportation, geographical position is superior. Existing staff2800 More than people, all kinds of professional and technical personnel 600 Senior advisers and expert group members 26 People. The main backbone enterprises of Xintongyue Group are: Xintongyue Group Co., Ltd., Shandong Dongyue Electric Vehicle Co., Ltd., Shandong Xintongyue Renewable Resources Technology Co., Ltd., Shandong Xinzhi Machinery Co., Ltd., etc.

This auditScopeForXINDONGYUE GROUP LIMITED,Floor Area138400 m²Building area 76000 m²The current production scale is the annual output of bionic meridian motorcycle tires.7 million sets, the main raw materials include natural rubber, synthetic rubber, recycled rubber and carbon black, and accessories include various additives, fiber cords, steel wires and capsules; the main power sources are electricity and steam. New Dongyue Group Co., Ltd. nearly 40 years of professional rubber products practical experience has spawned a strong technical team, the use of first-class product production, testing equipment, to create a first-class product design, research and development, quality control system, completed in 2009“Shandong Technical Center”One place has laid a solid foundation for enterprises to carry out independent innovation and technological upgrading.

At present, the actual number of employees of Xindongyue Group Co., Ltd. is800 people, of whom managers80People, technicians120People, production personnel600People, management personnel using day shift system, production shift system in addition to the dense refining workshop using one shift system, the other are using three shifts of operation system, each shift8Hours, annual working hours300Day.

2.Main production process of the enterpriseand discharge from production

The production process of tires is divided into rubber preparation and carcass preparation.(including tread sidewall preparation, inner liner preparation,Inner tube preparation, capsule preparation）Cutting and molding, shaping and vulcanization, product testing and other processes. Process flow and pollution generating ringSection See Fig. 1.

① Preparation of compound

 

The rubber preparation process is carried out in the internal mixing workshop, and raw materials such as natural rubber, synthetic rubber, recycled rubber, carbon black and the like are put into the internal mixer, and mixed by the internal mixer to prepare a film that can be used in the subsequent process. See the figure for the process flow and pollution production of the compound preparation process. 2.

Figure 2  Project glue preparation process process flow and pollution production link diagram.

Mixing makes all kinds of compounding agents completely and evenly dispersed in the raw rubber phase, and does not reduce the mechanical strength of the rubber as much as possible,The rubber material with reinforcing agent (carbon black) has good reinforcing effect.

Natural rubber and synthetic rubber, recycled rubber after cutting, with carbon black and other raw materials (activators, antioxidants, etc.) in accordance with the subsequent process required for different strength of the film process formula after automatic weighing, controlled by the computer.First stage mixing in internal mixer(Mother）The temperature is about 80~175C, after the master batch is compressed by the extrusion tablet press,After water cooling (add isolation agent in the cooling pool to prevent film sticking) and air cooling to room temperature, it enters the mixer for the second stage.mixing(Final Refining）. The masterbatch film is added with vulcanizing agent and accelerator for final refining in an internal mixer, and the rubber is cooled to room temperature after being compressed by a tablet press and stored for standby. The first stage of mixing and the second stage of mixing are carried out in the same internal mixer. The internal mixer is a closed rubber mixing machine. The raw materials are heated and mixed evenly by external force extrusion and stirring. The carbon black is space packaging, and the feeding method is pneumatic negative pressure conveying.

Pollution generation: carbon black dust from carbon black feeding system G₁Dust from mixture feeding system G₃Small materials(Fill inFilling agent, activator, antioxidant, softener, vulcanizing agent and accelerator）Feeding dust G₂Flue gas and film cooling of internal mixerBut exhaust gas G₄Waste packaging of carbon black, rubber and other raw materials S₁, film cooling and equipment cooling blowdown W₂, internal mixerNoise N₁. The main pollutants and treatment measures in the rubber preparation process are shown in the table. 1.

Table 1   Production links and treatment measures of main pollutants in rubber material preparation process

Kind	main pollution factor	main pollution source	take measures
G1	carbon black dust	Carbon black feeding	After dust removal by the bag filter36mhigh row Cylinder discharge
G2	Dust	Small material feeding	After dust removal by the bag filter36mhigh row Cylinder discharge
G3	Dust	Mixture dosing	After dust removal by the bag filter36mhigh row Cylinder discharge
G4	Non-methane total hydrocarbons, hydrogen sulfide	Mixing flue gas	Exhaust gas purification machine after purification,1 Root 36mHigh Exhaust Barrel Discharge
W2-1	Cl-,SS	Film cooling	Recycling, regular replenishment
W2-1	Cl-,SS	Equipment cooling	Discharged into the park municipal pipe network
N1	Mechanical noise	internal mixer	Shock absorption, indoor
S1	waste packaging bag	Feeding	Outselling

② Preparation of carcass

The carcass preparation process mainly includes tread and sidewall preparation, inner liner film preparation, inner tube preparation, etc., and the main pollutants and treatment measures are shown in the table.2.

1） Preparation of tread and sidewall

The mixed film is compounded by a double compound extruder to make the tread and sidewall, and the qualified tread and sidewall are cooled.After storage for standby; about 2%The production of non-conforming products, mainly using the open mill for calendering extrusion, and then into the double composite extrusion.Out of the machine, made of tread and sidewall. Friction heat generation during the operation of the mill, the temperature can reach 70℃, so there is no need to addHeat,. The process flow and pollution production link are shown in the figure. 2.3-3.

 

Fouling link: tread sidewall extruder noise N₂ and mill noise N₃.

2） Preparation of inner lining

The preparation of the inner liner is prepared by compounding the fiber cord and the inner lining rubber together. Among them, the preparation of fiber cord fabric mainly uses the purchased cord fabric, enters the four-roll calender, covers the glue and makes the fiber cord fabric, cools and cools on the production line. The mixed film is pressed out by the press-out production line to make the inner lining rubber, and the inner lining rubber and the fiber cord are bonded to make the inner lining layer. The process flow and pollution production link are shown in the figure.4.

 

Pollution production: waste cord from lining preparation S₂Extruder noise N₂Noise of four-roll calender N₄, Press outpipeline noise N₅.