The production policy of the holding group "Condor Eco-SF NIIOGAZ" is to improve the gas cleaning equipment of the new generation in order to reduce metal consumption and labor intensity of manufacturing, to increase reliability and competitiveness in both the domestic and foreign markets. For this purpose we developed measures aimed at development of the production technology of the original units of the electrostatic precipitators and bag filters.
In its production activities, the holding sees the following tasks: taking into account the technical level, production capacities, production culture, financial and economic status, quality and prices of products, competitiveness of enterprises that produce gas cleaning equipment, properly organize the fulfillment of orders to fully meet the customer's needs; the organization of its own production, characterized by mobility, independence, economy, observance of the guarantee of performance of orders in contractual terms, the possibility of manufacturing new experimental and specific elements of gas cleaning equipment.
Strong competition, increasingly stringent requirements of customers for the timing of manufacturing and delivery of the equipment, a significant increase in sales volumes determine the need to expand the scale of production:
- due to the development of its own production. These are, in the main, exclusive parts and components. Such as frame hose filters, sedimentation and corona elements of electrostatic precipitators, hose plates, etc;
- by placing the production of hull metal structures at other enterprises on a tender basis with mandatory inspection checks on the quality of the products.
This need is due to the territorial disparity of the main consumers. The development of relationships with enterprises manufacturing metal structures in various regions will allow customers to save significant funds for transportation, and thus increase the competitiveness of the products and services of the holding.
The development of own production must be carried out taking into account the mobility of technological equipment. The possibility of manufacturing metal-intensive and volumetric parts and components at the customer's enterprise (or in the immediate vicinity) plays a significant role.
The supply of gas-cleaning equipment holding, in addition to its own production, carries out on the basis of subcontracting, the most advanced production system, widely used in the world. The accepted practice for the production of equipment, when the majority (95 %) is produced in the same enterprise, ensure product quality, especially for new developments, because of the financial costs to new production technologies.
With the subcontracting system, the manufacture of individual assembly units and parts to ensure high quality is located at different enterprises that have modern manufacturing technologies. This is relevant for electrostatic precipitators supplied in the form of separate assembly units: perfection of the quality of manufacturing of precipitating electrodes, corona electrodes, drives is a guarantee of effective operation of the apparatus after installation and commissioning, especially since finally the electrostatic precipitator acquires the appearance of the finished product only after assembly on the installation site. So, for manufacturing of high-quality equipment of electrostatic precipitators, it is required to provide tolerances for rolling the profile of the precipitation element in the range 1-2 mm.
The efficiency of the electrostatic precipitator depends to a large extent on the quality of casting and stamping. Our subcontractors for casting are NPO Saturn, and for stamped products, OJSC Uralkhimmash is one of the few enterprises in Russia that can provide the required tolerances specified in our documentation.
The production of new high-efficiency corona elements has been mastered at the enterprises of the machine-building complex of OJSC Severstal, where there is a computer-aided design system for technological equipment, in particular stamps, as well as in the production areas of NIIOGAZ equipped with an automatic line for manufacturing elements of the corona electrodes.
We try to place the manufacture of electrostatic precipitator equipment, which has a lesser effect on the efficiency of the device, at enterprises that order equipment for electrostatic precipitators (in order to reduce transportation costs), as well as in controlled enterprises near equipment customers.
The provision of high-quality sheet metal cutting, which meets the tolerances in the technical documentation for new devices, is possible with the laser cutting method. This technology is widely used. The task of the owners of this technology is to load the expensive equipment as fully as possible. In the European part of Russia, our subcontractor for this technology is an enterprise in Ivanovo. Similar technologies exist in Krasnoyarsk, which are used by the Krasnoyarsk branch of CJSC Condor-Eco.
Thus, the use of the subcontracting system in the production of gas cleaning and dust-collecting equipment allows the use of modern manufacturing technologies existing in the country and, on the basis of the possibilities of new technologies, to offer devices delivered at a high scientific and technical level.
The work in the direction of expanding the production base of the holding through partnerships with producers makes it possible, on the terms of the competition, to choose a manufacturer that produces better products at lower prices.
Wide links with production partners allow us to successfully solve the problems of providing the holding's orders with material resources, components and purchased products. Working with suppliers on partial prepayment allows to attract current assets of suppliers, which significantly reduces the burden on the assets of the holding.
The holding has close economic ties with more than twenty manufacturers of component parts, from which, according to contracts, the firm receives power units, electrical equipment, control devices for power units, reducers, motor-reducers, vibrators, pneumatic equipment, valves, valves. Supplier reliability is assessed on a quarterly basis according to the criteria, the main ones being price, quality, delivery rhythm.
Using the advantages of subcontracting, the holding company remains a contractor and organizes closed production sites for the production of specific units that depend on the efficiency of the gas scrubbing system (precipitation, corona electrodes, frames, hoses, valve sections, shaker drives using frequency regulators, hose plates), design, marketing, assembly of units and devices, supervision, commissioning. It is planned to create a service department for regular operation of the environmental equipment from customers on the basis of relevant contracts, with all the ensuing consequences.
Further improvement of the holding's production activities is impossible without carrying out research and development work, bench tests, further constructive improvement of the electrostatic precipitator units and bag filters of the new generation. This role is performed by CJSC SF NIIOGAZ, which has an experienced scientific and technical staff, methods developed here, and a laboratory-benchmark base for testing nodes for reliability.
For the production of elements of precipitating electrodes for electrostatic precipitators, an automated line LA 65 has been created and is operating at the request of the holding company. The installation of the line for the automatic production of profiled parts LA 65 has made it possible to sharply increase the quality of the precipitation electrodes; to ensure minimum deviations from the nominal dimensions, which contributes to an increase in electric cleaning by 2 or more times, the process of regeneration improves, the reliability of the electrostatic precipitator increases. In comparison with the old equipment, the deviation of the geometrical dimensions has been significantly reduced on the new line: with a length of the precipitation electrode of 18 m - 2 mm (previously - 30 mm), sickle size is not more than 0.2 mm per 1 m of length, curvature along the plane of the element is not more than 0, 3 mm per 1 m of length, the maximum deviation of the profile angles is not more than ± 1°. Improves the quality of installation.
The automatic line LA 123 was put into operation to manufacture corona electrodes of the SF-1 type. The automatic line LA 123 provides an increased sharpness of the needles (the minimum radius of curvature), which leads to a decrease in the voltage of the corona discharge and, as a consequence, to an increase in the efficiency of electrical cleaning. The manufacture of the corona element on this automated line, introduced into production in 2006, is carried out with the help of a unique technological operation to form corona needles from one point. This technical solution is protected by the patent of the Russian Federation No. 2229939. The technical result of the introduction of the patent is to increase the efficiency of the electrostatic precipitator by using a new element of the corona electrode with a reduced voltage of ignition of the corona and providing a higher current to the crown by improving the geometric characteristics of the electrode.
In developed industrial countries there is a certain experience of cleaning flue gases in power engineering with bag filters. In the future, it is planned to expand their use in combined electrostatic precipitators. Thus, the improvement of the production of bag filters by the holding company in the future can be widely used in power engineering.
Our production technology of filter hoses is based on research and development work. Only we have stands for testing hoses and filter materials, developed scientifically-based methods of testing them. Each batch of filter materials passes the input control and gives a conclusion about the quality. Such a benchmark-bench base has not a single research institute of an analogical profile in Russia and CIS countries. We can select and recommend a filter material for the manufacture of hoses, taking into account all technological factors and operating conditions of a specific dust collection unit with an operating temperature of up to 250°C.
We manufacture filter sleeves from fabrics and needle-punched fabrics of both domestic and foreign production from fibers of propylene, nitron, polyester (lavsan), t-arylimides, polyphenyl sulfide, etc.
The suppliers of filter materials are well-known foreign companies TTL, BWF, Albarie, TOOM-TECHTIL, whose quality of products is checked by the market and time. A certificate of quality is issued for each batch of filter material. Our production is provided with the most modern specialized equipment. Sewing machines of the Japanese firm "JUKI" and the German firm "Durkopp Adler" allow performing the most diverse designs of filter hoses. We are responsible both for the correct selection of the filter material and for the quality of sewing sleeves, giving the customer a quality passport. In addition, we master the production of welded hose designs, which is now the most advanced technological process in the world. For this purpose, a welding line for fabric pipes is being designed for holding in Germany.
As an alternative to US-manufactured cartridge filters, BHA, the holding starts production of honeycomb sleeves, the design of which allows increasing the filtering area by 10 times.
An automatic line for the production of honeycomb filter material has already been manufactured and is being tested, from which any manufacturer of sleeves can sew a sleeve with a deposition area several times larger than usual.
he new frame design for the filter hoses developed in the holding company and protected by the patent excludes the use of the existing method of fastening hoses and frames on the hose plate, increases the service life of the carcasses and hoses by using a rigid connection of the component parts of the frames. Economic efficiency - lower operating costs for the replacement of sleeves more than 3 times.
The reliability of the bag filter depends entirely on the quality of the frame. Earlier, the holding company ordered wireframes at other enterprises, where there were corresponding production facilities. Their quality did not always satisfy our demand. In 2005, the holding company installed its own assembly for the assembly of welded frames of bag filters, which makes it possible to fabricate frames with a diameter of 130 mm and a length of up to 7 meters. The frame is assembled from rods and rings with a diameter of 4 mm by the method of contact welding in a semi-automatic mode. The diameter of the wire is 4 mm, and not 3 mm, which makes it possible to obtain a more rigid frame in comparison with competing samples, and also to significantly reduce the wear of the hoses due to the greater contact radius. Manufacturing technology (guides internal rods plus inner rings) provides the best straightness in comparison with spiral welding cages.
Thus, along with the constantly holding "Condor Eco-SF NIIOGAZ" holding the perfection of the design of the dust-collecting equipment, the process of improving its production continues, the possibilities of which are not yet fully exhausted. The organizational and practical combination of research, engineering and production capacities carried out in the holding company gives real prospects for the effective use in industry of dust collection equipment of the fourth generation.
Equal participation in tenders at the international level is one of the latest achievements of the holding, caused by both structural changes, and the increased scientific and technological level, and the correct economic policy. Of course, with the intense competition that is currently taking place on the market of environmental technology, the victory does not always remain behind the holding, but the defeat is different. For example, there was a tender for the Ladle Furnace at Severstal, which was attended by the well-known companies Quadra-Engineering (Canada), Lurgi (Germany), Alstom (France), the joint Russian-Finnish the company "Space-motors", the domestic firm "FINGO-complex". The victory was won by the Canadian firm, but participation in this prestigious tender with the involvement of the largest international corporations speaks about the high potential and the authority of the holding.
And more about patents. Now the holding has more than 30 recently obtained patents, some of which have already been introduced into production or are being implemented.
- Installations of gas cleaning are completed with electrostatic precipitators of the fourth generation EGA-M, EGAV, EGSM, EGV-M, EGSE.
These electrostatic precipitators, developed on the basis of the scientific foundations for the creation of a new generation of gas-cleaning equipment made in ZAO Condor-Eco, have a metal consumption of less than 20% and a smaller volume of 40% compared to the serial devices. The use of corona elements of the SF type with a low voltage of ignition of the corona and high-precision deposition elements allows to catch fine dust with a high specific electric resistance. At the same time, the dust content is reached up to 20...50mg/m3. In the reconstruction of electrostatic precipitators in cramped conditions, electrodes up to 18 m high can be made. For the first time in the domestic practice of gas purification, a combined apparatus consisting of an electrostatic precipitator and a filter, providing an exhaust dust content of 5...10mg/m3 with a service life of bags of 5 years, has been developed.
- Installations of gas purification with filtering devices IV generation FRIA, FRMI, FRI-OSD, FRKITS, FKI.
FRMI – are developed taking into account the requirements in the branches of heat power engineering, non-ferrous and ferrous metallurgy. They represent a set of modules that form a standard size range of filters with a filtering area from 800 to 16000 m2, with an estimated capacity for the cleaned gas from 70000 to 1380000 m3/h.
FRIA – for systems of "dry" gas purification of aluminum production, in order to reduce the abrasive wear of hoses due to the construction of the gas pipeline, moderate rates of dust and gas flow and its uniform distribution along the hoses are ensured.
FKI – cassette-type filters, can be installed in the premises of working shops, where space is limited.
- Cyclones SCN, CN, SKCN, VPC etc.
These devices are highly efficient, resistant to abrasion, with low hydraulic resistance. The theory of calculation and the method for selecting cyclones have been developed, as well as technical documentation of apparatuses. This allows you to meet all the requirements of the customer in the shortest time.