煉鋼廠生產(chǎn)成本分析的報告書

1、.wd.wd8/8.wd煉鋼廠2011年7月成本完成情況本月合格鋼坯產(chǎn)量162313.28噸，制造成本3794.61元/噸鋼,噸鋼加工費634.24元/噸鋼。7月份成本明細(xì)如下： 成本工程單位 單價 本月合格鋼坯產(chǎn)量:162313.28噸總成本 單位成本數(shù)量實際成本單耗單位成本一、原 材 料553489772.103410.011.鋼鐵料176707.07554807192.461.088683418.13鐵水噸3160.37163549.90516878064.121.007623184.45其中：鐵水(自產(chǎn)噸3086.00110382.64340640827.040.680062098.6

2、6鐵水(外購)噸3314.7753167.26176237237.080.327561085.78粘罐殘鐵噸3243.281792.005811956.640.0110435.81其中：當(dāng)月鐵水自產(chǎn)粘罐噸3086.00560.001728160.000.0034510.65當(dāng)月鐵水外購粘罐噸3314.771232.004083796.640.0075925.16沖當(dāng)月鐵水自產(chǎn)粘罐噸3086.00-560.00-1728160.00-0.00345-10.65沖當(dāng)月鐵水外購粘罐噸3314.77-1232.00-4083796.64-0.00759-25.16當(dāng)月使用粘罐殘鐵噸3243.28179

3、2.005811956.640.0110435.81鐵塊自產(chǎn)噸2867.648518.8624428981.150.05248150.51廢鋼：噸2701.112846.317688190.550.0175447.37其中：軋廢噸2859.312090.325976864.330.0128836.82工程廢鋼噸1841.34441.66813246.220.002725.01渣鋼噸2000.00449.04898080.000.001945.532 、壓球噸1004.223077.523090507.1300.0086519.043 、鐵球礦噸650.821170.98762097.630.0

4、07214.704、 回沖副產(chǎn)品-5170025.120-31.85其中：污泥噸520.06-3220.00-1674600.00-0.01984-10.32氧化鐵皮噸1000.00-289.95-289950.00-0.00179-1.79除塵灰噸500.00-300.00-150000.00-0.00185-0.92鋼渣粉噸5.98-19311.14-115510.12-0.11897-0.71鋼渣精粉噸500.00-5879.93-2939965.00-0.03623-18.11二、輔助材料35642350.95219.591.合金料2858.8522382080.160.0176113

5、7.89硅鐵噸6447.57305.651970699.770.0018812.14硅錳合金噸7415.582541.2418844771.330.01566116.10釩氮合金噸130987.3811.961566609.060.000079.652.承包費5458558.3933.63轉(zhuǎn)爐耐材承包費元389657.222.40鋼包耐材承包費元2085624.5012.85中間包耐材承包費元2597008.0016.00鐵包耐材承包費元386268.672.383.其他輔料7801712.4048.07冶金石灰噸353.9111811.554180221.270.0727725.75螢石噸9

6、41.5820.0018831.600.000120.12輕燒白云石噸鎂球噸441.312969.661310540.650.018308.07硅鈣粉噸硅鋁鋇鈣噸8699.304.8041756.640.000030.26硅鋇鈣噸8038.2745.50365741.290.000282.25鋼包覆蓋劑噸749.57110.9083127.580.000680.51增碳劑噸3479.39212.30738674.940.001314.55結(jié)晶器保護渣噸2814.0683.00233567.300.000511.44硅鈣線噸8920.1520.16179830.240.000121.11工藝件5

7、35097.633.30其它114323.260.70三、燃料及動力13747834.05084.70水方2.411186637.00450047.391.152.77電Kwh0.5714723869.002699249.0429.1016.63氧氣方0.5257142445.003749783.6244.0023.10氮氣方0.1652166653.00357497.7513.352.20氬氣方2.15067019.00144090.850.410.89煤氣回沖方0.200-6086777.00-1217355.40-37.50-7.50蒸氣回沖方-351094.80-2.16液氧、液氮噸轉(zhuǎn)

8、動力廠費用元3659257.0022.54分?jǐn)偠谥蒲跤秒奒wh0.5717449000.004256358.6045.8926.22五:工 資2651369.8316.33六:五險兩費一金874205.065.39七:制造費用9509976.0758.59制造成本615915508.063794.61噸鋼加工費634.247月份各鋼種產(chǎn)量及成本完成情況如下表：鋼種7月份產(chǎn)量噸比例%單位成本元/噸鋼加工費元/噸鋼HRB33565729.83640.50%3813.88653.51Q345b2032.4361.25%3816.30655.93HRB40023468.70014.46%3880.6

9、2720.25Q23571082.30843.79%3747.77587.40說明：本月開發(fā)新鋼種Q345b，共試生產(chǎn)19爐，噸鋼參考成本3816.30元。一、7月份成本與6月份成本比照7月份合格鋼坯產(chǎn)量162313.28噸，比6月份的157206.54噸提高5106.74噸。用7月份的消耗和6月份的物料價格對7月份成本重新計算，與6月份成本比照方下表： 成本工程7月份成本6月份成本7月與6月對比產(chǎn)量:162313.28t產(chǎn)量:157206.54t5106.74t單價 單耗單位成本單價 單耗單位成本價格單耗單位成本一、原 材 料3449.463470.48-21.021.鋼鐵料3171.541

10、.088683452.793185.681.088343467.10-14.000.00034-14.31鐵水3195.321.007623219.663200.531.023573275.95-5.21-0.01595-56.29其中：鐵水(自產(chǎn)3121.150.680062122.573121.150.667452083.220.0126139.35鐵水(外購)3349.300.327561097.103349.300.356111192.73-0.02855-95.63粘罐殘鐵3278.000.0110436.193296.580.0167955.36-18.58-0.00575-19.

11、17其中：當(dāng)月自產(chǎn)粘罐3121.150.0034510.773121.150.0038812.11-0.00043-1.34當(dāng)月鐵水外購粘罐3349.300.0075925.423349.300.0129143.25-0.00532-17.83沖當(dāng)月鐵水自產(chǎn)粘罐3121.15-0.00345-10.773121.15-0.00388-12.110.000431.34沖當(dāng)月鐵水外購粘罐3349.30-0.00759-25.423349.30-0.01291-43.250.0053217.83當(dāng)月使用粘罐殘鐵3278.000.0110436.193296.580.0167955.36-18.58-

12、0.00575-19.17鐵塊自產(chǎn)2856.530.05248149.922856.530.03550101.400.0169848.52廢鋼：2681.030.0175447.012756.040.0124834.39-75.010.0050612.62其中：軋廢2830.310.0128836.452830.310.0115332.640.001353.81工程廢鋼1849.190.002725.031849.190.000941.750.001783.28渣鋼2000.000.001945.532000.000.001945.53外購廢鋼內(nèi)部循環(huán)廢鋼0.0031290.037112 、壓

13、球1017.500.0086519.291017.500.0096121.45-0.00096-2.153 、鐵球礦674.320.007214.86674.320.005003.370.002211.494、燒結(jié)礦或球團5、 回沖副產(chǎn)品-27.49-21.44-6.05其中：污泥300.00-0.01984-5.95300.00-0.02327-6.980.003431.03鋼渣氧化鐵皮1000.00-0.00179-1.791000.00-0.00142-1.42-0.00037-0.37除塵灰500.00-0.00185-0.92500.00-0.00185-0.92鋼渣粉5.98-0.

14、11897-0.715.98-0.09577-0.57-0.02320-0.14鋼渣精粉500.00-0.03623-18.11500.00-0.02493-12.46-0.01130-5.65二、輔助材料213.64245.89-32.251.合金料0.01761135.510.01988166.69-0.00227-31.18硅鐵6420.940.0018812.096420.940.0019312.40-0.00005-0.31硅錳合金7262.470.01566113.707262.470.01776128.95-0.00210-15.25釩氮合金131896.350.000079.7

15、2131896.350.0001925.34-0.00012-15.622.承包費33.6336.98-3.35轉(zhuǎn)爐耐材承包費2.402.290.11鋼包耐材承包費12.8517.10-4.25中間包耐材承包費16.0015.300.70鐵包耐材承包費2.382.290.093.其他輔料44.5042.222.28冶金石灰306.730.0727722.32306.730.0621719.070.010603.25冶金石灰精煉螢石940.370.000120.12940.370.000320.30-0.00020-0.18螢石精煉輕燒白云石鎂球423.690.018307.75423.690.

16、017117.250.001190.50硅鈣粉硅鋁鋇鈣7806.070.000030.237806.070.000090.71-0.00006-0.48硅鋇鈣8773.170.000282.468773.170.000383.34-0.00010-0.88鋼包覆蓋劑749.570.000680.51749.570.000550.410.000130.10碳化稻殼581.200.001400.81-581.20-0.00140-0.81增碳劑3473.350.001314.543473.350.000983.400.000331.14結(jié)晶器保護渣2816.520.000511.442816.52

17、0.000551.54-0.00004-0.10硅鈣線9054.780.000121.129054.780.000181.64-0.00006-0.52碳芯線4685.810.000010.06-4685.81-0.00001-0.06碳化硅精煉渣電極工藝件3.302.920.38其它0.700.78-0.08三、燃料及動力83.9162.7321.18水2.4161.152.782.4161.172.82-0.02-0.04電0.56229.1016.360.56252.4229.45-23.31-13.09電精煉氧氣0.52544.0023.100.52551.5827.08-7.58-3

18、.98氮氣0.16513.352.200.16517.732.93-4.39-0.73氬氣2.1500.410.892.1500.220.470.200.42煤氣回沖0.200-37.50-7.500.200-47.80-9.5610.302.06蒸氣回沖-2.16-2.16液氧、液氮轉(zhuǎn)動力廠費用22.5422.54分?jǐn)偠谥蒲跤秒?5.709.5528.8416.15五:工 資16.3320.24-3.91六:五險兩費一金5.395.84-0.45七:制造費用58.5970.02-11.43制造成本3827.323875.21-47.89噸鋼加工費632.00674.68-42.687月份鋼

19、坯成本為3827.32元/噸鋼，比6月份下降47.89元/噸鋼，加工費為632.00元/噸鋼，比6月份下降42.68元/噸鋼。具體情況分析如下：1、鋼鐵料本月鋼鐵料成本3452.79元/噸鋼，比6月份的3467.10元/噸鋼下降14.31元/噸鋼。下降的主要原因是鐵水用量下降，冷料比提高。本月鐵水成本3219.66元/噸，比上月降低56.29元/噸鋼。其中：鐵水平均價格3195.32元/噸鋼，比6月份的3200.53元/噸鋼降低5.21元/噸鋼，導(dǎo)致成本降低5.32元/噸。本月鐵水單耗1007.62Kg，比6月份1023.57Kg減少15.95Kg，導(dǎo)致成本下降50.97元/噸鋼；本月冷料成本

20、233.12元/噸鋼，比上月升高41.97元/噸鋼。其中：冷料單耗81.06Kg，比6月份的64.77Kg增加16.29Kg，導(dǎo)致成本升高46.84元/噸鋼。冷料平均價格2875.88元/噸鋼，比6月份的2951.07元/噸鋼降低75.19元，導(dǎo)致成本降低4.87元/噸鋼。2、輔助材料本月輔料成本213.64元/噸鋼，比6月份的245.89元/噸，降低32.25元/噸鋼，其中：合金料：本月合金成本135.51元/噸，比6月份的166.69元/噸鋼降低31.18元/噸鋼，本月單耗17.61公斤，比6月份的19.88公斤降低2.27公斤，合金用量減少的原因主要是鋼種構(gòu)造不同造成。各鋼種產(chǎn)量7月份所

21、占比例與6月份所占比例對照如下表：鋼種7月產(chǎn)量所占比例6月產(chǎn)量所占比例7月與6月對比HRB33540.50%23.74%16.76%HRB335a0.00%8.89%-8.89%HRB40014.46%33.04%18.58%Q23543.79%33.92%9.87%Q345b1.25%0.00%1.25%HRB500a0.00%0.40%-0.40%耐材費本月耐材成本33.63元/噸鋼，比6月份的36.98元/噸降低3.35元/噸鋼。其他輔料：本月其他輔料單位成本44.50元/噸鋼，比6月份的42.22元/噸鋼低2.28元/噸鋼。其中石灰消耗72.77公斤/噸鋼，比6月份的62.17公斤/噸

22、鋼上升10.60公斤/噸鋼。原因主要有兩個：一是本月鐵水Si比上月上升0.06%，影響石灰消耗上升5.16公斤；二是石灰質(zhì)量較上月有所下降，尤其是外購石灰質(zhì)量較差，因石灰質(zhì)量原因影響石灰消耗上升約3公斤。近兩月鐵水及石灰主要成分如下：月份鐵水成分%SiMnSP6月0.560.230.020.107月0.620.270.020.107月比6月0.060.040.000.00月份外購石灰成分%SiO2CaO活性度灼減6月1.5085.392859.17月1.0084.4128110.67月比6月-0.5-0.98-41.5月份石灰窯石灰成分%SiO2CaO活性度灼減6月0.7388.243298.

23、457月0.7386.0531010.087月比6月0.00-2.19-191.633、燃料及動力本月單位成本83.91元，比6月份的62.73元/噸鋼高21.18元/噸鋼。主要原因是：本月轉(zhuǎn)帳動力廠費用22.54元/噸鋼，上月無動力廠費用；本月轉(zhuǎn)帳二期制氧用電744萬度，噸鋼25.70元，上月轉(zhuǎn)268萬度，噸鋼17.05元，本月比上月多轉(zhuǎn)476萬度電，噸鋼16.15元。4、工資及五險兩費一金本月工資及五險兩費一金成本比6月份低4.36元/噸鋼。5、制造費用本月制造費用噸鋼成本58.59元，比6月份的70.02元/噸鋼降低11.43元/噸鋼。與6月份相比，費用減少較多的工程如下：折舊費比6月份

24、減少20.78萬元，噸鋼1.28元；機物料消耗比6月份減少110.96萬元/噸鋼，噸鋼6.84元；修理費比6月份減少16.08萬元/噸鋼，噸鋼0.99元；辦公費、運輸費等費用合計比6月份減少噸鋼2.32元。二、7月份成本與“五個一百工程目標(biāo)成本比照以“五個一百工程目標(biāo)成本價格重新計算7月份各鋼種成本與目標(biāo)成本對比如下：1、Q235鋼坯成本與目標(biāo)成本比照 成本工程7月份Q235成本Q235目標(biāo)成本7月與目標(biāo)成本對比單價 單耗單位成本單價 單耗單位成本價格單耗單位成本一、原 材 料3436.263338.7397.541.鋼鐵料3147.371.095793448.863100.561.07908

25、3345.7646.810.01671103.10鐵水3174.891.004243188.353128.560.980643068.0046.330.02360120.36其中：鐵水(自產(chǎn)3065.000.677782077.403065.000.796242440.48-0.11846-363.08鐵水(外購)3403.040.326461110.963403.040.18440627.520.14206483.44粘罐殘鐵3300.910.0110036.310.003300.910.0110036.31鐵塊自產(chǎn)2812.500.06037169.792812.500.000641.80

26、0.05973167.99廢鋼：2697.260.0201754.402821.680.09780275.96-124.42-0.07763-221.56其中：軋廢2860.050.0148142.362860.050.06738192.71-0.05257-150.35工程廢鋼1811.760.003135.671811.760.000851.540.002284.13渣鋼2858.970.002236.382858.970.0062417.84-0.00401-11.46外購廢鋼2737.682737.680.0233363.87-0.02333-63.872 、壓球499.660.018

27、969.47499.660.014917.450.004052.023 、鐵球礦674.000.007214.866740.007214.864、 回沖副產(chǎn)品-26.93-14.48-12.45其中：污泥300.00-0.01984-5.95300.00-0.03516-10.550.015324.60氧化鐵皮900.00-0.00179-1.60900.00-0.00086-0.77-0.00093-0.83鋼渣66.5766.57-0.04747-3.160.047473.16除塵灰300.00-0.00185-0.56300.00-0.00185-0.56鋼渣粉5.98-0.11897-

28、0.715.98-0.11897-0.71鋼渣精粉500.00-0.03623-18.11500.00-0.03623-18.11二、輔助材料153.71132.0621.651.合金料7090.640.0094468.377245.440.0082359.63-154.800.001218.74硅鐵6969.700.0019813.806969.700.0016511.500.000332.30硅錳合金7314.590.0074654.577314.590.0065848.130.000886.442.承包費36.9832.604.38轉(zhuǎn)爐耐材承包費2.292.52-0.23鋼包耐材承包費1

29、7.1013.583.52中間包耐材承包費15.3016.50-1.20鐵包耐材承包費2.292.293.其他輔料48.3739.838.54冶金石灰300.350.0727721.86300.350.0484114.540.024367.32螢石945.450.000120.11945.450.000550.52-0.00043-0.41輕燒白云石305.07305.070.009672.95-0.00967-2.95鎂球436.120.018307.98436.120.009083.960.009224.02硅鈣粉19000.000.000010.19-0.00001-0.19硅鋇鈣881

30、4.810.000645.648814.810.000544.760.000100.88鋼包覆蓋劑742.860.000680.51742.860.000700.52-0.00002-0.01增碳劑3404.260.001294.393404.260.001414.80-0.00012-0.41結(jié)晶器保護渣2829.790.000511.442829.790.000471.330.000040.11硅鈣線9800.000.000282.749800.000.000201.960.000080.78碳芯線5000.005000.000.000100.50-0.00010-0.50工藝件2.913

31、.22-0.31其它0.780.580.20三、燃料及動力77.7791.54-13.77水2.4301.152.792.4300.982.370.170.42電0.51029.1014.840.51071.7036.57-42.60-21.73氧氣0.52044.0022.880.52049.9526.22-5.94-3.34氮氣0.16013.352.140.16027.414.52-14.06-2.38氬氣2.1500.410.892.1500.861.84-0.44-0.95煤氣回沖-37.50-9.56-8.35-37.50-1.21蒸氣回沖-2.16-2.16液氧、液氮23.70-

32、23.70轉(zhuǎn)動力廠費用22.5422.54分?jǐn)偠谥蒲跤秒?3.414.6718.74五:工 資16.3314.921.41六:五險兩費一金5.395.380.01七:制造費用58.5952.566.03制造成本3748.053635.19112.87噸鋼加工費573.16506.6366.54本月成本3748.05元/噸,比目標(biāo)成本3635.19元/噸高112.87元/噸；噸鋼加工費573.16元/噸，比目標(biāo)506.63元/噸高66.54元/噸。本月轉(zhuǎn)動力廠費用22.54元/噸和二期制氧用電成本23.41元/噸鋼，合計45.95元/噸鋼。目標(biāo)成本中分?jǐn)倸怏w及液氧、液氮28.37元/噸鋼。本月

33、多轉(zhuǎn)17.58元/噸鋼?？鄢速M用，本月成本3730.57元/噸鋼，比目標(biāo)高95.28元/噸鋼。噸鋼加工費555.58元，比目標(biāo)高48.95元。主要情況分析如下：鋼鐵料：本月鋼鐵料消耗1095.79公斤/噸鋼，比目標(biāo)1079.08公斤/噸鋼高16.71公斤，噸鋼成本3448.86元，比目標(biāo)3345.76元高103.10元/噸。鐵水：本月噸鋼消耗1004.24公斤，比目標(biāo)0.98064高23.60公斤，噸鋼成本高120.36元/噸。目標(biāo)成本鋼鐵料消耗中鐵水消耗量是根據(jù)鐵水硅0.50%，溫度1350，出鋼溫度1680-1700測算，因外購鐵水溫度低7月份外購鐵水溫度最低的1161，最高的1285，平均1252度。，根據(jù)我廠鐵水溫度變動控制經(jīng)歷值，溫度每降低10度約減少廢鋼用量5噸，按此計算共增加鐵水消耗14.84Kg/t,使鐵水消耗增加，未能完成980.95公斤的目標(biāo)要求。目標(biāo)外購鐵水消耗為184.40公斤，占目標(biāo)鐵水總量的18.80%，本月實際外購鐵水消耗326.46公斤，占本月鐵水總量的32.51%，本月外購鐵水用量比目標(biāo)增加142