煉鋼廠生產成本分析報告

第4頁煉鋼廠2011年7月成本完成情況本月合格鋼坯產量162313.28噸，制造成本3794.61元/噸鋼,噸鋼加工費634.24元/噸鋼。7月份成本明細如下：成本項目單位單價本月合格鋼坯產量: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176707.07554807192.461.088683418.13①鐵水噸3160.37163549.90516878064.121.007623184.45其中：鐵水(自產）噸3086.00110382.64340640827.040.680062098.66鐵水(外購)噸3314.7753167.26176237237.080.327561085.78②粘罐殘鐵噸3243.281792.005811956.640.0110435.81其中：當月鐵水（自產）粘罐噸3086.00560.001728160.000.0034510.65當月鐵水（外購）粘罐噸3314.771232.004083796.640.0075925.16沖當月鐵水（自產）粘罐噸3086.00-560.00-1728160.00-0.00345-10.65沖當月鐵水（外購）粘罐噸3314.77-1232.00-4083796.64-0.00759-25.16當月使用粘罐殘鐵噸3243.281792.005811956.640.0110435.81③鐵塊（自產）噸2867.648518.8624428981.150.05248150.51④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650.821170.98762097.630.007214.704、回沖副產品-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2858.8522382080.160.01761137.89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941.5820.0018831.600.000120.12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535097.633.30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、液氮噸轉動力廠費用元3659257.0022.54分攤二期制氧用電Kwh0.5717449000.004256358.6045.8926.22五: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月份各鋼種產量及成本完成情況如下表：鋼種7月份產量（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%3880.62720.25Q23571082.30843.79%3747.77587.40說明：本月開發(fā)新鋼種Q345b，共試生產19爐，噸鋼參考成本3816.30元。一、7月份成本與6月份成本對比7月份合格鋼坯產量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月份成本對比如下表：成本項目7月份成本6月份成本7月與6月比較產量:162313.28t產量: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3171.541.088683452.793185.681.088343467.10-14.000.00034-14.31①鐵水3195.321.007623219.663200.531.023573275.95-5.21-0.01595-56.29其中：鐵水(自產）3121.150.680062122.573121.150.667452083.220.0126139.35鐵水(外購)3349.300.327561097.103349.300.356111192.73-0.02855-95.63②粘罐殘鐵3278.000.0110436.193296.580.0167955.36-18.58-0.00575-19.17其中：當月（自產）粘罐3121.150.0034510.773121.150.0038812.11-0.00043-1.34當月鐵水（外購）粘罐3349.300.0075925.423349.300.0129143.25-0.00532-17.83沖當月鐵水（自產）粘罐3121.15-0.00345-10.773121.15-0.00388-12.110.000431.34沖當月鐵水（外購）粘罐3349.30-0.00759-25.423349.30-0.01291-43.250.0053217.83當月使用粘罐殘鐵3278.000.0110436.193296.580.0167955.36-18.58-0.00575-19.17③鐵塊（自產）2856.530.05248149.922856.530.03550101.400.0169848.52④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⑤內部循環(huán)廢鋼0.0031290.037112、壓球1017.500.0086519.291017.500.0096121.45-0.00096-2.153、鐵球礦674.320.007214.86674.320.005003.370.002211.494、燒結礦或球團5、回沖副產品-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1000.00-0.00179-1.791000.00-0.00142-1.42-0.00037-0.376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0.7388.243298.457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：①本月轉帳動力廠費用22.54元/噸鋼，上月無動力廠費用；②本月轉帳二期制氧用電744萬度，噸鋼25.70元，上月轉268萬度，噸鋼17.05元，本月比上月多轉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，費用減少較多的項目如下：①折舊費比6月份減少20.78萬元，噸鋼1.28元；②機物料消耗比6月份減少110.96萬元/噸鋼，噸鋼6.84元；③修理費比6月份減少16.08萬元/噸鋼，噸鋼0.99元；④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”目標成本對比以“五個一百工程”目標成本價格重新計算7月份各鋼種成本與目標成本比較如下：1、Q235鋼坯成本與目標成本對比成本項目7月份Q235成本Q235目標成本7月與目標成本比較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3147.371.095793448.863100.561.079083345.7646.810.01671103.10①鐵水3174.891.004243188.353128.560.980643068.0046.330.02360120.36其中：鐵水(自產）3065.000.677782077.403065.000.796242440.48-0.11846-363.08鐵水(外購)3403.040.326461110.963403.040.18440627.520.14206483.44②粘罐殘鐵3300.910.0110036.310.003300.910.0110036.31③鐵塊（自產）2812.500.06037169.792812.500.000641.800.05973167.99④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499.660.018969.47499.660.014917.450.004052.023、鐵球礦674.000.007214.866740.007214.864、回沖副產品-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5.98-0.11897-0.715.98-0.11897-0.71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轉爐耐材承包費2.292.52-0.23鋼包耐材承包費17.1013.583.52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8814.810.000645.648814.810.000544.760.000100.88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2.913.22-0.31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23.70-23.70轉動力廠費用22.5422.54分攤二期制氧用電23.414.6718.74五: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,比目標成本3635.19元/噸高112.87元/噸；噸鋼加工費573.16元/噸，比目標506.63元/噸高66.54元/噸。本月轉動力廠費用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。目標成本中分攤氣體及液氧、液氮28.37元/噸鋼。本月多轉17.58元/噸鋼。扣除此費用，本月成本3730.57元/噸鋼，比目標高95.28元/噸鋼。噸鋼加工費555.58元，比目標高48.95元。主要情況分析如下：⑴鋼鐵料：本月鋼鐵料消耗1095.79公斤/噸鋼，比目標1079.08公斤/噸鋼高16.71公斤，噸鋼成本3448.①鐵水：本月噸鋼消耗1004.24公斤，比目標0.98064高23目標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)驗值，溫度每降低10度約減少廢鋼目標外購鐵水消耗為184.40公斤，占目標鐵水總量的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增加142.06公斤，成本增加483.44元/噸鋼，如果使用相同數(shù)量的自產鐵水可降低成本48.03元/噸鋼。②冷料：本月噸鋼消耗91.54公斤，目標噸鋼98.⑵回沖副產品：與目標回沖副產品相比，增加了鋼渣精粉、鋼渣粉的回沖，成本噸鋼降低12.45元/噸。⑶輔助材料：本月成本153.71元/噸，比目標132.06元/噸高21.65元/噸。①合金料：本月噸鋼消耗9.44公斤，比目標8.23公斤高1.21公斤②耐材承包費：本月實際單位成本36.98元/噸，比雙百的32.6元/噸高4.38元/噸。③其他輔料：本月比目標高8.54元/噸。主要是