ta Michael Kelly, Allied PhotoChemical, da David Hagood, Kammala Hanyoyin Fasaha
Ka yi tunanin samun damar kawar da kusan dukkanin VOCs (Magungunan Halitta masu Wutar Lantarki) a cikin tsarin kera bututu da bututu, wanda ya kai 10,000 na fam na VOCs a kowace shekara.Hakanan tunanin samar da sauri cikin sauri tare da ƙarin kayan aiki da ƙarancin farashi kowane sashi / ƙafar layi.
Dorewar hanyoyin masana'antu mabuɗin don tuƙi zuwa ingantacciyar masana'anta da ingantattun masana'antu a kasuwannin Arewacin Amurka.Ana iya auna dorewa ta hanyoyi da dama:
Ragewar VOC
Ƙananan amfani da makamashi
Ingantattun ma'aikata
Fitowar masana'anta da sauri (ƙari tare da ƙasa)
Ingantacciyar amfani da jari
Bugu da ƙari, yawancin haɗuwa na sama
Kwanan nan, babban mai kera bututu ya aiwatar da sabuwar dabara don ayyukan rufewar sa.Matakan da masana'antun suka je-zuwa kayan shafa na baya sun kasance tushen ruwa, waɗanda suke da girma a cikin VOCs kuma suna faruwa suna ƙonewa kuma.Dandalin mai dorewa mai ɗorewa wanda aka aiwatar shine fasahar suturar ultraviolet mai ƙarfi 100% (UV).A cikin wannan labarin, an taƙaita matsalar farko ta abokin ciniki, tsarin suturar UV, haɓaka aikin gabaɗaya, ajiyar kuɗi da rage VOC.
Ayyukan Rufewa a cikin Masana'antar Tube
Mai sana'anta yana amfani da tsarin rufin ruwa wanda ya bar baya da rikici, kamar yadda aka nuna a Hotuna 1a da 1b.Ba wai kawai tsarin ya haifar da ɓarna kayan shafa ba, ya kuma haifar da haɗarin bene na kanti wanda ya ƙara bayyanar VOC da haɗarin wuta.Bugu da ƙari, abokin ciniki yana son ingantacciyar aikin rufewa idan aka kwatanta da aikin rufe ruwa na yanzu.
Yayin da yawancin masana masana'antu za su kwatanta suturar ruwa kai tsaye zuwa rufin UV, wannan ba kwatankwacin gaske bane kuma yana iya zama yaudara.Ainihin murfin UV wani yanki ne na tsarin suturar UV.
Hoto 1. Tsarin aiwatar da aikin
UV tsari ne
UV tsari ne wanda ke ba da fa'idodin muhalli masu mahimmanci, haɓaka tsarin gabaɗaya, ingantaccen aikin samfur da, i, kowace tanadin shafi na ƙafa.Don samun nasarar aiwatar da aikin suturar UV, dole ne a kalli UV azaman tsari tare da manyan abubuwa guda uku - 1) abokin ciniki, 2) aikace-aikacen UV da mai haɗa kayan aikin warkewa da 3) abokin haɗin gwiwar fasahar sutura.
Duk waɗannan ukun suna da mahimmanci ga ingantaccen tsari da aiwatar da tsarin suturar UV.Don haka, bari mu kalli tsarin aiwatar da aikin gabaɗaya (Hoto na 1).A mafi yawan lokuta, wannan ƙoƙarce-ƙoƙarce yana jagorantar abokin fasahar suturar UV.
Makullin kowane aiki mai nasara shine samun ma'anar matakan haɗin kai a sarari, tare da ginanniyar sassauci da ikon daidaitawa da nau'ikan abokan ciniki da aikace-aikacen su.Waɗannan matakan haɗin gwiwa guda bakwai sune ginshiƙi don cin nasarar aikin haɗin gwiwa tare da abokin ciniki: 1) tattaunawar tsari gabaɗaya;2) Tattaunawar ROI;3) ƙayyadaddun samfur;4) ƙayyadaddun tsari na gaba ɗaya;5) gwajin gwaji;6) RFQ / ƙayyadaddun aikin gaba ɗaya;da 7) ci gaba da sadarwa.
Ana iya bin waɗannan matakan haɗin gwiwa a jere, wasu na iya faruwa a lokaci guda ko kuma a iya musanya su, amma duk dole ne a kammala su.Wannan sassaucin da aka gina a ciki yana ba da mafi girman damar samun nasara ga mahalarta.A wasu lokuta, yana iya zama mafi kyau don haɗa ƙwararrun tsarin UV azaman hanya tare da ƙwarewar masana'antu mai mahimmanci a cikin duk nau'ikan fasahar sutura, amma mafi mahimmanci, ƙwarewar aiwatar da UV mai ƙarfi.Wannan ƙwararren na iya kewaya duk batutuwan kuma yayi aiki azaman hanyar tsaka tsaki don kimanta fasahohin shafa yadda ya kamata kuma daidai.
Mataki na 1. Gabaɗaya Tattaunawar Tsari
Anan ne ake musayar bayanan farko game da tsarin abokin ciniki na yanzu, tare da bayyanannen ma'anar shimfidar wuri na yanzu da tabbataccen ma'ana.A yawancin lokuta, yarjejeniyar rashin bayyana juna (NDA) yakamata ta kasance a wurin.Bayan haka, ya kamata a gano maƙasudin inganta tsarin aiki a sarari.Waɗannan na iya haɗawa da:
Dorewa - Ragewar VOC
Ragewar aiki da ingantawa
Ingantacciyar inganci
Ƙara saurin layi
Rage sararin samaniya
Binciken farashin makamashi
Tabbatar da tsarin sutura - kayan gyara, da dai sauransu.
Bayan haka, ana ayyana takamaiman ma'auni dangane da waɗannan ingantaccen tsarin da aka gano.
Mataki na 2. Tattaunawar Komawa-kan Zuba Jari (ROI).
Yana da mahimmanci a fahimci ROI don aikin a farkon matakan.Duk da yake matakin daki-daki baya buƙatar zama matakin da za a buƙaci don amincewar aikin, abokin ciniki ya kamata ya sami fayyace madaidaicin ƙimar halin yanzu.Waɗannan yakamata su haɗa da farashin kowane samfur, kowane ƙafar layi, da sauransu;farashin makamashi;farashin kayan fasaha (IP);farashin inganci;farashin mai aiki / kulawa;tsadar dorewa;da tsadar jari.(Don samun damar yin lissafin ROI, duba ƙarshen wannan labarin.)
Mataki na 3. Tattaunawar Ƙididdigar Samfur
Kamar kowane samfurin da aka ƙera a yau, ana bayyana ƙayyadaddun samfuran asali a cikin tattaunawar aikin farko.Dangane da aikace-aikacen shafa, waɗannan ƙayyadaddun samfuran sun samo asali akan lokaci don saduwa da buƙatun samarwa kuma yawanci ba a saduwa da tsarin shafi na abokin ciniki na yanzu.Muna kiransa "yau vs. gobe."Ayyukan daidaitawa ne tsakanin fahimtar ƙayyadaddun samfuran na yanzu (wanda ƙila ba za a sadu da abin rufewa na yanzu ba) da ayyana buƙatun gaba waɗanda suke da gaske (wanda koyaushe shine aikin daidaitawa).
Mataki na 4. Gabaɗaya Tsari Tsari
Hoto 2. Tsarin haɓakawa da ake samu lokacin motsawa daga tsarin suturar ruwa zuwa tsarin suturar UV
Abokin ciniki ya kamata ya fahimta sosai kuma ya ayyana tsarin na yanzu, tare da tabbatacce da kuma mummunan ayyukan da ake ciki.Wannan yana da mahimmanci ga mai haɗa tsarin UV ya fahimta, don haka abubuwan da ke tafiya da kyau da abubuwan da ba su da kyau ana iya la'akari da su a cikin ƙirar sabon tsarin UV.Wannan shine inda tsarin UV ke ba da fa'idodi masu mahimmanci waɗanda zasu iya haɗawa da haɓaka saurin sutura, rage buƙatun bene, da rage zafin jiki da zafi (duba Hoto 2).Ziyarar haɗin gwiwa zuwa wurin masana'anta na abokin ciniki ana ba da shawarar sosai kuma yana ba da babban tsari don fahimtar buƙatun abokin ciniki da buƙatun.
Mataki na 5. Zanga-zangar da Gwaji
Abokin ciniki da na'ura mai haɗawa da tsarin UV ya ziyartan wurin samar da kayan shafa don ba da damar kowa ya shiga cikin simintin tsarin suturar UV na abokin ciniki.A wannan lokacin, sabbin dabaru da shawarwari da yawa za su fito yayin da ayyuka masu zuwa ke gudana:
Kwaikwayo, samfurori da gwaji
Alamar ta hanyar gwada samfuran sutura masu gasa
Bitar mafi kyawun ayyuka
Bitar hanyoyin tabbatar da ingancin inganci
Haɗu da masu haɗa UV
Ƙirƙirar dalla dalla dalla-dalla shirin aiwatar da ci gaba
Mataki na 6. RFQ / Ƙayyadaddun Ayyuka na Gabaɗaya
Takaddun RFQ na abokin ciniki yakamata ya ƙunshi duk bayanan da suka dace da buƙatun don sabon aikin shafa UV kamar yadda aka ayyana a cikin tattaunawar tsari.Daftarin aiki ya kamata ya haɗa da mafi kyawun ayyuka da kamfanin fasaha na UV ke ganowa, wanda zai iya haɗawa da dumama rufin ta hanyar tsarin zafi mai ɗauke da jaket zuwa guntun bindiga;tote dumama da tashin hankali;da ma'auni don auna amfani da shafi.
Mataki na 7. Ci gaba da Sadarwa
Hanyoyin sadarwa tsakanin abokin ciniki, UV integrator da UV coatings kamfanin yana da mahimmanci kuma ya kamata a ƙarfafa shi.Fasaha a yau tana sa ya dace sosai don tsarawa da shiga cikin kira na zuƙowa / nau'in taro na yau da kullun.Kada a sami abin mamaki lokacin da ake shigar da kayan aikin UV ko tsarin.
Sakamakon Maƙerin Bututu Ya Gane
Wani yanki mai mahimmanci don la'akari a cikin kowane aikin rufin UV shine tanadin farashi gaba ɗaya.A wannan yanayin, masana'anta sun fahimci tanadi a wurare da yawa, ciki har da farashin makamashi, farashin aiki da abubuwan amfani da sutura.
Kudin Makamashi - UV mai ƙarfi na Microwave vs. Induction Dumama
A cikin tsarin suturar ruwa na yau da kullun, akwai buƙatar dumama bututu kafin ko bayan shigar da shi.Masu dumama na'ura mai ƙarfi suna da tsada, masu amfani da kuzari kuma suna iya samun mahimman abubuwan kulawa.Bugu da ƙari, maganin tushen ruwa yana buƙatar 200 kw induction makamashi amfani da makamashi da 90kw da fitilun microwave UV ke amfani dashi.
Tebura 1. Tattalin kuɗi fiye da 100 kw / awa ta amfani da tsarin UV na lantarki mai fitila 10 vs. tsarin dumama shigarwa.
Kamar yadda aka gani a cikin Tebu 1, mai kera bututun ya sami tanadin sama da kw 100 a sa'a guda bayan aiwatar da fasahar shafa UV, yayin da kuma rage farashin makamashi da sama da dala 71,000 a shekara.
Hoto 3. Misalin ajiyar kuɗin wutar lantarki na shekara-shekara
An kiyasta tanadin kuɗi don wannan rage yawan amfani da makamashi bisa ƙiyasin farashin wutar lantarki a 14.33 cents/kWh.Rage 100 kw / awa na amfani da makamashi, ƙididdige sama da sauyi biyu na makonni 50 a kowace shekara (kwanaki biyar a kowane mako, sa'o'i 20 a kowane lokaci), yana haifar da tanadi na $71,650 kamar yadda aka kwatanta a hoto 3.
Rage Kudin Ma'aikata - Masu Gudanarwa da Kulawa
Yayin da ƙungiyoyin masana'antu ke ci gaba da kimanta farashin aikinsu, tsarin UV yana ba da tanadi na musamman wanda ya shafi ma'aikata da sa'o'in kulawa.Tare da suturar ruwa, rufin rigar na iya ƙarfafa ƙasa akan kayan sarrafa kayan, wanda a ƙarshe dole ne a cire shi.
Ma'aikatan masana'anta sun cinye jimlar sa'o'i 28 a kowane mako suna cirewa / tsaftace rufin ruwa daga kayan sarrafa kayan sa na ƙasa.
Baya ga tanadin farashi (kimanin awoyi 28 na aiki x $36 [farashin nauyi] a cikin awa ɗaya = $1,008.00 a kowane mako ko $50,400 a kowace shekara), buƙatun aiki na zahiri ga masu aiki na iya zama takaici, cin lokaci da haɗari.
Abokin ciniki ya yi niyya don tsaftace shafi na kowane kwata, tare da farashin aiki na $1,900 a kowace kwata, tare da farashin cire murfin da aka jawo, na jimlar $2,500.Jimlar tanadi a kowace shekara ya kai $10,000.
Rufin Tattalin Arziki - Ruwan ruwa vs. UV
Samar da bututu a wurin abokin ciniki shine ton 12,000 a kowane wata na bututu mai diamita 9.625-inch.A taƙaice, wannan yayi daidai da kusan ƙafar layi 570,000 / ~ guda 12,700.Tsarin aikace-aikacen sabon fasahar suturar UV ya haɗa da manyan bindigogin feshi masu ƙarfi/ƙananan matsa lamba tare da kauri mai kauri na mils 1.5.An yi maganin warkewa ta hanyar amfani da fitilun microwave na Heraeus UV.Ana taƙaice tanadin kuɗi a cikin farashin sutura da sufuri/kudin kula da ciki a cikin Tables 2 da 3.
Tebur 2. Kwatankwacin farashin sutura - UV vs. rufin ruwa na kowane ƙafar layi
Tebur 3. Ƙarin ajiyar kuɗi daga ƙananan farashin sufuri mai shigowa da rage yawan sarrafa kayan aiki a wurin
Bugu da ƙari, ƙarin kayan aiki da tanadin kuɗin aiki da ingantaccen samarwa za a iya gane su.
Abubuwan da ake amfani da su na UV (ba su da rufin ruwa), suna ba da izinin aƙalla 96% inganci.
Masu aiki suna kashe ɗan lokaci don tsaftacewa da kiyaye kayan aiki saboda murfin UV ba ya bushe sai an fallasa shi da ƙarfin UV mai ƙarfi.
Saurin samarwa yana da sauri, kuma abokin ciniki yana da damar haɓaka saurin samarwa daga ƙafa 100 a minti daya zuwa ƙafa 150 a minti daya - haɓakar 50%.
Kayan aikin UV yawanci yana da ginanniyar tsarin zagayowar ruwa, wanda ake sa ido kuma ana tsara shi ta sa'o'i na aikin samarwa.Ana iya daidaita wannan bisa ga bukatun abokin ciniki, wanda ke haifar da ƙarancin ƙarfin da ake buƙata don tsabtace tsarin.
A cikin wannan misali, abokin ciniki ya gane ajiyar kuɗi na $ 1,277,400 kowace shekara.
Ragewar VOC
Aiwatar da fasahar suturar UV kuma ta rage VOCs, kamar yadda aka gani a hoto na 4.
Hoto 4. Ragewar VOC sakamakon aiwatar da suturar UV
Kammalawa
Fasahar suturar UV tana ba masu kera bututu damar kusan kawar da VOCs a cikin ayyukan su na sutura, yayin da kuma suna isar da tsarin masana'anta mai dorewa wanda ke haɓaka yawan aiki da aikin samfur gabaɗaya.Tsarin rufin UV kuma yana haifar da tanadin farashi mai mahimmanci.Kamar yadda aka bayyana a cikin wannan labarin, jimlar ajiyar abokin ciniki ya zarce $1,200,000 a shekara, tare da kawar da sama da 154,000 lbs na hayaƙin VOC.
Don ƙarin bayani da samun damar yin lissafin ROI, ziyarci www.alliedphotochemical.com/roi-calculators/.Don ƙarin haɓakar tsari da misali kalkuleta na ROI, ziyarci www.uvebtechnology.com.
SIDEBAR
Dorewa Tsarin Rufe UV / Amfanin Muhalli:
Babu Haɗaɗɗen Ƙirar Halitta (VOCs)
Babu Gurbacewar iska (HAPs)
Mara Flammable
Babu masu kaushi, ruwa ko filoli
Babu zafi ko yanayin samar da yanayin zafi
Gabaɗaya Haɓaka Tsarukan da ake bayarwa ta Rufin UV:
Saurin samarwa sama da ƙafa 800 zuwa 900 a cikin minti ɗaya, ya danganta da girman samfur
Ƙananan sawun jiki na ƙasa da ƙafa 35 (tsawon linzamin kwamfuta)
Ƙananan aiki-a cikin tsari
Nan take bushe ba tare da buƙatun warkewa ba
Babu al'amurran da suka shafi jika na ƙasa
Babu daidaitawar shafi don yanayin zafi ko zafi
Babu kulawa/ajiya ta musamman yayin canje-canjen canji, kulawa ko rufewar karshen mako
Rage farashin ma'aikata da ke da alaƙa da masu aiki da kulawa
Ikon maido da overspray, sake tacewa da sake dawo da tsarin sutura
Ingantattun Ayyukan Samfura tare da Rufin UV:
Ingantattun sakamakon gwajin zafi
Babban sakamakon gwajin hazo gishiri
Ikon daidaita halayen shafi da launi
Shafaffen riguna, ƙarfe da launuka akwai
Ƙananan farashin suturar ƙafar kowane layi kamar yadda aka nuna ta ROI kalkuleta:
Lokacin aikawa: Dec-14-2023
