Series (3): A low-carbon road written on a piece of cloth
With the acceleration of the "carbon peaking and carbon neutrality" action and the advent of the era of digital technology and digital economy, traditional industrial enterprises have entered a new historical stage that requires in-depth reform and innovation for development.
Keqiao has always attached great importance to the promotion and development of the textile printing and dyeing industry, focusing on the development goals of green, smart and fashion, through transformation and upgrading, many enterprises from energy production to product research and development, and then to all aspects of consumption guidance, reduce consumption, reduce losses and pollutant emissions, stop waste, and effectively and rationally use energy.
Now, according to the spirit of the "No. 1 Development Project" for the innovation and quality improvement of the digital economy in Zhejiang Province, Keqiao has begun to plan a new leap in "industrial energy level, innovation model, digital empowerment, data value, and inclusive sharing". The green, recyclable and intelligent Keqiao printing and dyeing industry is subverting the public's stereotype of the traditional textile printing and dyeing industry.
Printing and dyeing factory equipped with "smart brain"
With the pulse of economic development, digital reform continues to penetrate all walks of life, and also supports the iteration and innovation of the industry. As the most advanced textile industry cluster in the country, in recent years, Keqiao District has innovated to create the "weaving printing and dyeing industry brain" based on the current situation of the weaving printing and dyeing industry, through the comprehensive interconnection of people, machines and things, the system integrates the information flow of the industrial chain such as weaving, printing and dyeing, trade, etc., and provides services such as overall planning and guidance, preferential enterprise policies, talent services, and enterprise burden reduction, which effectively solves the shortcomings of the traditional manufacturing industry such as the allocation of production factors by manual budget, manual scheduling of production schedule, and low efficiency of industrial chain coordination.
Up to now, the weaving printing and dyeing industry brain built by Keqiao District has been launched in the provincial industrial brain competence center, with a total of 20 application scenarios such as digital supply chain, equipment cloud connection, intelligent scheduling, and more than 1,800 textile printing and dyeing enterprises, basically realizing the full coverage of printing and dyeing enterprises in the whole district, promoting the industry's production efficiency to increase by more than 8%, reduce energy consumption by more than 10%, and increase the yield rate by more than 15%.
Walking into the printing and dyeing workshop of Shaoxing Xingming Dyeing and Finishing Co., Ltd., you can't see sewage, can't smell pungent odors, can't hear the roaring sound of machines, and are clean and tidy everywhere. I saw that in the finalized workshop, the information such as equipment operation, employee output, production situation, and output trend was clear at a glance; In the dyeing workshop, the operation steps and execution status of different dissolving machines are updated in real time; Intelligent three-dimensional warehouse, stacker crane in accordance with the program in an orderly manner, task type, customer information, material information, etc. are detailed and clear.
Zhong Jianjun, chairman of Shaoxing Xingming Dyeing and Finishing Co., Ltd., told reporters that they realized the automatic management of the production process through equipment interconnection, and the efficiency of the machine was increased by more than 35%, the labor was reduced by 36%, and the energy was saved by more than 20%.
Subsequently, the staff of Shaoxing Xingming Dyeing and Finishing Co., Ltd. used their mobile phones to open the interface of "printing and dyeing brain", and the data report, basic diagnosis, and real-time monitoring of 50 dyeing vat of Xingming dyeing and finishing were clear at a glance.
"The intelligent 'printing and dyeing brain' can monitor the production cost and production status of each cylinder of cloth in real time, which not only realizes the first time to 'take the pulse' and improve the one-time yield rate, but also can accurately modulate the optimal process and the best energy consumption of a product according to historical data in the later stage." The staff told reporters that if there is an abnormality in the operation process of the dyeing vat, a timely warning will be issued, which effectively improves the dyeing pass rate. At the same time, in terms of environmental protection, it will be more accurate to monitor whether there are substances harmful to human health in dyes to the discharge of waste gas and wastewater.
"Digital transformation has made the production process more scientific and reasonable, and the stability of product quality has been greatly improved." Zhong Jianjun said.
This is the epitome of Keqiao District's implementation of the digitalization of the printing and dyeing industry and the use of scientific and technological innovation to promote competitiveness. It is understood that the "printing and dyeing brain" is a digital and intelligent service platform for the printing and dyeing industry, which can effectively improve the first-pass rate of dyeing, realize energy saving, emission reduction, quality and efficiency improvement of enterprises.
At the same time, industrial transformation and upgrading, and intelligent transformation of enterprises are inseparable from the strong support of the government. Zhu Jianbiao, Keqiao Branch of Shaoxing Ecological Environment Bureau, told Environmental Economy that during the agglomeration process, the government gave enterprises 15% of equipment subsidies; In the process of digital and intelligent upgrading, more than 30% of software subsidies will be given to enterprises to encourage transformation and upgrading.
"With the promotion of digitalization, we continue to promote the green and high-end development of the industry." Zhu Jianbiao told reporters that since 2010, Keqiao has continuously promoted the construction of modern textile clusters. From the original decentralized operation of 259 enterprises to the current cluster development of 110 enterprises, the expansion has shifted to quality improvement, the pollution discharge has been reduced, and the efficiency has been improved.
Technological transformation, to the green high-end
A few days ago, the reporter saw in the production workshop of Zhejiang Baofang Printing and Dyeing Co., Ltd. that a brand-new setting machine was operating.
Chen Zhongdong, director of the office of Zhejiang Baofang Printing and Dyeing Co., Ltd., told reporters that the setting machine is a high energy-consuming equipment in the production process of printing and dyeing enterprises, and its exhaust gas has the characteristics of high temperature, large gas volume and complex composition, and its energy consumption accounts for more than 40% of the total energy consumption of the entire enterprise, of which the heat emitted by the exhaust gas of the setting machine accounts for about 60%. As an important part of energy conservation and emission reduction, waste heat utilization has great potential for energy saving.
"We have invested more than 5 million yuan to upgrade the single-width single-layer setting machine to a double-width double-layer setting machine for the first time in the national industry, and the production efficiency of each setting machine can be more than doubled under the same water, electricity and gas consumption." Chen Zhongdong said.
According to reports, the waste heat utilization transformation is to carry out multi-stage treatment of the exhaust gas discharged from the setting machine, and convert the heat energy in the exhaust gas into effective high-temperature fresh air through the gas-gas heat exchanger for the use of the setting oven; The normal temperature water is converted into hot water through the gas-water exchanger, which is used in the dyeing and finishing workshop; At the same time, the exhaust gas is purified, and finally the exhaust gas with low temperature, small gas volume and high cleanliness is obtained.
Chen Zhongdong told reporters that after the transformation, the energy-saving rate of the setting machine has increased by more than 20%, which can save more than 3,000 tons of standard coal and reduce carbon dioxide emissions by about 9,000 tons per year.
According to incomplete statistics, there are more than 2,600 printing and dyeing machines in Keqiao District, and a single setting machine needs about 700 tons of standard coal for drying heat every year, if the energy saving rate is calculated by 20%, after the full promotion of waste heat utilization technology, the use of 364,000 tons of standard coal can be reduced every year, and carbon dioxide emissions can be reduced by 1.048 million tons. The transformed setting machine is an effective measure for the green and low-carbon transformation of the printing and dyeing industry.
"Waste heat recovery of setting machine" is a vivid silhouette of Keqiao's technology upgrade and low-carbon transformation. More and more high-energy-consuming enterprises in Keqiao have enhanced their core competitiveness in market competition by optimizing production processes and carrying out green upgrading methods such as equipment optimization and transformation.
Keqiao printing and dyeing industry not only "work hard" in technological transformation, but also constantly explore new printing and dyeing technologies and processes.
Taking non-watermark dyeing as an example, unlike the traditional dye vat, "non-watermark dyeing" "hits" the dye like inkjet, saving 100% of salt, saving 100% of water and reducing energy consumption by 39.3%, the color fixation rate of dyes reaches more than 97%, and the solvent recovery rate is as high as 99%...
It is reported that no watermark dyeing uses organic solvent instead of water as a medium for dyeing, which means that there is no need to pre-treat and post-dye the yarn, and the whole printing and dyeing process does not use water at all, nor does it need to add other chemicals such as dyeing salts, so as to achieve or even exceed the effect of traditional water medium dyeing, at the same time, this organic solvent is a highly recyclable medium, with a recycling rate of more than 99%, basically a one-time investment, and it can be recycled in the dye vat all the time. There is no longer any waste water discharge in printing and dyeing production, and there is no need to do sewage treatment, and it will not cause any environmental pollution.
According to incomplete statistics, if the "waterless dyeing" technology is used in the whole industry in China, about 194 West Lakes can be saved every year.
"It used to be less than 20 tons of cloth a day, but now it can dye 30 tons a day, and the efficiency has skyrocketed." The person in charge of Zhejiang Lego Industrial Co., Ltd. said that because of the high color fastness and no cylinder difference of the "no watermark dyeing" product, the added value is also 40% higher than that of ordinary printing and dyeing fabrics.
Li Chuanhai, president of Zhejiang Printing and Dyeing Industry Association and Keqiao Printing and Dyeing Industry Association, told reporters that compared with conventional water medium dyeing, "anhydrous dyeing" technology has a huge range of savings in chemical consumption, water consumption, energy consumption, etc., which is a subversive technological breakthrough in the traditional textile printing and dyeing industry, which not only enhances the core competitiveness of the enterprise itself, but also helps the entire textile industry to take off the black hat of "large polluters", help the industry save energy and reduce emissions, green production, and achieve sustainable and high-quality development.
With the help of the east wind of printing and dyeing agglomeration, Keqiao's printing and dyeing enterprises are eliminating backward production capacity on schedule and gradually applying a large number of high-end processes and technologies such as watermark dyeing. In the past five years, Keqiao District has eliminated 3.816 billion meters of backward printing and dyeing production capacity, invested more than 1.5 billion yuan in environmental protection equipment, increased the proportion of international advanced equipment application from 30% to 60%, and the comprehensive energy consumption of industrial added value above the scale of the district decreased by 8.1% year-on-year, and the added value of printing and dyeing cloth per meter increased by more than 15%.
energy substitution,Guide enterprises to use green electricity
In 2022, the total energy consumption of the district will reach 10.18 million tons of standard coal, the total greenhouse gas emissions will reach about 25 million tons of carbon dioxide equivalent, and the total net emissions will be about 20 million tons of carbon dioxide equivalent, accounting for about 50% of the city's total greenhouse gas emissions.
近年来，柯桥着力推进工业提档升级，全面开展清洁energy substitution,单位GDP二氧化碳排放量和单位GDP能耗逐年持续下降。
朱建彪介绍，柯桥大力推进energy substitution,Guide enterprises to use green electricity，提升天然气和电的使用比重，大力发展分布式光伏，逐步实现可再生能源替代传统化石能源。去年，全区当年新并网装机光伏发电规模231.6兆瓦，超额完成全年任务。
Zhejiang Red, Green and Blue Textile Printing and Dyeing Co., Ltd., which focuses on the printing and dyeing production of women's clothing fabrics, looks down from the air, and it can be seen that a large dark solar collector panel on the top of the company's plant is converting solar energy into electricity through its own absorption function.
The person in charge of the company said that in 2019, the company installed solar photovoltaic panels on the top of the plant, with a total area of 12,000 square meters, a power of 12,000 megawatts, and an annual power generation of about 1.5 million kWh, realizing the replacement of clean electricity, reducing electricity costs, and helping to achieve the "double carbon" goal.
Whether the implementation of green and low-carbon production is good or not, enterprises have the most right to speak. Shaoxing Shengxin Printing and Dyeing Co., Ltd., which is in the same Keqiao printing and dyeing industry cluster area as "red, green and blue", has been trying to devote itself to energy conservation and emission reduction, replacing the original traditional motor with permanent magnet motor and maglev motor to reduce power consumption. As of the end of July, the installed photovoltaic capacity in Keqiao District was 300.18 megawatts, and the annual power generation capacity could reach about 300 million kilowatt hours, which is equivalent to reducing about 330,000 tons of carbon dioxide emissions per year.
For enterprises in Keqiao District, energy conservation and emission reduction, green and low-carbon are not so much the requirements of superiors, but the spontaneous requirements for improving the quality of development after the development of enterprises reaches a certain stage.
carbon footprint certification,A key to the international market
From a piece of cotton, to a silk thread, to a piece of grey cloth, to a piece of clothing; From a drop of wood pulp, to a fiber, to a piece of cloth, to a piece of clothing... Every step of the way is a life-cycle carbon footprint.
Li Chuanhai told reporters that the use of carbon footprint, carbon labels and other key achievements is an important means to promote the optimization and upgrading of the industrial structure, promote the synergy of pollution reduction and carbon reduction, and build a modern textile industry, and is an important path to promote the green and low-carbon development of the textile industry.
Carbon footprint, simply put, is the greenhouse gas emissions of a product throughout its life cycle, from raw material extraction, manufacturing, transportation and use, to disposal or recycling. The "carbon footprint label" is the certification of the carbon footprint evaluation.
It is reported that there are nearly 8,000 textile enterprises in Keqiao District, including more than 700 enterprises above designated size, more than 200,000 employees, and the printing and dyeing production capacity accounts for about 1/3 of the country and nearly 1/4 of the global textile product trading volume. This city, known as "the city on the cloth", relying on the unique advantages of "industry + market" and the comprehensive advantages of the industrial chain, is currently the most complete textile industry chain, the largest textile production capacity and the largest textile industry cluster in the professional market.
Zhu Jianbiao told reporters that with this certification system, it is possible to measure and trace carbon emissions at all stages of the product, achieve pollution reduction and carbon reduction in a more targeted manner, and at the same time deal with international carbon trade barriers in developed countries such as Europe and the United States.
The person in charge of environmental protection of Zhejiang Baofang Printing and Dyeing Co., Ltd. told reporters that as a pilot enterprise of chemical fiber fabrics, it has carried out data collection of the whole life cycle of carbon footprint. On their company's ERP information management system, the energy consumption of gas, water and electricity for each batch of products produced by each equipment has been collected in real time, and the collection scope covers the whole process of printing and dyeing such as dyeing, shaping, and finishing. Through the accumulation of big data, the typical carbon footprint of chemical fiber fabrics in the printing and dyeing process can be calculated.
"At present, the 'carbon footprint label' of the textile industry in Keqiao District focuses on the three major production links of chemical fiber, weaving and printing and dyeing, which are divided into four major fields: chemical fiber, cotton and linen, silk and clothing, and the local standards of "Technical Specifications for Product Carbon Footprint Evaluation" are established one by one." Zhu Jianbiao said that recently, the technical specifications for the evaluation of the "carbon footprint" of products in the three fields of chemical fiber, cotton and linen and silk have completed the establishment of local standards, and only the local standards for the "carbon footprint" in the field of clothing have not yet been established. "It is expected that all projects will be completed by the end of the year and obtain internationally recognized certification."
"In the future, this certification will be a key for companies to open up the international market." Zhu Jianbiao said. At present, there is no unified standard in this area in the world, once Shaoxing "run" in front, it can win more initiative for the textile industry in the future market competition, and improve the core competitiveness of enterprises. Not only that, Keqiao is also actively carrying out the application of the carbon footprint management platform for textile products in Keqiao District, Shaoxing City and the establishment of a provincial green certification alliance.
