炼钢厂生产成本分析报告.doc

炼钢厂2011年7月成本完成情况本月合格钢坯产量162313.28吨，制造成本3794.61元/吨钢,吨钢加工费634.24元/吨钢。7月份成本明细如下： 成本项目单位 单价 本月合格钢坯产量:162313.28吨总成本 单位成本数量实际成本单耗单位成本一、原 材 料553489772.103410.011.钢铁料176707.07554807192.461.088683418.13铁水吨3160.37163549.90516878064.121.007623184.45其中：铁水(自产）吨3086.00110382.64340640827.040.680062098.66铁水(外购)吨3314.7753167.26176237237.080.327561085.78粘罐残铁吨3243.281792.005811956.640.0110435.81其中：当月铁水（自产）粘罐吨3086.00560.001728160.000.0034510.65当月铁水（外购）粘罐吨3314.771232.004083796.640.0075925.16冲当月铁水（自产）粘罐吨3086.00-560.00-1728160.00-0.00345-10.65冲当月铁水（外购）粘罐吨3314.77-1232.00-4083796.64-0.00759-25.16当月使用粘罐残铁吨3243.281792.005811956.640.0110435.81铁块（自产）吨2867.648518.8624428981.150.05248150.51废钢：吨2701.112846.317688190.550.0175447.37其中：轧废吨2859.312090.325976864.330.0128836.82工程废钢吨1841.34441.66813246.220.002725.01渣钢吨2000.00449.04898080.000.001945.532 、压球吨1004.223077.523090507.1300.0086519.043 、铁球矿吨650.821170.98762097.630.007214.704、 回冲副产品-5170025.120-31.85其中：污泥吨520.06-3220.00-1674600.00-0.01984-10.32氧化铁皮吨1000.00-289.95-289950.00-0.00179-1.79除尘灰吨500.00-300.00-150000.00-0.00185-0.92钢渣粉吨5.98-19311.14-115510.12-0.11897-0.71钢渣精粉吨500.00-5879.93-2939965.00-0.03623-18.11二、辅助材料35642350.95219.591.合金料2858.8522382080.160.01761137.89硅铁吨6447.57305.651970699.770.0018812.14硅锰合金吨7415.582541.2418844771.330.01566116.10钒氮合金吨130987.3811.961566609.060.000079.652.承包费5458558.3933.63转炉耐材承包费元389657.222.40钢包耐材承包费元2085624.5012.85中间包耐材承包费元2597008.0016.00铁包耐材承包费元386268.672.383.其他辅料7801712.4048.07冶金石灰吨353.9111811.554180221.270.0727725.75萤石吨941.5820.0018831.600.000120.12轻烧白云石吨镁球吨441.312969.661310540.650.018308.07硅钙粉吨硅铝钡钙吨8699.304.8041756.640.000030.26硅钡钙吨8038.2745.50365741.290.000282.25钢包覆盖剂吨749.57110.9083127.580.000680.51增碳剂吨3479.39212.30738674.940.001314.55结晶器保护渣吨2814.0683.00233567.300.000511.44硅钙线吨8920.1520.16179830.240.000121.11工艺件535097.633.30其它114323.260.70三、燃料及动力13747834.05084.70水方2.411186637.00450047.391.152.77电Kwh0.5714723869.002699249.0429.1016.63氧气方0.5257142445.003749783.6244.0023.10氮气方0.1652166653.00357497.7513.352.20氩气方2.15067019.00144090.850.410.89煤气回冲方0.200-6086777.00-1217355.40-37.50-7.50蒸气回冲方-351094.80-2.16液氧、液氮吨转动力厂费用元3659257.0022.54分摊二期制氧用电Kwh0.5717449000.004256358.6045.8926.22五:工 资2651369.8316.33六:五险两费一金874205.065.39七:制造费用9509976.0758.59制造成本615915508.063794.61吨钢加工费634.247月份各钢种产量及成本完成情况如下表：钢种7月份产量（吨）比例（%）单位成本（元/吨钢）加工费（元/吨钢）HRB33565729.83640.50%3813.88653.51Q345b2032.4361.25%3816.30655.93HRB40023468.70014.46%3880.62720.25Q23571082.30843.79%3747.77587.40说明：本月开发新钢种Q345b，共试生产19炉，吨钢参考成本3816.30元。一、7月份成本与6月份成本对比7月份合格钢坯产量162313.28吨，比6月份的157206.54吨提高5106.74吨。用7月份的消耗和6月份的物料价格对7月份成本重新计算，与6月份成本对比如下表： 成本项目7月份成本6月份成本7月与6月比较产量:162313.28t产量:157206.54t5106.74t单价 单耗单位成本单价 单耗单位成本价格单耗单位成本一、原 材 料3449.463470.48-21.021.钢铁料3171.541.088683452.793185.681.088343467.10-14.000.00034-14.31铁水3195.321.007623219.663200.531.023573275.95-5.21-0.01595-56.29其中：铁水(自产）3121.150.680062122.573121.150.667452083.220.0126139.35铁水(外购)3349.300.327561097.103349.300.356111192.73-0.02855-95.63粘罐残铁3278.000.0110436.193296.580.0167955.36-18.58-0.00575-19.17其中：当月（自产）粘罐3121.150.0034510.773121.150.0038812.11-0.00043-1.34当月铁水（外购）粘罐3349.300.0075925.423349.300.0129143.25-0.00532-17.83冲当月铁水（自产）粘罐3121.15-0.00345-10.773121.15-0.00388-12.110.000431.34冲当月铁水（外购）粘罐3349.30-0.00759-25.423349.30-0.01291-43.250.0053217.83当月使用粘罐残铁3278.000.0110436.193296.580.0167955.36-18.58-0.00575-19.17铁块（自产）2856.530.05248149.922856.530.03550101.400.0169848.52废钢：2681.030.0175447.012756.040.0124834.39-75.010.0050612.62其中：轧废2830.310.0128836.452830.310.0115332.640.001353.81工程废钢1849.190.002725.031849.190.000941.750.001783.28渣钢2000.000.001945.532000.000.001945.53外购废钢内部循环废钢0.0031290.037112 、压球1017.500.0086519.291017.500.0096121.45-0.00096-2.153 、铁球矿674.320.007214.86674.320.005003.370.002211.494、烧结矿或球团5、 回冲副产品-27.49-21.44-6.05其中：污泥300.00-0.01984-5.95300.00-0.02327-6.980.003431.03钢渣氧化铁皮1000.00-0.00179-1.791000.00-0.00142-1.42-0.00037-0.37除尘灰500.00-0.00185-0.92500.00-0.00185-0.92钢渣粉5.98-0.11897-0.715.98-0.09577-0.57-0.02320-0.14钢渣精粉500.00-0.03623-18.11500.00-0.02493-12.46-0.01130-5.65二、辅助材料213.64245.89-32.251.合金料0.01761135.510.01988166.69-0.00227-31.18硅铁6420.940.0018812.096420.940.0019312.40-0.00005-0.31硅锰合金7262.470.01566113.707262.470.01776128.95-0.00210-15.25钒氮合金131896.350.000079.72131896.350.0001925.34-0.00012-15.622.承包费33.6336.98-3.35转炉耐材承包费2.402.290.11钢包耐材承包费12.8517.10-4.25中间包耐材承包费16.0015.300.70铁包耐材承包费2.382.290.093.其他辅料44.5042.222.28冶金石灰306.730.0727722.32306.730.0621719.070.010603.25冶金石灰（精炼）萤石940.370.000120.12940.370.000320.30-0.00020-0.18萤石（精炼）轻烧白云石镁球423.690.018307.75423.690.017117.250.001190.50硅钙粉硅铝钡钙7806.070.000030.237806.070.000090.71-0.00006-0.48硅钡钙8773.170.000282.468773.170.000383.34-0.00010-0.88钢包覆盖剂749.570.000680.51749.570.000550.410.000130.10碳化稻壳581.200.001400.81-581.20-0.00140-0.81增碳剂3473.350.001314.543473.350.000983.400.000331.14结晶器保护渣2816.520.000511.442816.520.000551.54-0.00004-0.10硅钙线9054.780.000121.129054.780.000181.64-0.00006-0.52碳芯线4685.810.000010.06-4685.81-0.00001-0.06碳化硅精炼渣电极工艺件3.302.920.38其它0.700.78-0.08三、燃料及动力83.9162.7321.18水2.4161.152.782.4161.172.82-0.02-0.04电0.56229.1016.360.56252.4229.45-23.31-13.09电（精炼）氧气0.52544.0023.100.52551.5827.08-7.58-3.98氮气0.16513.352.200.16517.732.93-4.39-0.73氩气2.1500.410.892.1500.220.470.200.42煤气回冲0.200-37.50-7.500.200-47.80-9.5610.302.06蒸气回冲-2.16-2.16液氧、液氮转动力厂费用22.5422.54分摊二期制氧用电25.709.5528.8416.15五:工 资16.3320.24-3.91六:五险两费一金5.395.84-0.45七:制造费用58.5970.02-11.43制造成本3827.323875.21-47.89吨钢加工费632.00674.68-42.687月份钢坯成本为3827.32元/吨钢，比6月份下降47.89元/吨钢，加工费为632.00元/吨钢，比6月份下降42.68元/吨钢。具体情况分析如下：1、钢铁料本月钢铁料成本3452.79元/吨钢，比6月份的3467.10元/吨钢下降14.31元/吨钢。下降的主要原因是铁水用量下降，冷料比提高。本月铁水成本3219.66元/吨，比上月降低56.29元/吨钢。其中：铁水平均价格3195.32元/吨钢，比6月份的3200.53元/吨钢降低5.21元/吨钢，导致成本降低5.32元/吨。本月铁水单耗1007.62Kg，比6月份1023.57Kg减少15.95Kg，导致成本下降50.97元/吨钢；本月冷料成本233.12元/吨钢，比上月升高41.97元/吨钢。其中：冷料单耗81.06Kg，比6月份的64.77Kg增加16.29Kg，导致成本升高46.84元/吨钢。冷料平均价格2875.88元/吨钢，比6月份的2951.07元/吨钢降低75.19元，导致成本降低4.87元/吨钢。2、辅助材料本月辅料成本213.64元/吨钢，比6月份的245.89元/吨，降低32.25元/吨钢，其中：合金料：本月合金成本135.51元/吨，比6月份的166.69元/吨钢降低31.18元/吨钢，本月单耗17.61公斤，比6月份的19.88公斤降低2.27公斤，合金用量减少的原因主要是钢种结构不同造成。各钢种产量7月份所占比例与6月份所占比例对照如下表：钢种7月产量所占比例6月产量所占比例7月与6月比较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%耐材费本月耐材成本33.63元/吨钢，比6月份的36.98元/吨降低3.35元/吨钢。其他辅料：本月其他辅料单位成本44.50元/吨钢，比6月份的42.22元/吨钢低2.28元/吨钢。其中石灰消耗72.77公斤/吨钢，比6月份的62.17公斤/吨钢上升10.60公斤/吨钢。原因主要有两个：一是本月铁水Si比上月上升0.06%，影响石灰消耗上升5.16公斤；二是石灰质量较上月有所下降，尤其是外购石灰质量较差，因石灰质量原因影响石灰消耗上升约3公斤。近两月铁水及石灰主要成分如下：月份铁水成分%SiMnSP6月0.560.230.020.107月0.620.270.020.107月比6月0.060.040.000.00月份外购石灰成分%SiO2CaO活性度灼减6月1.5085.392859.17月1.0084.4128110.67月比6月-0.5-0.98-41.5月份石灰窑石灰成分%SiO2CaO活性度灼减6月0.7388.243298.457月0.7386.0531010.087月比6月0.00-2.19-191.633、燃料及动力本月单位成本83.91元，比6月份的62.73元/吨钢高21.18元/吨钢。主要原因是：本月转帐动力厂费用22.54元/吨钢，上月无动力厂费用；本月转帐二期制氧用电744万度，吨钢25.70元，上月转268万度，吨钢17.05元，本月比上月多转476万度电，吨钢16.15元。4、工资及五险两费一金本月工资及五险两费一金成本比6月份低4.36元/吨钢。5、制造费用本月制造费用吨钢成本58.59元，比6月份的70.02元/吨钢降低11.43元/吨钢。与6月份相比，费用减少较多的项目如下：折旧费比6月份减少20.78万元，吨钢1.28元；机物料消耗比6月份减少110.96万元/吨钢，吨钢6.84元；修理费比6月份减少16.08万元/吨钢，吨钢0.99元；办公费、运输费等费用合计比6月份减少吨钢2.32元。二、7月份成本与“五个一百工程”目标成本对比以“五个一百工程”目标成本价格重新计算7月份各钢种成本与目标成本比较如下：1、Q235钢坯成本与目标成本对比 成本项目7月份Q235成本Q235目标成本7月与目标成本比较单价 单耗单位成本单价 单耗单位成本价格单耗单位成本一、原 材 料3436.263338.7397.541.钢铁料3147.371.095793448.863100.561.079083345.7646.810.01671103.10铁水3174.891.004243188.353128.560.980643068.0046.330.02360120.36其中：铁水(自产）3065.000.677782077.403065.000.796242440.48-0.11846-363.08铁水(外购)3403.040.326461110.963403.040.18440627.520.14206483.44粘罐残铁3300.910.0110036.310.003300.910.0110036.31铁块（自产）2812.500.06037169.792812.500.000641.800.05973167.99废钢：2697.260.0201754.402821.680.09780275.96-124.42-0.07763-221.56其中：轧废2860.050.0148142.362860.050.06738192.71-0.05257-150.35工程废钢1811.760.003135.671811.760.000851.540.002284.13渣钢2858.970.002236.382858.970.0062417.84-0.00401-11.46外购废钢2737.682737.680.0233363.87-0.02333-63.872 、压球499.660.018969.47499.660.014917.450.004052.023 、铁球矿674.000.007214.866740.007214.864、 回冲副产品-26.93-14.48-12.45其中：污泥300.00-0.01984-5.95300.00-0.03516-10.550.015324.60氧化铁皮900.00-0.00179-1.60900.00-0.00086-0.77-0.00093-0.83钢渣66.5766.57-0.04747-3.160.047473.16除尘灰300.00-0.00185-0.56300.00-0.00185-0.56钢渣粉5.98-0.11897-0.715.98-0.11897-0.71钢渣精粉500.00-0.03623-18.11500.00-0.03623-18.11二、辅助材料153.71132.0621.651.合金料7090.640.0094468.377245.440.0082359.63-154.800.001218.74硅铁6969.700.0019813.806969.700.0016511.500.000332.30硅锰合金7314.590.0074654.577314.590.0065848.130.000886.442.承包费36.9832.604.38转炉耐材承包费2.292.52-0.23钢包耐材承包费17.1013.583.52中间包耐材承包费15.3016.50-1.20铁包耐材承包费2.292.293.其他辅料48.3739.838.54冶金石灰300.350.0727721.86300.350.0484114.540.024367.32萤石945.450.000120.11945.450.000550.52-0.00043-0.41轻烧白云石305.07305.070.009672.95-0.00967-2.95镁球436.120.018307.98436.120.009083.960.009224.02硅钙粉19000.000.000010.19-0.00001-0.19硅钡钙8814.810.000645.648814.810.000544.760.000100.88钢包覆盖剂742.860.000680.51742.860.000700.52-0.00002-0.01增碳剂3404.260.001294.393404.260.001414.80-0.00012-0.41结晶器保护渣2829.790.000511.442829.790.000471.330.000040.11硅钙线9800.000.000282.749800.000.000201.960.000080.78碳芯线5000.005000.000.000100.50-0.00010-0.50工艺件2.913.22-0.31其它0.780.580.20三、燃料及动力77.7791.54-13.77水2.4301.152.792.4300.982.370.170.42电0.51029.1014.840.51071.7036.57-42.60-21.73氧气0.52044.0022.880.52049.9526.22-5.94-3.34氮气0.16013.352.140.16027.414.52-14.06-2.38氩气2.1500.410.892.1500.861.84-0.44-0.95煤气回冲-37.50-9.56-8.35-37.50-1.21蒸气回冲-2.16-2.16液氧、液氮23.70-23.70转动力厂费用22.5422.54分摊二期制氧用电23.414.6718.74五:工 资16.3314.921.41六:五险两费一金5.395.380.01七:制造费用58.5952.566.03制造成本3748.053635.19112.87吨钢加工费573.16506.6366.54本月成本3748.05元/吨,比目标成本3635.19元/吨高112.87元/吨；吨钢加工费573.16元/吨，比目标506.63元/吨高66.54元/吨。本月转动力厂费用22.54元/吨和二期制氧用电成本23.41元/吨钢，合计45.95元/吨钢。目标成本中分摊气体及液氧、液氮28.37元/吨钢。本月多转17.58元/吨钢。扣除此费用，本月成本3730.57元/吨钢，比目标高95.28元/吨钢。吨钢加工费555.58元，比目标高48.95元。 主要情况分析如下：钢铁料：本月钢铁料消耗1095.79公斤/吨钢，比目标1079.08公斤/吨钢高16.71公斤，吨钢成本3448.86元，比目标3345.76元高103.10元/吨。铁水：本月吨钢消耗1004.24公斤，比目标0.98064高23.60公斤，吨钢成本高120.36元/吨。目标成本钢铁料消耗中铁水消耗量是根据铁水硅0.50%，温度1350，出钢温度1680-1700测算，因外购铁水温度低（7月份外购铁水温度最低的1161，最高的1285，平均1252度。），根据我厂铁水温度变动控制经验值，温度每降低10度约减少废钢用量5吨，按此计算共增加铁水消耗14.84Kg/t,使铁水消耗增加，未能完成980.95公斤的目标要求。目标外购铁水消耗为184.40公斤，占目标铁水总量的18.80%，本月实际外购铁水消耗326.46公斤，占本月铁水总量的32.51%，本月外购铁水用量比目标增加142.06公斤，成本增加483.44元/吨钢，如果使用相同数量的自产铁水可降低成本48.03元/吨钢。冷料：本月吨钢消耗91.54公斤，目标吨钢98.44公斤，冷料用量接近目标。回冲副产品：与目标回冲副产品相比，增加了钢渣精粉、钢渣粉的回冲，成本吨钢降低12.45元/吨。辅助材料：本月成本153.71元/吨，比目标132.06元/吨高21.65元/吨。合金料：本月吨钢消耗9.44公斤，比目标8.23公斤高1.21公斤，吨钢成本高8.74元/吨。耐材承包费：本月实际单位成本36.98元/吨，比