1. Project Background
Jiangsu Boyue Alloy Materials Co., Ltd. is a high-tech enterprise focusing on the R&D, production and sales of high-performance nickel alloy materials. With the surging demand for high-temperature and corrosion-resistant alloys in high-end equipment, nuclear power, new energy and other fields, the traditional processes have obvious pain points such as high energy consumption, heavy pollution and insufficient stability. The company urgently needed green and intelligent upgrading to build a benchmark production line for high-quality nickel-based alloy welding wire, meeting the strict international standards and low-carbon development requirements.
2. Project Objectives
- Build an intelligent production line with an annual output of 1,500 tons of high-end nickel-based alloy welding wire, with product performance reaching the international advanced level.
- Introduce distributed photovoltaic and energy-saving processes to reduce unit energy consumption by 18% and carbon emissions by 16%, and be rated as a provincial-level green factory.
- Achieve CNC rate of core equipment ≥95%, product defect rate ≤0.8%, and on-time order delivery rate ≥98%.
3. Project Implementation
- Green Process Reconstruction: Adopt the double process of vacuum induction melting + electroslag remelting to precisely control the alloy composition (Ni≥70%, Cr 15-20%) and reduce impurity content to below 50ppm; develop acid-free surface treatment technology to replace traditional pickling process, reducing wastewater discharge by 90% and realizing clean production.
- Intelligent Production Line Construction: Configure an integrated automatic production line of wire drawing - heat treatment - finishing - packaging, integrate AI visual inspection system to real-time monitor dimensional accuracy (tolerance ±0.01mm) and surface defects; deploy a digital twin management platform to realize real-time collection of production data, dynamic optimization of process parameters and intelligent early warning of equipment failures (early warning accuracy over 95%).
- Green Energy Supporting Project: Build a 1.2MW distributed photovoltaic power station with an annual power generation of about 1.2 million kWh, meeting 30% of the enterprise's electricity demand and reducing carbon emissions by about 900 tons annually; support a waste heat recovery system to convert waste heat from heat treatment into steam for production, improving energy utilization rate by 25%.
4. Project Achievements
- Economic Benefits: After reaching full production, the annual output value exceeds 300 million yuan, maintaining a growth rate of more than 10% for two consecutive years, becoming a core supplier of high-end nickel-based alloy welding wire in China.
- Technological Breakthrough: The products have passed EU CE and US AWS certifications, successfully replacing imports and being applied to key components such as nuclear power steam generators and new energy battery foil rolling rolls, breaking foreign monopolies.
- Industry Benchmark: Rated as a "National High-Tech Enterprise" and "Jiangsu Provincial Specialized, Refined, Peculiar and New Enterprise", and its green intelligent manufacturing model was listed as a demonstration case of Jiangsu new material industry.
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