Discussion on soybean oil production process optimization and cost reduction

Discussion on soybean oil production process optimization and cost reduction

A. The importance of reducing the cost of soybean oil processing

Soybean oil refining process cost control and reduction, has always been the top priority of each oil production plant. In the fierce competition in the market, who has low costs, who holds the initiative. The maintenance of the process of processing soybean crude oil to finished oil and ensuring normal production operations require special attention to the quality of the product and cost control.

In the premise of ensuring the quality of finished soybean oil and equipment life, that is, to meet the production process of its necessary functions, remove redundant functions, optimize the production process, both to reduce the cost of soybean oil production and to ensure that the quality of soybean oil qualified. This will undoubtedly be a good approach. As we all know, the price - cost = revenue, process cost reduction is a variety of cost-reduction measures in the most important, most effective, the most effective way to achieve technical innovation to obtain revenue growth.

Second, the basic idea of optimizing the production process to reduce costs

Optimization of production processes to reduce costs is to consider the process design, how to use the most economical, the most effective, process structure, the most appropriate raw and auxiliary materials, the most effective process control, the most concise way to achieve cost reduction.

The whole process of soybean oil production, each key control point should be carefully analyzed to find the breakthrough of optimizing the process.

1. Whether the direction of the pipeline is reasonable, try to find the best way and choose a reasonable pipe diameter.

2. Whether the equipment of pump conveying equipment is suitable, the head of conveying pump, flow rate and the equipment of motor, try to control in a reasonable range, if necessary, can use frequency conversion motor.

3. whether the use of auxiliary materials in the best condition.

The above three specific directions throughout the entire soybean oil production process control, that is, from the soybean oil into the warehouse to the finished oil sales, process optimization to reduce costs is a continuous improvement, continuous improvement process.

(A) cancel unnecessary processes or merge processes, using a new process [1]

Many processes in the process of process execution are duplicated, or in order to achieve the same purpose and play the same role, the purpose and role of several processes is the same, in such cases can be retained one of them, simplify the process, save man-hours and improve production efficiency. ［2］

In order to ensure the quality of refined oil products, the original process uses the finished oil processing qualified, first into the workshop finished oil temporary storage tank temporary storage, and then by the finished oil temporary storage tank equipped with the finished oil pump transported to the finished plant storage tank storage, such process design is to prevent the initial start-up production process, equipment operation is not stable, there is unqualified finished oil directly into the finished plant storage tank.

Through careful argumentation, the refinery decided to optimize the finished oil processing process and reduce electricity consumption by using the original production process at the beginning of each production start-up, and then switch to the optimized process after the equipment and process have stabilized and the quality of the finished oil has stabilized, so as to reduce the operation of one finished oil transfer pump and achieve the purpose of saving electricity consumption.

(2) Use low cost process auxiliary materials under the premise of achieving the same effect

Can play the same effect under the premise of a variety of process methods for comparison, compare two or more process auxiliary material costs, the lower cost priority use.

In the process of oil refining, kerosene is one of the essential auxiliary materials. In the refining process of gross oil, the acid price of gross oil is a necessary factor to determine the consumption of alkali, and the acid price of gross oil directly affects the level of alkali consumption. Usually, the index of alkali consumption is determined according to the acid price of gross oil.

In the past, the refining workshop has been using flake kerosene as the main auxiliary material, and the laborers dump the flake kerosene into the lye tank, add water and stir to dilute it into 38Be concentration lye for the workshop production. The content of flake kerosene is generally 98%-100.5%. Due to the uncertainty of adding water, the concentration of lye is also high and low, which causes fluctuation to the consumption index of the workshop. After many inquiries, the refining workshop compared with the same industry, the flake kerosene decisively changed to the concentration of 32% liquid alkali to use, through comparison in the production process, liquid alkali is easier to adjust than flake alkali, alkali consumption is more stable, which reduces the purchase cost, and save labor costs, and avoid the flake alkali feeding process, powder splash, inhalation and other safety risks.

Phosphoric acid is also a necessary auxiliary material for the production of the refining plant, as phosphoric acid is packaged in plastic drums, each time dumped to the acid tank, there are some hanging walls and residues in the drums, the workshop added a plastic water pipe on site, each time the completion of the dumping of phosphoric acid drums are flushed, so as not to waste, although the residual amount is not large, but through the accumulation of months and years, but still can reduce costs.

Process optimization to reduce costs is simply a reorganization or improvement of the original process to improve operating efficiency, reduce production costs, to achieve technically advanced and economically rational, that is, better than the current process of a method of operation, in the details of the process work to find the entry point for process optimization to reduce costs.