Report on the Investigation of Environmental Protection Issues in Equipment Manufacturing Enterprises in Shandong Province
In recent years, with the official implementation of the new Environmental Protection Law and the tightening of domestic environmental protection efforts, some cities in the province have concentrated on shutting down and rectifying a batch of emissions that do not meet the standardsScattered and polluted small and medium-sized enterprises,It has played a positive role in promoting the improvement of the atmospheric environment throughout the province.but at the same timeMechanical processing enterprises that meet certain emission standards are also facing unprecedented environmental pressure, often requiring production restrictions or even shutdowns, which to some extent affects the normal production and operation of the enterprises. There is a hidden danger of high-quality enterprises relocating and losing orders, which affects the healthy and sustainable development of the economy. Shandong Province is a major province in the equipment manufacturing industry. In order to effectively carry out environmental protection work in the machinery industry and promote the healthy development of the province's machinery industry, based on the actual environmental protection situation reflected by the general machinery industry in the province,In late April,The Provincial Equipment Association and Jining Machinery Industry Association conducted a special research on the environmental protection work of equipment manufacturing enterprises. Key research was conducted on the relatively concentrated machinery industry in Rencheng District, Zoucheng City, Jiaxiang County, and High tech Zone of Jining CitySeventeen key enterprises, and through holding symposiums, inspecting production sites, filling out survey questionnaires, etc., listened to and understood the introduction of the current environmental protection situation by the enterprise leaders. The specific situation is reported as follows:
1、 Basic information
The 17 companies surveyed mainly cover industries such as construction machinery, specialized vehicles, forging and casting, and mold processing. The emissions during the production process are mainly dust.
1、山东金鼎实业股份有限公司是按照高标准设计、高标准设备配置的新建（搬迁）企业， 2016年初投产。在铸造生产的熔化工序，采用美国中频电炉熔炼，配置2套布袋除尘器，22米高空达标排放；在砂处理工序，采用德国混砂设备，配置7套布袋除尘器，22米高空达标排放；在造型工序使用德国、意大利自动造型设备，配置集气罩联通砂处理除尘器或独立配置布袋除尘器，22米高空排放；在清理工序，使用潘邦清理成套装备封闭清理，配置布袋除尘器，20米高空达标排放。该公司的机械加工生产部分，均在独立高标准车间进行，车间内配置德国、日本、韩国和台湾等国家和地区的先进数控机床，对毛坯进行成品零件加工，无粉尘、废气产生。该公司针对熔化工序、砂处理工序、造型工序和清理工序等存在污染的环节，全部对应配置环保设备，配套环保设施投资2700多万元。
2. Shandong Jixin Auto Parts Co., Ltd. invested 1.59 million yuan to install 5 sets of dust collectors, including 3 sets of pulse filter cartridge dust collectors and 2 sets of pulse bag dust collectors, for cleaning and electric furnace dust removal; The smoke and dust generated by the electric furnace during the production process are collected by the cyclone dust collector cover and filtered by a set of GMC-320/5 pulse filter bag dust collectors to meet the standards before being discharged through an 18 meter high exhaust pipe; Sand processing, core sand transportation, and sand mixing are carried out in a closed manner. The dust generated is removed by three sets of MT26-1040, MT19-760, and MT10-400 pulse filter cartridges and discharged through an 18 meter high exhaust pipe after meeting the dust removal standards; Shot blasting cleaning uses sealed steel shot cleaning, and the generated dust is filtered by a DMC-320 pulse filter cartridge dust collector to meet the standard, and then discharged through an 18 meter high exhaust pipe.
3. Komatsu (Shandong) Engineering Machinery Co., Ltd. has installed protective covers and equipped efficient welding dust collectors (with a dust removal rate of over 90%) in welding production. Compared with traditional methods, it has the advantages of source sealing and fixed adsorption, and the effect is improved by more than 50%; The company's painting process is water curtain painting, and filtering measures such as activated carbon are installed in front of the exhaust pipe. The overall device is vacuum sealed, which has greatly improved compared to traditional methods; At the same time, Komatsu hires qualified third-party professional testing institutions recognized by the Environmental Protection Bureau every year for testing, and the emission concentration and emission rate are both lower than the second level standard of the Comprehensive Emission Standards for Air Pollutants (GB16297-1996); In the near future, the company plans to refer to the treatment measures of Komatsu Corporation in Japan for exhaust gas and carry out technological transformation of related processes to further improve the efficiency of exhaust gas treatment.
4. On the basis of its original production process, Dajing Machinery (Shandong) Co., Ltd. actively promotes the upgrading and transformation of environmental protection facilities, investing 2.08 million yuan to install a new welding smoke purification system, achieving 100% sealed collection of smoke and dust; The powder spraying line adopts an automatic electrostatic spraying device, and the waste powder in the powder spraying room is 100% recovered; In the paint spraying room, the water spinning spray purification device is used to treat the paint mist. On the ground, the laminar flow technology is used to supply air from top to bottom to prevent the paint mist from spreading. Under the ground, the water spinning power pipe is used to treat the paint mist, with an efficiency of more than 98%; The company invested 87800 yuan to install a painting exhaust gas adsorption and purification system, and added 5 activated carbon adsorption boxes to further improve the treatment effect. After monitoring, all pollutants meet the emission standards.
5. The sewage from the Maifuwei wheel factory area is discharged after sedimentation, filtration and other procedures to meet the standards. After testing, the water quality of the final discharge outlet of the sewage treatment plant in the factory area meets the Class 1B standard in Table 1B of the "Water Quality Standards for Sewage Discharged into Urban Sewers" (CJ343-2010) and the acceptance standards of the Jining High tech Zone Sewage Treatment Plant; The waste gases generated from the shot blasting process, painting and drying process, electrophoresis drying process, acid washing process, and welding process in the factory area are all treated by purification devices. After monitoring by authoritative institutions, the wastewater and waste gases generated by the company are all discharged in compliance with standards. The company's painting process adopts a water rotary tower+UV photolysis process for treatment, which has a more stable treatment effect compared to traditional activated carbon adsorption process, while not producing secondary pollutants and having lower operation and maintenance costs; The welding process is planned to adopt a centralized filter collection and processing method, which has higher treatment efficiency, better results, and lower resource consumption compared to traditional movable dust removal equipment. At the same time, the company has built a standardized hazardous waste temporary storage room as required, and all hazardous waste is managed for inbound and outbound according to regulations, and a qualified third-party company is entrusted to handle it.
Although there are certain pollution processes in the production process of the other 12 enterprises, they have all taken effective environmental protection measures and all pollution discharge indicators have been met.
2、 Regulations on Heavy Pollution Weather
The heavy pollution weather warning in Jining City is divided into four levels, from light to heavy, namely blue warning (level IV), yellow warning (level III), orange warning (level II), and red warning (level I). Taking the casting industry as an example, according to the "Emergency Plan for Heavy Pollution Weather in Jining City", the casting industry implements production restrictions or staggered production. Except for electric furnaces and natural gas furnaces that meet the emission standards, all other casting enterprises will be shut down during the heating season. If production is necessary in special circumstances, approval from the municipal government should be obtained. Electric furnaces and natural gas furnaces should be shut down during periods of yellow warning or above heavy pollution. When the Level IV blue warning emergency response is activated, it is required that "waste gas emitting enterprises improve the operational efficiency of pollution control facilities, ensure stable and compliant emissions, and stop production for any hourly emissions exceeding the standard. If production cannot be stopped immediately, production should be limited to the maximum extent possible and the operational efficiency of pollution control facilities should be improved"; When the Level III yellow warning and above emergency response are activated, it is required that "casting enterprises (including electric furnaces and natural gas furnaces) implement production stoppage" and "welding, painting and other VOCs emission processes stop production".
经过调研，济宁市从2017年10月17日开始实施重污染天气预警，至2018年3月30日结束，限产163天，其中停产76天。在我们调研的这17家企业中，均不同程度的停产、限产，其中以工程机械、铸造锻造最为严重。山东金鼎实业股份有限公司因多个产品迟迟不能按时交付国外客户，已有3家终止业务合作。同时，因违约原有货款不再给付，5家客户提出不同数额的索赔，总体损失1000多万元。山东济信汽车配件有限公司由于不能按时交付公司客户长春一汽业务，被其他供应商代替并给予了高达1000万元的索赔，回款中断；国际客户订单由于不能正常生产，原来所接订单不能按时交付，但船期客户均已订好，给该公司带来高额的滞港费以及船期延误造成的索赔。仅山东金鼎实业股份有限公司和山东济信汽车配件有限公司两家企业合计损失已达3000余万元，多家新的订单更不敢承接。
三、环保治理现状
近年来，我省加大了治理环保污染的力度，尤其是2015年以来施行的新环保法，号称史上最严。但环保问题往往不是一个环保部门就能解决的问题，很多时候需要多个部门联合执法。环保部门的权利、精力都有限，需要多部门联合执法才效果更好。我们认为那些说为了环保而关停企业民生受损的做法，是非常不恰当的。在调研的过程中，我们了解到因为环保问题，一部分中小型企业因环保设备、设施不过关而关停，其实深究原因不难发现，这些关停的企业很多都是一些产能较为落后、装备较为落后的企业，这些企业被关停，其实是符合我省新旧动能转换要求的。这些关停的企业如果想涅槃重生，要想有一个脱胎换骨的变化，唯有加大资金、设备投入，开快新产品开发，尽快淘汰一些落后的工艺和装备，实现企业的转型升级。部分企业是因为个别县市区对环保治理采取了“一刀切”的态度，导致这些环保达标的企业也因此受到牵连。
调研的这些企业，环保治理情况基本分为三类。第一类为治污设施安装完备，治理工艺处于国际领先水平，且污染物排放达到标准要求的环保治理规范企业，如小松山东、大京机械、重汽商用车、邹城金鼎实业、济信汽车配件等；
第二类为治污设备较为完备，治理工艺处于国内领先水平且计划进一步提升改进的环保治理较为规范的企业，如麦孚威车轮、胜代机械、永生重工、华屹重工、宁润文正等；
第三类为环保设施落后，治理措施简易，焊接、涂装等工序治理工艺水平较低的企业。
四、下一步的建议
根据济宁市的调研情况，我们又通过走访、电话调研的方式对其他地市进行了摸底调研，通过调研发现，其他地市的很多装备制造业企业也出现了类似的情况。鉴于目前我省各地市环保情况的重要性，同时按照国家环保政策的要求，建议省有关领导及环保领域专家赴以上企业进行调研论证，在全面评估其环保设施及排放达标情况后根据实际进行分门别类监管。
1、统一思想认识，环保治理不但是政府的职责更是企业的社会责任。继续加强环保督查力度，对于一些环保设备落后、加工工艺污染严重、产品结构不合理的企业坚决予以关停，限期整改。积极落实我省“新旧动能转换”的政策精神，对于过剩产能和落后产能坚决予以淘汰。指导我省装备制造业企业进行技术革新和生产工艺升级，对于转型升级较好的企业，建议各市财政给予一定的资金扶持或奖励。
2、差异化措施，确保环保治理、生产两不误。尽快制定完善“一企一策”的环保政策。对原有《应急预案》进行修改和明确，对于治污设施安装完备，治理工艺处于国际领先水平，且污染物排放达到标准要求的第一类环保治理规范企业，建议在重污染天气应急响应时免于采取限产、停产等措施。对于治污设备较为完备，治理工艺处于国内领先水平且计划进一步提升改进的第二类较为规范的企业，建议在重污染天气Ⅲ级黄色预警及以上级别应急响应时执行部分工序限产、停产的措施，并建立倒逼机制，督促其进一步提升治理水平。对环保设施落后，治理措施、工艺水平较低的第三类企业执行更加严格的停产要求，督促其整改提升，整改不达标的坚决予以淘汰。
3、环保治理标准先行。环保标准根据不同的行业制定不同的环保排污标准，真正做到检查标准的一致性。
4、加大环保治理的宣传，多部门联动形成齐抓共管新模式。建议环保部门要做好政策的宣讲引导，同时加强环保执法人员队伍的专业化建设。建议各地市政府成立专门的环保治理部门，以环保为主，经济、政策、司法、社会组织等共同参与，齐抓共管，实施全方位监管、查处机制。
5、积极推进试点示范。对在节能环保治理方面做好的企业，进行积极宣传，总结其好的做法，提供场合言传身教，起到示范效应。同时，相关部门给予大力表彰，让企业感受到环保治理的严肃性，同时又能体验到达标后的成果。
通过此次调研我们也确实感受到了环保治理的重要性和艰巨性，同时也了解到绝大部分企业非常愿意在环保部门的指导下对不达标的工序进行整改，而且希望环保部门给予长期的监管确保环保达标，担负起让山更青、水更绿、空气更清晰的社会责任。环保治理是一项长期工程，不可能通过短期风暴式执法达到要求，需要政府相关部门根据地方企业特点采取有针对性的措施，完善标准，加大宣传，疏堵结合，齐抓共管，方可实现治理的长效性和有效性。
Shandong Equipment Manufacturing Industry Association
二〇一八年六月十五日
