Development method of steelmaking furnace charge consumption cost accounting model

Abstract

The invention belongs to the technical field of steelmaking, and discloses a method for developing a steelmaking furnace charge consumption cost accounting model, and the specific technical scheme is as follows: 1, determining key data; 2, acquiring and assembling data; 3, calculating and storing a CR / NI grade value; 4, the actual CR / NI grade of production feeding is determined; 5, obtaining the CR / NI grade value of the direct supply material; 6, material conversion unit price calculation; 7, NI / CR alloy correction amount calculation and total cost accounting are carried out; and 8, model display and tendency chart generation: organically combining detailed information such as cost, consumption, furnace charge CR grade, furnace charge NI grade and heat of the stainless steel furnace charge, and accurately calculating the cost per ton of steel of different steel grades through a data integration and treatment technology. And a solid and reliable data support is provided for a plurality of key fields such as product pricing, process design, order optimization, material purchasing, benefit prediction, operation decision and the like.

Description

Technical Field

[0001] The invention belongs to the technical field of steelmaking, and specifically discloses a development method of a steelmaking furnace material consumption cost accounting model based on digital technology support. Background Art

[0002] In the steelmaking industry, accurate and timely accounting of steelmaking furnace consumption costs is crucial for enterprises. However, there are many problems with traditional accounting methods. In the past, data collection and collation relied on manual work, which was inefficient and prone to errors. Data collection was incomplete and inaccurate, and lacked effective integration, resulting in unreliable cost accounting results. Cost calculations are mostly rough estimates or fixed-cycle statistics, which cannot be calculated in real time and in detail, making it difficult to grasp cost dynamics, affecting the timeliness and accuracy of decision-making. For stainless steel production, the composition of furnace materials is complex, and the existing accounting methods cannot accurately reflect the impact of key elements on costs, nor can they distinguish the cost differences between different furnaces and steel grades.

[0003] With the development of steelmaking technology and the intensification of market competition, enterprises have an urgent need for refined and intelligent cost control. Traditional accounting methods can no longer meet these needs, which has seriously restricted the competitiveness and sustainable development capabilities of enterprises. Summary of the invention

[0004] In order to solve the technical problems existing in the prior art, the present invention provides an automatic real-time accounting model for steelmaking furnace material consumption costs based on digital technology support. By integrating digital technology, automatic real-time and accurate cost accounting is realized, providing steelmaking enterprises with an effective cost management solution and a more accurate, efficient and real-time cost management model.

[0005] To achieve the above object, the technical solution adopted by the present invention is: a method for developing a steelmaking charge consumption cost accounting model, the specific steps of which are:

[0006] Step 1: Identify key data

[0007] Clarify the key data that the model needs to automatically calculate and present in real time in the stainless steel production process, including detailed information on furnace charging (such as furnace number, weight, steel type, charging elements and weight and time), various cost data (such as raw material purchase price, operating cost, step fee, etc.), and the content and related data of key elements CR and NI in the raw materials;

[0008] Step 2: Data acquisition and assembly

[0009] Obtain production material input data, raw material consumption data, raw material decision price and other related data from the production system, smart quality system, cost decision system and procurement system, transfer them to the DB2 database through a specific interface, and assemble them according to predefined standards. Specifically include:

[0010] Obtain furnace charging information (furnace number, material number, charging weight, steel-out weight and time, etc.) from the production system, collect furnace raw material price data (outbound quantity, unit price and discount price, etc.), furnace charge product composition cost data (recovery volume, step fee and other cost data) and scrap iron and steel liquid information (material number, usage price, CR grade value, NI grade value, etc.), and transfer them to the DB2 database through microservices and other methods;

[0011] Step 3: Calculation and storage of CR / NI grade values

[0012] For the CR / NI grade value of raw materials, the principle of priority re-inspection is adopted according to the differences in raw material batches and specifications. If there is re-inspection data, it will be used. If there is no re-inspection, the average value will be calculated according to the original belt composition and stored in the DB2 database after regular batch processing.

[0013] Step 4: Actual CR / NI grade of production feed

[0014] For the actual grade value of CR / NI of the input material, the CR / NI input amount is obtained from the actual production furnace composition table, and the average value is calculated based on the cumulative time and then stored.

[0015] The actual CR / NI grade value of the raw materials input into production is obtained from the actual production furnace composition table and the average value is calculated and stored according to the cumulative time;

[0016] Step 5: Obtaining CR / NI grade values ​​of direct supply materials

[0017] The CR / NI grade values ​​of direct supply materials are retrieved from the cost decision system through microservices and stored in the DB2 database.

[0018] Step 6: Calculate the material unit price

[0019] Design the charge structure and material comparison maintenance view, and calculate the material conversion unit price according to different pricing modes. There are three conversion unit price algorithms: one is conversion price / 1.13*Ni% charge weight; the second is conversion price / 1.13 / 50%*charge weight*Cr%; the third is conversion price / 1.13*charge weight.

[0020] Among them, / represents the division sign and * represents the multiplication sign.

[0021] Step 7: Calculation of NI / CR alloy correction and total cost accounting

[0022] Calculate the deviation of NI and CR alloys using the following formula: theoretical input - total actual input = [(received quantity * actual grade of NI and CR) / NI and CR recovery rate] - [material consumption * actual grade NI and CR input], and obtain the deviation cost of the charge. Combined with the theoretical total cost per ton of steel, calculate the corrected total cost per ton of steel.

[0023] Step 8: Model display and trend chart generation

[0024] Based on production feed data, CR / NI grade value and raw material cost price, the alloy feed cost, auxiliary material feed cost, NI / CR total input, NI / CR deviation, deviation cost, corrected cost per ton of steel, step fee, etc. are calculated and designed for integration. The integrated display model is used to generate a charge consumption calculation model display, and the cost trend chart per ton of steel is displayed through data.

[0025] In step one, the key data include furnace charging information, furnace raw material price, furnace charge product composition cost and scrap steel information. The furnace charging information includes charging number, charging weight, charging type, steel tapping weight and steel tapping time.

[0026] In step 2, the relevant information obtained includes:

[0027] 1) Acquisition and transmission of furnace charging information:

[0028] From the production system, using the furnace number as the keyword, obtain the feeding number, feeding weight, steel tapping weight and steel tapping time, and transfer the data to the DB2 database through the telegram function interface;

[0029] 2) Collection and sorting of furnace raw material prices:

[0030] Collect the raw material price data of each batch, including the material's outbound quantity, unit price and discounted price;

[0031] Collect the cost composition of charge products, including the recovery volume, recovery price, recycling fee, process fee, auxiliary material cost, energy consumption, labor cost, depreciation fee, NI recovery rate, and CR recovery rate of each steel type;

[0032] 3) Collection and transmission of scrap steel information:

[0033] Collect relevant information including scrap steel material number, scrap steel usage price, recycling price, operating cost, actual usage price, CR grade value, and NI grade value, and transfer the data to the DB2 database through microservices.

[0034] In step three, by connecting with the procurement system, the CR component data and NI component data of the raw materials are obtained, and processed according to the principle of priority re-inspection. If there is re-inspection data, it will be adopted. If there is no re-inspection data, the average value will be calculated based on the original belt composition; the calculated data will be stored in the DB2 database using a scheduled batch processing method.

[0035] In step 4, the CR content value and the NI content value are obtained from the actual production furnace composition table, and the average value of the CR content value and the NI content value is calculated according to the cumulative time, and the calculated average value is stored in the DB2 database.

[0036] In step seven, the theoretical input is calculated through the received quantity, CR actual grade, CR recovery rate, NI actual grade, and NI recovery rate. The theoretical input is compared with the total input, and the CR deviation and NI deviation are calculated to obtain the deviation cost of the charge. The corrected total ton of steel cost of the charge is calculated by combining the theoretical total cost per ton of steel with the deviation cost.

[0037] In step eight, the display model includes two types, one is a feeding model integrated and displayed by factory and internal steel grades, and the other is a feeding model integrated and displayed by steel grade.

[0038] Compared with the prior art, the present invention has the following beneficial effects:

[0039] The detailed information such as the cost, consumption, CR grade, NI grade and furnace number of stainless steel charge are organically combined, and the cost per ton of steel of different steel grades is accurately calculated through advanced data integration and governance technology. This method provides solid and reliable data support for many key areas such as product pricing, process design, order optimization, material procurement, benefit forecasting and business decision-making, and has significant advantages and positive impacts.

[0040] The specific explicit indicators are as follows:

[0041] 1. Change of business model: The company has achieved a transformation from traditional extensive management to intensive management, which has greatly shortened the calculation cycle of stainless steel furnace material costs, from the previous monthly calculation to accurate calculation on a daily basis.

[0042] 2. Upgrade of calculation method: The calculation of stainless steel charge consumption cost has achieved a leap from cumbersome manual operations to intelligent and efficient model automatic calculation. It can timely and accurately calculate the charge cost of steelmaking on the previous day, greatly improving the timeliness and accuracy of the data.

[0043] 3. Refinement of calculation granularity: The calculation granularity of charge cost can be refined to the specific furnace and steel type within steelmaking. No matter how complex the situation is, this model can realize automatic and accurate calculation, providing more detailed and in-depth information for cost analysis and control. DETAILED DESCRIPTION

[0044] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0045] The development method of the steelmaking charge consumption cost accounting model includes the following steps:

[0046] Step 1: Discussion and clarification of key data: In-depth discussion was conducted on the stainless steel production process to accurately determine the key data that the model needs to automatically calculate and present in real time. After comprehensive and detailed discussion, the following key data were clarified:

[0047] 1. Detailed information on the charging of the furnace, including the number, weight, type of charging, weight and time of steel output. These data are the basis for accurate calculation of charging input and output.

[0048] 2. Various cost data related to stainless steel furnace materials, such as the purchase price of raw materials (including the quantity shipped out, unit price and discounted price), operating costs, recycling prices, etc. These data are indispensable for accurate cost calculation.

[0049] 3. The content and related data of key elements CR and NI in stainless steel charge have an important impact on the evaluation of charge quality and cost.

[0050] In step one, the key data include furnace charging information, furnace raw material price, furnace charge product composition cost and scrap steel information. The furnace charging information includes charging number, charging weight, charging type, steel tapping weight and steel tapping time.

[0051] Step 2: Acquisition and assembly of key data: According to the key data of stainless steel feeding set by the model, relevant data is obtained from the production system, intelligent quality system, cost decision system and procurement system, and transmitted to the DB2 database through the interface, and assembled according to predefined standards.

[0052] In step 2, the relevant information obtained includes:

[0053] 1) Acquisition and transmission of furnace charging information:

[0054] From the production system, using the furnace number as the keyword, key information such as the feeding number, feeding weight, steel output weight and steel output time are accurately obtained, and the data is transferred to the DB2 database through the telegram function (visual BM2F_ENTERACE_TELE) interface.

[0055] 2) Collection and sorting of furnace raw material prices:

[0056] Collect detailed raw material price data including the material outbound quantity, unit price and discounted price;

[0057] Collect cost data on the composition of charge products, including recovery volume, recovery price, recycling fee, step fee, auxiliary material cost, energy consumption, labor cost, depreciation fee, NI recovery rate, CR recovery rate, etc. of each steel type, to provide a comprehensive perspective for cost evaluation.

[0058] 3) Collection and transmission of scrap steel information:

[0059] Collect relevant information about scrap steel liquid, including scrap steel material number, scrap steel usage price, recycling price, operating cost, actual usage price, CR grade value, NI grade value, etc., and transfer this data to the DB2 database through microservices.

[0060] In order to effectively process and display the data, this embodiment uses the visual studio tool software to design a unified and standardized data format parsing rule for the data set technology. In this way, the data can be parsed into a data set that can be recognized by the visual studio software, and a clear and intuitive data display is performed. Considering the diversity of stainless steel feed materials, there are differences in the CR and NI contents of different materials.

[0061] Step 3. Calculation of CR / NI grade values ​​of raw materials: In view of the differences in batches and specifications of raw materials, the contents of element CR and element NI are different. By connecting with the procurement system, the element CR and element NI composition data of the raw materials are obtained, and the CR grade value and NI grade value of the raw materials are calculated. According to the differences in batches and specifications of raw materials, they are processed according to the principle of priority re-inspection. If there is re-inspection data, it will be adopted. If there is no re-inspection data, the average value will be calculated based on the original belt composition, and the calculated data will be stored in the DB2 database in a regular batch processing manner.

[0062] In step three, by connecting with the procurement system, the CR component data and NI component data of the raw materials are obtained, and processed according to the principle of priority re-inspection. If there is re-inspection data, it will be adopted. If there is no re-inspection data, the average value will be calculated based on the original belt composition; the calculated data will be stored in the DB2 database using a scheduled batch processing method.

[0063] Step 4. Calculation of actual CR / NI grade of feed: Calculate the actual CR grade and NI grade of feed, obtain the CR content and NI content from the actual production furnace composition table, and calculate their average values ​​according to the cumulative time. The calculated average value is stored in the DB2 database to provide accurate data support for subsequent cost accounting.

[0064] In step 4, the CR content value and the NI content value are obtained from the actual production furnace composition table, and their average values ​​are calculated according to the cumulative time, and the calculated average values ​​are stored in the DB2 database.

[0065] Step 5. Obtaining the CR / NI grade value of direct-supplied materials: Since direct-supplied materials are delivered directly to the production workshop without passing through the procurement center, their CR / NI grade values ​​need to be retrieved from the cost decision system through microservices and stored in the DB2 database.

[0066] Step 6. Calculation of material conversion unit price: Due to the different CR / NI content in the raw materials, there are significant differences in their prices, and this difference is mainly caused by different pricing modes. For this reason, a maintenance view of the charge structure and material comparison is created to maintain the pricing mode of the material. Different pricing modes correspond to different conversion unit price calculation logics, which improves the accuracy of the charge unit price.

[0067] Step 7. Calculation of CR / NI alloy correction and total cost accounting: Calculate the theoretical input amount through the received quantity, CR / NI actual grade and yield. Then, compare the theoretical input amount with the total input amount, calculate the CR / NI deviation, and then get the deviation cost of the charge. Combine the theoretical total cost per ton of steel with the deviation cost, and finally calculate the corrected total ton of steel cost of the charge. This corrected total ton of steel cost can more accurately reflect the actual ton of steel cost.

[0068] The theoretical input is calculated by the received quantity, CR / NI actual grade and recovery rate. Then, the theoretical input is compared with the total input, the CR / NI deviation is calculated, and the deviation cost of the charge is obtained. Combining the theoretical total cost per ton of steel with the deviation cost, the corrected total ton of steel cost of the charge is finally calculated. This corrected total ton of steel cost can more accurately reflect the actual ton of steel cost.

[0069] In step seven, the theoretical input is calculated through the received quantity, CR actual grade and recovery rate, NI actual grade and recovery rate, and the theoretical input is compared with the total input. The CR deviation and NI deviation are calculated to obtain the deviation cost of the charge. The corrected total ton steel cost of the charge is calculated by combining the theoretical total cost per ton of steel with the deviation cost.

[0070] Step 8. Based on data integration design, integrate the display model and generate a ton of steel cost trend chart.

[0071] Through comprehensive integration of the above basic data, two practical model display methods are designed:

[0072] 1. The feeding model integrated and displayed by factory and internal steel grade can clearly present the feeding situation and related cost data of different factories and steel grades.

[0073] 2. The integrated feed model displayed by steel grade helps to deeply analyze and compare the cost structure of specific steel grades.

[0074] At the same time, through complex logical operations on the above data, the model can also display an intuitive and clear trend chart of the cost per ton of steel in real time, enabling relevant personnel to observe and analyze the changing trend of the cost per ton of steel more conveniently and intuitively, providing a strong basis for decision-making.

[0075] The accounting model developed by the present invention, relying on advanced digital technology, deeply integrates various data in the steelmaking production process, and realizes automatic, real-time and accurate accounting of the steelmaking furnace material consumption cost.

[0076] The present invention develops an automatic real-time accounting model for steelmaking furnace consumption costs based on digital technology support. The model integrates raw material procurement, consumption, cost and furnace charge ratio data by connecting to multiple production systems, realizes the automatic calculation of furnace charge per ton of steel cost and applies it to stainless steel grade ratio and production. The model not only develops classification maintenance and comparison of pricing modes for different raw materials, simplifies the difficulty of per ton of steel algorithm, and realizes flexible conversion between raw material procurement price and use price, but also fully considers the balance of chromium and nickel ratio content of stainless steel, ensuring that the deviation between calculated cost and actual cost is controlled within 4.3%. In addition, the model achieves 100% coverage of steel grades, and can calculate and query per ton of steel cost on a daily basis, providing efficient and accurate support for stainless steel grade analysis, and providing steelmaking enterprises with more accurate, efficient and real-time cost management tools.

[0077] The present invention can comprehensively acquire key data from multiple related systems, and perform standardized processing and integration according to predefined standards to ensure the integrity and consistency of the data.

[0078] The present invention designs a special calculation method for accurately calculating the cost according to the content difference of key elements (such as CR, NI) in stainless steel furnace charge and the characteristics of different furnaces and steel types.

[0079] The present invention abandons the traditional manual accounting method and can provide the cost data of the steelmaking material of the previous day in a short time (such as 8 o'clock in the morning of the next day) through automatic calculation of the model, thereby realizing real-time update of cost accounting.

[0080] The present invention refines the cost calculation granularity to the furnace and steel grade within steelmaking, providing enterprises with more detailed and accurate cost information, which is conducive to precise cost control and decision-making.

[0081] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention should be included in the scope of the present invention.

Claims

1. A method for developing a cost accounting model for steelmaking furnace material consumption, characterized in that: The specific steps are: Step 1: Identify key data Identify the key data that the model needs to automatically calculate and present in real time during the stainless steel production process, including detailed information on furnace charging, various cost data, and the content of key elements CR and NI in the raw materials; Step 2: Data acquisition and assembly Obtain production material input data, raw material consumption data, and raw material decision prices from the production system, smart quality system, cost decision system, and procurement system, and transfer them to the DB2 database through a specific interface and assemble them according to predefined standards, including: Obtain furnace charging information from the production system, collect furnace raw material price data, furnace charge product composition cost data, and scrap iron and steel liquid information, and transfer them to the DB2 database through microservices; Step 3: Calculation and storage of CR / NI grade values For the CR / NI grade value of raw materials, the principle of priority re-inspection is adopted according to the differences in raw material batches and specifications. If there is re-inspection data, it will be used. If there is no re-inspection, the average value is calculated according to the original belt composition and stored in the DB2 database after regular batch processing; Step 4: Actual CR / NI grade of production feed For the actual grade value of CR / NI of the input materials, the CR and NI input amounts are obtained from the actual production furnace composition table, and the average value is calculated based on the cumulative time and then stored; The actual CR / NI grade value of the raw materials input into production is obtained from the actual production furnace composition table and the average value is calculated and stored according to the cumulative time; Step 5: Obtaining CR / NI grade values ​​of direct supply materials The CR / NI grade values ​​of direct-supplied materials are retrieved from the cost decision system through microservices and stored in the DB2 database; Step 6: Calculate the material unit price Design the charge structure and material comparison maintenance view, calculate the material conversion unit price according to different pricing modes, and there are three conversion unit price algorithms: the first is conversion price / 1.13*Ni% charge weight; the second is conversion price / 1.13 / 50%*charge weight*Cr%; the third is conversion price / 1.13*charge weight; Step 7: Calculation of NI / CR alloy correction and total cost accounting The specific formula is: theoretical input - total actual input = [(receipt*actual grade of NI, CR) / receipt rate of NI, CR] - [material consumption*actual grade NI, CR input], which is used to calculate the deviation cost of the charge and the corrected total cost per ton of steel based on the theoretical total cost per ton of steel. Step 8: Model display and trend chart generation Based on the production feed data, CR / NI grade value and raw material cost price, the alloy feed cost, auxiliary material feed cost, NI / CR total input, NI / CR deviation, deviation cost, corrected cost per ton of steel and step fee are calculated for integrated design, the integrated display model is generated and the charge consumption calculation model display is generated, and the cost trend chart per ton of steel is displayed through data.

2. The method for developing a steelmaking charge consumption cost accounting model according to claim 1, characterized in that: In step one, the key data include furnace charging information, furnace raw material price, furnace charge product composition cost and scrap steel information. The furnace charging information includes charging number, charging weight, charging type, steel tapping weight and steel tapping time.

3. The method for developing a steelmaking charge consumption cost accounting model according to claim 1, characterized in that: In step 2, the relevant information obtained includes: 1) Acquisition and transmission of furnace charging information: From the production system, using the furnace number as the keyword, obtain the feeding number, feeding weight, steel tapping weight and steel tapping time, and transfer the data to the DB2 database through the telegram function interface; 2) Collection and sorting of furnace raw material prices: Collect the raw material price data of each batch, including the material's outbound quantity, unit price and discounted price; Collect the cost composition of charge products, including the recovery volume, recovery price, recycling fee, process fee, auxiliary material cost, energy consumption, labor cost, depreciation fee, NI recovery rate, and CR recovery rate of each steel type; 3) Collection and transmission of scrap steel information: Collect relevant information including scrap steel material number, scrap steel usage price, recycling price, operating cost, actual usage price, CR grade value, and NI grade value, and transfer the data to the DB2 database through microservices.

4. The method for developing a steelmaking charge consumption cost accounting model according to claim 1, characterized in that: In step three, by connecting with the procurement system, the CR component data and NI component data of the raw materials are obtained, and processed according to the principle of priority re-inspection. If there is re-inspection data, it will be adopted. If there is no re-inspection data, the average value will be calculated based on the original belt composition; the calculated data will be stored in the DB2 database using a scheduled batch processing method.

5. The method for developing a steelmaking charge consumption cost accounting model according to claim 1, characterized in that: In step 4, the CR content value and the NI content value are obtained from the actual production furnace composition table, and their average values ​​are calculated according to the cumulative time, and the calculated average values ​​are stored in the DB2 database.

6. The method for developing a steelmaking charge consumption cost accounting model according to claim 1, characterized in that: In step seven, the theoretical input is calculated through the received quantity, CR actual grade, CR recovery rate, NI actual grade, and NI recovery rate. The theoretical input is compared with the total input, and the CR deviation and NI deviation are calculated to obtain the deviation cost of the charge. The corrected total ton of steel cost of the charge is calculated by combining the theoretical total cost per ton of steel with the deviation cost.

7. The method for developing a steelmaking charge consumption cost accounting model according to claim 1, characterized in that: In step eight, the display model includes two types, one is a feeding model integrated and displayed by factory and internal steel grades, and the other is a feeding model integrated and displayed by steel grade.