四川板式家具企业制造能耗分析与研究
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摘要
在低碳经济背景下,开展板式家具制造能耗研究符合国家“可持续发展”战略。我国家具制造业需要翔实的综合能耗数据和家具低碳制造理论。四川板式家具产业集群有工业基础,开展四川板式家具企业制造能耗分析研究可明晰四川家具产业现状,促进四川板式家具设计与制造技术的发展。本文采用调查法、归纳比较法、田间作业法等系列科学方法,构建板式家具制造能耗分析与研究理论,开展四川板式家具制造综合能耗分析研究。文章主要内容由板式家具制造能耗理论、四川板式家具制造能耗分析与研究、板式家具企业适用节能技术等三部分组成。
研究内容和结论如下:
(1)开展板式家具制造能耗理论研究,构建板式家具制造能耗分析与研究的基础。开展板式家具能源审计能容与方法研究。结合板式家具设计与制造的典型特征,指出板式家具制造能耗分析主要工作是板式家具企业产值和电费的数据审计。板式家具制造业能源审计内容包括企业用能概况,设备用能效率分析和适用综合能耗计算,板式家具适用综合能耗计算是研究重点。板式家具适用综合能耗包括企业综合能耗、单位产值综合能耗和可比产品单位产量综合能耗,本文提出了板式家具企业制造综合能耗、单位产值综合能耗和可比产品单位板材面积综合能耗适用计算公式。
研究板式家具可比产品单位板材面积综合能耗。在板式家具企业可比产品单位产量综合能耗研究的基础上,指出板式家具可比产品单位产量综合能耗研究关键为板式家具可比产品的界定。板式家具可比单位产品是指反映企业产品设计、生产和销售特点,体现板材消耗、能源消耗情况,反映主要用能设备应用的产品组合而成的家具系列。可比产品单位板材面积综合能耗是板式家具企业可比产品单位产量综合能耗的有效表现。典型产品、工艺分析、瓶颈工序和产能是可比产品单位板材面积综合能耗的影响要素;本文提出了可比产品板材总面积与可比产品单位板材面积综合能耗计算公式。
研究工业工程与能源审计在家具制造业的应用。工业工程(Industry Engineering ,简称IE)在家具制造业中应用面临运行基础不牢、普适度低、人员构成不完整等三方面问题;能源审计在家具制造中的应用面临研究定位缺失、无制造能耗定额标准和能源审计需求有限三方面问题;工业工程和能源审计在家具制造中的应用具有辩证性。在板式家具能源审计中应用IE技术研究企业工艺流程,分析综合能耗与产品造型、工艺、制造技术的关系,研究能耗和板材面积的相关性。
(2)四川板式家具制造能耗分析与研究是本课题研究的主要内容。
归纳分析四川板式家具产品类型与典型工艺。四川板式家具制造业一般按板材表面装饰特性和产品功能分类;据常见板式家具表面装饰特性分类有三聚氰胺浸渍纸预贴面板式家具、“白亮光”家具、和“板木”家具;四川板式家具产品功能分类与其他家具集群区域一致。三聚氰胺浸渍纸预贴面板式家具制造工艺是四川板式家具制造工艺基础,四川板式家具制造能耗调查、分析应以该工艺流程为依据。四川板式家具企业的主要不足为用能设备搭配应用不合理,瓶颈工序制约企业产能。
调查分析四川板式家具企业制造综合能耗。选择大、中、小不同规模板式家具企业,调查四川板式家具产业集群制造能耗现状与能耗研究需求。调查方式和调查表设计是四川板式家具制造综合能耗的调查基础。调查采用网络问卷调查、邀约调查和生产现场拍照调查相结合的方式。调查问卷涉及企业概况、材料应用、用能设备、加工环境、产品结构和企业用能审计需求等内容。参考板式家具企业制造能耗分析与研究相关理论,分析数据,计算四川板式家具企业单位产值综合能耗。经计算,大型和小型受调查板式家具企业单位产值综合能耗均在0.05(吨)(标准煤)/万元RMB左右,比中等产值规模企业单位产值综合能耗高。研究发现产品设计附加值高的板式家具企业,单位产值综合能耗小;生产环境好的企业,单位产值综合能耗小;产品工艺结构影响板式家具企业单位产值综合能耗,但影响因素复杂,规律不明显;人均耗能量大小和受调查板式家具企业单位产值综合能耗无必然联系。受调查板式家具企业人均综合能耗范围在0.64~1.64(吨)(标准煤)/人;单位产值综合能耗范围在0.0226~0.0538(吨)(标准煤)/万元RMB,平均值约0.0465(吨)(标准煤)/万元RMB。将板式家具制造业单位产值综合能耗与纺织业、铝业和造纸业等传统高能耗产业单位产值综合能耗比较,初步判断板式家具制造不属于高能耗产业范畴。
分析研究四川某板式家具企业2008年制造综合能耗。调查阐述该企业概况和工艺现状,该企业生产青少年板式家具,位于四川成都十陵工业园,员工85人,08年产值1926万元RMB;企业工艺为封闭色彩涂饰三聚氰胺浸渍纸预贴面板式家具制造工艺。分析企业生产周期内所有产品加工情况和物料应用情况;根据分析结果,研究以801和803系列家具为企业08年典型产品。在上述研究基础上,计算08年该企业每月可比产品板材总面积、单位产值综合能耗和可比产品单位板材面积综合能耗。企业2008年单位产值综合能耗范围0.0516~0.0558(吨)标准煤/万元RMB,可比产品单位板材面积综合能耗范围0.514~0.56(0kg)标准煤/m2。企业每月单位产值综合能耗和可比产品单位板材面积综合能耗变化与生产现状相符,证明板式家具可比产品单位板材面积综合能耗计算方法可行,反映其生产实际变化。
(3)开展板式家具企业适应节能技术研究,构建板式家具企业适用节能体系。
重点研究了影响板式家具单位产值综合能耗的因素,分析了板式家具节能技术应用的目的,归纳了常见板式家具设计、工艺与制造技术;在上述研究的基础上构建了板式家具适用节能技术体系并进行其应用案例分析。
研究将节能技术体系构架理论应用与某四川板式家具企业,验证了部分节能技术的有效性;研究指出儿童家具色彩设计、零部件标准化设计、通用零部件设计、产品工艺结构设计和企业节能制度建设等节能制造技术适用于该企业;为板式家具企业应用节能技术,实现低碳制造,提高企业工业化水平,提供了操作模式和参照案例,实现了板式家具节能技术应用的初步实践。
It was answered the Chinese economy strategy which called“the sustainable development”to study the manufacturing energy consumption of panel-furniture when the low-carbon economy was fashionable. The clearly data of manufacturing energy consumption for furniture and the theory of low-carbon manufacture technique of furniture were required. There was the basic of industrialization to the clusters of Sichuan panel-furniture industry. The manufacturing status of Sichuan panel-furniture industry would be clear when the manufacturing energy consumptions of panel-furniture manufacturers in Sichuan were studied and analyzed. In this paper survey, induction and comparative methods were applied to build the theory of studying energy consumption in Sichuan panel-furniture manufacturing. The key content of this paper was composed of three parts. The 1st was theory of studying energy consumption of panel furniture manufacturing; the 2nd was the analysis and research of manufacturing energy consumption of the panel-furniture manufacturer in Sichuan; the 3rd studied the energy-saving technique of panel furniture manufacturing.
The content and conclusions of this paper was as follows.
(1) The paper studied energy consumption in panel furniture manufacture, carried out theoretical research of panel-furniture manufacturing energy consumption.
It studied the content & method of energy audit in panel-furniture manufacture. Audited enterprise output and electricity fee was the main work of the manufacture energy consumption study in panel furniture enterprise. The manufacture energy audit in panel furniture manufacturer included the content such as the overview of energy using, efficiency of equipment, and the useful calculation of comprehensive energy consumption. The study about comprehensive energy consumption in panel furniture manufacturer focused on the calculating of energy consumption. Energy consumption, comprehensive energy consumption per unit output value and the comprehensive energy consumption per unit panel area in panel furniture manufacture were the useful types of comprehensive energy consumption. The calculation of the comprehensive energy consumption was indicated in this paper.
It studied comprehensive energy consumption per unit panel area of comparable products in panel furniture manufacturer. The determination of comparable products was the key step of the calculating of comprehensive energy consumption per unit panel area of comparable products in panel furniture manufacturer. Comparable panel furniture is the furniture unit which could reflect the situation of panel material & energy consumption, manufacturing device applications in panel furniture manufacture. Elements which influenced the comprehensive energy consumption unit panel area of comparable products include the typical product shape, process analysis, process and capacity bottlenecks in panel furniture manufacturer. The calculation of the comprehensive energy consumption per unit panel area of comparable products in panel furniture manufacturer was indicated in this paper.
Industry engineering & energy audit were different methods to promoting the industrialization level of Chinese furniture manufacturing. When industry engineering was applied to furniture industry, enterprise faced three questions, such as low level of manufactures industrialization, low universal of application, and low quality of employees. The study of furniture manufacturer energy audit was lack of study area, with unclear research position and no energy scale. Industry engineering could be used in energy audit of furniture manufacturing. Industry engineering offered energy audit techniques, base data and knowledge system. Energy audit displayed a fresh field to promote the industrialization level of Chinese furniture manufacturing.
(2) The study of Sichuan panel furniture manufacturing energy consumption is the main content of the research
The type and characteristics of Sichuan panel-furniture were summarized and analyzed. It summarized the typical manufacturing process of Sichuan panel furniture manufacturer. The study provided series definite methods to study the energy consumption in Sichuan panel furniture manufacturer. The study should investigate the enterprise which used the MDF covered melamine-impregnated-paper as basic material to manufacture panel-furniture.
It investigated and analyzed the energy consumption in Sichuan panel furniture manufacturer. Seven panel furniture manufacturers in Sichuan accepted this investigation. The research indicated that the manufacturing energy consumptions per unit value of large and the small scale panel furniture manufacturers were higher than those middle scales. The study also displayed that good furniture designs brought enterprises low comprehensive energy consumption per unit output value, good furniture manufacturing process & structure design did that so. The study showed that the comprehensive energy consumption per unit output in the investigated panel furniture manufacturer which manufacturing environments were good was lower than those which manufacturing environments were bad.
The comprehensive energy consumption per unit output value of the investigated panel-furniture manufacturer was within the limit of 0.0226~0.0538(T) (SCE) / million RMB. The average of the comprehensive energy consumption per unit output value of the investigated panel-furniture manufacturer was 0.0465(T) (SCE) / million RMB.
The study showed that the comprehensive energy consumption per unit output value of the investigated panel-furniture manufacturer was much less than the value of those tradition high energy consumption industries, such as textile industry, aluminum industry, and paper-making industry. It was shown that the panel-furniture manufacturing industry was not belonging to the high energy consumption industries.
It investigated the comprehensive energy consumption of a teenager-use panel furniture manufacture in Sichuan. It described the overview & the manufacturing status of this enterprise. Analyzed the manufacturing status and materials using of all production, counted the main manufacturing process of this company, 801 & 803 series products were identified as typical products. The comprehensive energy consumption per unit output value of this enterprise in 2008 was within the limit of 0.0516~0.0558 (T) (SCE) / million RMB. The comprehensive energy consumption per unit panel area of panel furniture comparable products in this enterprises was within the limit of 0.514~0.560 (Kg) (SCE) / m2. The result of research was consistent with the present manufacturing situation of this enterprise. The study verified that the count method and formula of the comprehensive energy consumption unit panel area of panel furniture comparable products was right and useful. The research provided some useful energy-saving technologies for this enterprise, such as children furniture color design technique, furniture standardized design technique, general use parts design, product structure optimization technique & enterprise energy-saving policy system building.
(3) It proposed series of energy-saving technologies for panel furniture manufacture. There were four main aims of using the energy-saving technologies in panel furniture manufacturing industry, such as promoting enterprise industrialization, raising the level of enterprise standardization, promoting advanced manufacturing technology and manufacturing use in panel-furniture industry. There are four key factors which effected the comprehensive energy consumption per unit output in panel furniture manufacturers, such as worker, production, manufacturing process system, and manufacturing environment. The energy-saving technology in panel furniture industry was composed by three parts, such as furniture design and manufacturing process, working management, and management and administration of panel-furniture enterprise.
研究内容和结论如下:
(1)开展板式家具制造能耗理论研究,构建板式家具制造能耗分析与研究的基础。开展板式家具能源审计能容与方法研究。结合板式家具设计与制造的典型特征,指出板式家具制造能耗分析主要工作是板式家具企业产值和电费的数据审计。板式家具制造业能源审计内容包括企业用能概况,设备用能效率分析和适用综合能耗计算,板式家具适用综合能耗计算是研究重点。板式家具适用综合能耗包括企业综合能耗、单位产值综合能耗和可比产品单位产量综合能耗,本文提出了板式家具企业制造综合能耗、单位产值综合能耗和可比产品单位板材面积综合能耗适用计算公式。
研究板式家具可比产品单位板材面积综合能耗。在板式家具企业可比产品单位产量综合能耗研究的基础上,指出板式家具可比产品单位产量综合能耗研究关键为板式家具可比产品的界定。板式家具可比单位产品是指反映企业产品设计、生产和销售特点,体现板材消耗、能源消耗情况,反映主要用能设备应用的产品组合而成的家具系列。可比产品单位板材面积综合能耗是板式家具企业可比产品单位产量综合能耗的有效表现。典型产品、工艺分析、瓶颈工序和产能是可比产品单位板材面积综合能耗的影响要素;本文提出了可比产品板材总面积与可比产品单位板材面积综合能耗计算公式。
研究工业工程与能源审计在家具制造业的应用。工业工程(Industry Engineering ,简称IE)在家具制造业中应用面临运行基础不牢、普适度低、人员构成不完整等三方面问题;能源审计在家具制造中的应用面临研究定位缺失、无制造能耗定额标准和能源审计需求有限三方面问题;工业工程和能源审计在家具制造中的应用具有辩证性。在板式家具能源审计中应用IE技术研究企业工艺流程,分析综合能耗与产品造型、工艺、制造技术的关系,研究能耗和板材面积的相关性。
(2)四川板式家具制造能耗分析与研究是本课题研究的主要内容。
归纳分析四川板式家具产品类型与典型工艺。四川板式家具制造业一般按板材表面装饰特性和产品功能分类;据常见板式家具表面装饰特性分类有三聚氰胺浸渍纸预贴面板式家具、“白亮光”家具、和“板木”家具;四川板式家具产品功能分类与其他家具集群区域一致。三聚氰胺浸渍纸预贴面板式家具制造工艺是四川板式家具制造工艺基础,四川板式家具制造能耗调查、分析应以该工艺流程为依据。四川板式家具企业的主要不足为用能设备搭配应用不合理,瓶颈工序制约企业产能。
调查分析四川板式家具企业制造综合能耗。选择大、中、小不同规模板式家具企业,调查四川板式家具产业集群制造能耗现状与能耗研究需求。调查方式和调查表设计是四川板式家具制造综合能耗的调查基础。调查采用网络问卷调查、邀约调查和生产现场拍照调查相结合的方式。调查问卷涉及企业概况、材料应用、用能设备、加工环境、产品结构和企业用能审计需求等内容。参考板式家具企业制造能耗分析与研究相关理论,分析数据,计算四川板式家具企业单位产值综合能耗。经计算,大型和小型受调查板式家具企业单位产值综合能耗均在0.05(吨)(标准煤)/万元RMB左右,比中等产值规模企业单位产值综合能耗高。研究发现产品设计附加值高的板式家具企业,单位产值综合能耗小;生产环境好的企业,单位产值综合能耗小;产品工艺结构影响板式家具企业单位产值综合能耗,但影响因素复杂,规律不明显;人均耗能量大小和受调查板式家具企业单位产值综合能耗无必然联系。受调查板式家具企业人均综合能耗范围在0.64~1.64(吨)(标准煤)/人;单位产值综合能耗范围在0.0226~0.0538(吨)(标准煤)/万元RMB,平均值约0.0465(吨)(标准煤)/万元RMB。将板式家具制造业单位产值综合能耗与纺织业、铝业和造纸业等传统高能耗产业单位产值综合能耗比较,初步判断板式家具制造不属于高能耗产业范畴。
分析研究四川某板式家具企业2008年制造综合能耗。调查阐述该企业概况和工艺现状,该企业生产青少年板式家具,位于四川成都十陵工业园,员工85人,08年产值1926万元RMB;企业工艺为封闭色彩涂饰三聚氰胺浸渍纸预贴面板式家具制造工艺。分析企业生产周期内所有产品加工情况和物料应用情况;根据分析结果,研究以801和803系列家具为企业08年典型产品。在上述研究基础上,计算08年该企业每月可比产品板材总面积、单位产值综合能耗和可比产品单位板材面积综合能耗。企业2008年单位产值综合能耗范围0.0516~0.0558(吨)标准煤/万元RMB,可比产品单位板材面积综合能耗范围0.514~0.56(0kg)标准煤/m2。企业每月单位产值综合能耗和可比产品单位板材面积综合能耗变化与生产现状相符,证明板式家具可比产品单位板材面积综合能耗计算方法可行,反映其生产实际变化。
(3)开展板式家具企业适应节能技术研究,构建板式家具企业适用节能体系。
重点研究了影响板式家具单位产值综合能耗的因素,分析了板式家具节能技术应用的目的,归纳了常见板式家具设计、工艺与制造技术;在上述研究的基础上构建了板式家具适用节能技术体系并进行其应用案例分析。
研究将节能技术体系构架理论应用与某四川板式家具企业,验证了部分节能技术的有效性;研究指出儿童家具色彩设计、零部件标准化设计、通用零部件设计、产品工艺结构设计和企业节能制度建设等节能制造技术适用于该企业;为板式家具企业应用节能技术,实现低碳制造,提高企业工业化水平,提供了操作模式和参照案例,实现了板式家具节能技术应用的初步实践。
It was answered the Chinese economy strategy which called“the sustainable development”to study the manufacturing energy consumption of panel-furniture when the low-carbon economy was fashionable. The clearly data of manufacturing energy consumption for furniture and the theory of low-carbon manufacture technique of furniture were required. There was the basic of industrialization to the clusters of Sichuan panel-furniture industry. The manufacturing status of Sichuan panel-furniture industry would be clear when the manufacturing energy consumptions of panel-furniture manufacturers in Sichuan were studied and analyzed. In this paper survey, induction and comparative methods were applied to build the theory of studying energy consumption in Sichuan panel-furniture manufacturing. The key content of this paper was composed of three parts. The 1st was theory of studying energy consumption of panel furniture manufacturing; the 2nd was the analysis and research of manufacturing energy consumption of the panel-furniture manufacturer in Sichuan; the 3rd studied the energy-saving technique of panel furniture manufacturing.
The content and conclusions of this paper was as follows.
(1) The paper studied energy consumption in panel furniture manufacture, carried out theoretical research of panel-furniture manufacturing energy consumption.
It studied the content & method of energy audit in panel-furniture manufacture. Audited enterprise output and electricity fee was the main work of the manufacture energy consumption study in panel furniture enterprise. The manufacture energy audit in panel furniture manufacturer included the content such as the overview of energy using, efficiency of equipment, and the useful calculation of comprehensive energy consumption. The study about comprehensive energy consumption in panel furniture manufacturer focused on the calculating of energy consumption. Energy consumption, comprehensive energy consumption per unit output value and the comprehensive energy consumption per unit panel area in panel furniture manufacture were the useful types of comprehensive energy consumption. The calculation of the comprehensive energy consumption was indicated in this paper.
It studied comprehensive energy consumption per unit panel area of comparable products in panel furniture manufacturer. The determination of comparable products was the key step of the calculating of comprehensive energy consumption per unit panel area of comparable products in panel furniture manufacturer. Comparable panel furniture is the furniture unit which could reflect the situation of panel material & energy consumption, manufacturing device applications in panel furniture manufacture. Elements which influenced the comprehensive energy consumption unit panel area of comparable products include the typical product shape, process analysis, process and capacity bottlenecks in panel furniture manufacturer. The calculation of the comprehensive energy consumption per unit panel area of comparable products in panel furniture manufacturer was indicated in this paper.
Industry engineering & energy audit were different methods to promoting the industrialization level of Chinese furniture manufacturing. When industry engineering was applied to furniture industry, enterprise faced three questions, such as low level of manufactures industrialization, low universal of application, and low quality of employees. The study of furniture manufacturer energy audit was lack of study area, with unclear research position and no energy scale. Industry engineering could be used in energy audit of furniture manufacturing. Industry engineering offered energy audit techniques, base data and knowledge system. Energy audit displayed a fresh field to promote the industrialization level of Chinese furniture manufacturing.
(2) The study of Sichuan panel furniture manufacturing energy consumption is the main content of the research
The type and characteristics of Sichuan panel-furniture were summarized and analyzed. It summarized the typical manufacturing process of Sichuan panel furniture manufacturer. The study provided series definite methods to study the energy consumption in Sichuan panel furniture manufacturer. The study should investigate the enterprise which used the MDF covered melamine-impregnated-paper as basic material to manufacture panel-furniture.
It investigated and analyzed the energy consumption in Sichuan panel furniture manufacturer. Seven panel furniture manufacturers in Sichuan accepted this investigation. The research indicated that the manufacturing energy consumptions per unit value of large and the small scale panel furniture manufacturers were higher than those middle scales. The study also displayed that good furniture designs brought enterprises low comprehensive energy consumption per unit output value, good furniture manufacturing process & structure design did that so. The study showed that the comprehensive energy consumption per unit output in the investigated panel furniture manufacturer which manufacturing environments were good was lower than those which manufacturing environments were bad.
The comprehensive energy consumption per unit output value of the investigated panel-furniture manufacturer was within the limit of 0.0226~0.0538(T) (SCE) / million RMB. The average of the comprehensive energy consumption per unit output value of the investigated panel-furniture manufacturer was 0.0465(T) (SCE) / million RMB.
The study showed that the comprehensive energy consumption per unit output value of the investigated panel-furniture manufacturer was much less than the value of those tradition high energy consumption industries, such as textile industry, aluminum industry, and paper-making industry. It was shown that the panel-furniture manufacturing industry was not belonging to the high energy consumption industries.
It investigated the comprehensive energy consumption of a teenager-use panel furniture manufacture in Sichuan. It described the overview & the manufacturing status of this enterprise. Analyzed the manufacturing status and materials using of all production, counted the main manufacturing process of this company, 801 & 803 series products were identified as typical products. The comprehensive energy consumption per unit output value of this enterprise in 2008 was within the limit of 0.0516~0.0558 (T) (SCE) / million RMB. The comprehensive energy consumption per unit panel area of panel furniture comparable products in this enterprises was within the limit of 0.514~0.560 (Kg) (SCE) / m2. The result of research was consistent with the present manufacturing situation of this enterprise. The study verified that the count method and formula of the comprehensive energy consumption unit panel area of panel furniture comparable products was right and useful. The research provided some useful energy-saving technologies for this enterprise, such as children furniture color design technique, furniture standardized design technique, general use parts design, product structure optimization technique & enterprise energy-saving policy system building.
(3) It proposed series of energy-saving technologies for panel furniture manufacture. There were four main aims of using the energy-saving technologies in panel furniture manufacturing industry, such as promoting enterprise industrialization, raising the level of enterprise standardization, promoting advanced manufacturing technology and manufacturing use in panel-furniture industry. There are four key factors which effected the comprehensive energy consumption per unit output in panel furniture manufacturers, such as worker, production, manufacturing process system, and manufacturing environment. The energy-saving technology in panel furniture industry was composed by three parts, such as furniture design and manufacturing process, working management, and management and administration of panel-furniture enterprise.
引文
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