Development and application of green manufacturing and superhard products

1 Introduction

Green manufacturing is a manufacturing model based on low carbon, low energy consumption, low pollution and low emissions. Its essence is the issue of efficient use of energy, development of clean energy, and the pursuit of green GDP. The core is the fundamental transformation of energy technology and emission reduction technology innovation, industrial structure and institutional innovation and human production development concepts. This is a noble mission and a top priority task that the times have given us. As a scientific and technical worker, especially as a scientific and technical worker in the research and development and production of super-hard materials, he should be proactively dedicated to this great technological change, and make the super-hard materials of unparalleled materials of other materials stand out. .

Regarding the development and application of green manufacturing and super-hard products, this topic should be elaborated from two aspects. First, how to achieve low-carbon green energy-saving and emission reduction in the manufacturing process of super-hard materials tools; It plays an important technical support role in promoting low-carbon green and energy-saving emission reduction in all fields of modern industry. This article will only give a brief explanation of the latter.

2. PDC drill bit opens the way for green energy drilling

Among the fossil-type energy sources, natural gas is a kind of combustible gas that has been produced by the organism in the deep high temperature and high pressure environment of the stratum. The main component is methane, and the calorific value is about 8500 kcal/m3, mainly in the natural gas field. In oil fields and some gas fields, there are few impurities such as sulfur in the composition, and CO2 and water are generated after combustion, and other pollutants are rarely emitted. Therefore, it is a clean and environmentally friendly energy source compared with coal and oil. It is predicted that after 2020, natural gas will surpass oil and coal as the mainstay of primary energy consumption. In China, the proportion of natural gas in primary energy is currently only 3.8%, and there is huge room for development.

Under the double pressure of shallow oil and gas resources after nearly one hundred years of continuous mining, less and less reserves, and the increasing dependence of global economic development on oil and gas resources, people are constantly exploring the possibility of storing oil and natural gas in deeper layers. With the advancement of science and technology and the deepening of people's understanding of deep-terrain geological structures, the discovery and exploitation of oil and gas resources in deeper and deeper strata has become a realistic scientific issue.

Carbon dioxide is one of the main reasons for the continuous warming of the Earth's climate. How to reduce carbon dioxide emissions is a common challenge facing humanity today. Among the new technologies developed by people, geological storage of carbon dioxide and carbon dioxide flooding are a new method of emission reduction. Experts estimate that these underground carbon dioxide will gradually dissolve in the rock layer after 2000 years and form new minerals.

In general, a ton of crude oil produced will burn about 2.68 tons of carbon dioxide after combustion. If the amount of carbon dioxide stored in the formation at the same time as the production of one ton of oil reaches or exceeds 2.68 tons, the carbon dioxide produced by the combustion of the crude oil and the carbon dioxide stored in the ground cancel each other, thereby realizing the green mining of the crude oil.

This green oil recovery technology has been widely used in the United States. According to relevant information, in 2008, the United States used carbon dioxide to drive crude oil to reach 114 million tons.

According to estimates by relevant experts, from the oil and gas geology of China, it is possible that 40.50% of the crude oil produced by carbon dioxide is carbon-free, and at least the level of low-carbon oil can be mined by carbon dioxide production technology. According to China's current proven oil geological reserves, the low-permeability reservoirs suitable for carbon dioxide mining have a geological reserve of 6.3 billion tons, which has great potential for crude oil exploitation in deep strata, and also has the potential to store carbon dioxide.

The exploration and development of natural gas wells has huge investment in single wells, deep drilling depth, long construction period and high technical difficulty. The wear resistance of synthetic diamond is much higher than that of cemented carbide. Applying it to petroleum drill bit will bring about a qualitative leap in the whole drilling technology [1]. The use of advanced PDC bits to replace traditional carbide roller cones can speed up drilling, reduce drilling time and cost, and achieve green drilling as much as possible. The problem now is to use the domestic PDC drill bit, the depth of 3000 ~ 4000m is acceptable, and the deep sea drilling more than 5000m will use the imported drill bit. Therefore, during the “Twelfth Five-Year Plan” period, China should increase the research and development of PDC and its raw materials, and manufacture deep-sea PDC drill bits with a depth of more than 5,000 meters, which is our goal.

3. Superhard tool and green cutting

The development and application history of high-speed cutting tool technology in foreign countries prove that superhard tools represented by PCD and PCBN tools have higher hardness and better wear resistance than cemented carbide and ceramic tools, and can adapt to higher cutting speed. It is more obvious that the basic characteristics of modern advanced cutting technology are “efficient, precise and flexible”. Therefore, they are the ideal high-speed cutting tools, representing the development direction of modern high-efficiency high-speed cutting tools [2].

Due to the application of advanced cutting technology such as “hard grinding”, “hard processing” and “dry cutting” for super-hard tools, the environmental pollution caused by cutting (grinding) cutting and cutting (grinding) cuttings is avoided. Clean production can be achieved. Therefore, the ultra-hard tool high-speed cutting technology is recognized as an efficient, green and resource-efficient, energy-saving processing tool in the 21st century.

Hard cutting refers to the cutting of hardened parts with single- or multi-blade tools. It is a new process of “cutting and grinding” and a new application field for high-speed cutting technology. Compared with traditional grinding, high-speed hard cutting has the advantages of high efficiency, good flexibility, no environmental pollution caused by cutting fluid, less process, and low investment [3].

According to the guiding principle of green manufacturing “saving energy, saving resources, minimizing pollution, and environmental protection”, in order to eliminate the adverse effects of cutting fluid, the most effective and effective processing method is dry cutting, and the dry cutting processing technology is quite good in western developed countries. Applications.

When processing aluminum and magnesium alloy materials with high silicon content, the life of cemented carbide tools is too low to be competent. The durability of PCD tools is 10 to 50 times that of hard alloys, which can ensure the dimensional stability of parts and greatly improve Cutting speed, processing efficiency and processing quality fully reflect the development direction of its low carbon economy.

According to reports, the annual output value of PCD and PCBN tools in Japan accounts for about 4% of the total output value of various domestic tools, 4.14% in the US, and 6% to 7% in Russia (Russian tungsten deficiency, less carbide tool, PCBN tool) Large amount) [4]. At present, the annual output of PCD and PCBN cutting tools in China is only about 400,000, and the sales volume is less than 200 million yuan, which is about 0.5% of the total output value of various domestic tools. There are still 2/3 of the PCD and PCBN tool markets imported. Products, domestic PCD, PCBN tools less than 1/3 share, and the use of PCD, PCBN tool raw materials are almost imported products abroad, therefore, China's PCD, PCBN tool development and foreign countries still have a big gap.

At present, the total sales volume of global superhard tools is about 1 billion US dollars, of which PCD tools and PCBN tools account for 1/2 each, and the market share is 1/3 of the US market, Asia Pacific market and European market. The potential market sales of the two tools will exceed $1.5 billion. Research on high-performance PCD and PCBN tool blank materials and research on precision PCD and PCBN tool manufacturing technology and their application are the only way to develop superhard material tools [5].

With the development of manufacturing technology and difficult-to-machine materials, the development of tool technology is moving toward high-speed cutting, high-precision and hard dry cutting, and ultra-hard tools that can achieve high efficiency, high stability and long-life processing are becoming more and more popular [ 16], plays an important role in the fields of automobile, aerospace, energy, military, and machinery. Ultra-hard tools meet the requirements of modern high speed, high efficiency, high stability, low cost and low carbon environmental protection. It is an ideal green cutting tool.

In recent years, with the increasing awareness of environmental protection and sustainable development in society, people have begun to pay attention to a series of negative effects brought by the entire life cycle of cutting fluid. In order to eliminate the adverse effects of cutting fluid, the most effective and effective processing method is Dry cutting, which has a fairly good application in Western industrialized countries [17,18].

As an important means in modern cutting, PCD and PCBN super-hard tools have unparalleled superiority in machining precision, cutting efficiency and tool life. The promotion and application of such tools can create huge economic benefits. The development of new cutting technology and superhard tool materials will promote the further development of China's modern manufacturing industry [19].

4. High-speed CBN grinding wheel and green processing

Environment and resources are major issues facing today's society. Achieving cost-saving and efficiency reduction, reducing waste emissions, and establishing a coordinated development model of production, consumption, environment and resources have become the only way for the sustainable development of human society. Green manufacturing is a sustainable development model and an important feature of manufacturing in the 21st century [6].

Accelerating the development of various green processing technologies is of great significance to protecting the environment, conserving energy and resources, and realizing the modernization, greening and sustainable development of the manufacturing industry. Green processing refers to making full use of resources without sacrificing product quality, cost, reliability, function and energy utilization, and minimizing the harmful effects on the environment during processing. The connotation refers to saving raw materials and energy and shortening production. Cycle, reduce production costs, improve the economic efficiency of enterprises, and achieve coordinated and optimized sustainable development among the economy, society and the environment. It is imperative to implement green processing in the manufacturing industry [7].

Since the 1990s, with the advent of high-speed, ultra-high-speed CNC grinding machines, high-speed CBN grinding wheels have become more useful, replacing ordinary corundum grinding wheels. CBN grinding wheels are high-precision, high-efficiency, low-consumption, and low-production. Excellent performance abrasives such as cost, low pollution and high degree of automation are the development direction of modern advanced grinding tools [8].

The automotive industry is a major area of ​​high-speed CBN grinding wheel applications, particularly the machining of camshafts and crankshafts for key parts of the engine. The performance of ordinary corundum abrasive grinding wheel is difficult to adapt to the requirements of high-efficiency machining. It has low durability and low service life. It needs frequent dressing and replacement. The grinding wheel is used in a large amount, and the grinding residue containing a large amount of corundum abrasive is generated, and the grinding fluid is added. The amount of filtration and cleaning has caused certain pollution to the environment, and it has increased the difficulty in recycling and recycling. Due to the huge consumption of energy and energy in the corundum series of abrasives, it has aggravated its adverse impact on the environment. The application of high-speed CBN grinding technology can solve the problems of resources, energy and environment generated in the traditional grinding process. It represents a major direction in the development of abrasive products in the world today, an effective means to achieve green processing goals, and a tool to promote the development of green manufacturing.

5. Contribute to the development of the photovoltaic industry

The solar photovoltaic industry is one of the fastest growing industries in the world. In order to achieve energy and environmental sustainability, all countries in the world regard solar photovoltaic power generation as the focus of new energy and renewable energy development.

Recently, countries around the world have generally raised the development of renewable energy to a strategic position, and green photovoltaic power generation technology has become the top priority for achieving sustainable development. This undoubtedly stems from two aspects: (1) inexhaustible solar energy resources, inexhaustible, can be exploited everywhere; (2) the positive effect of photovoltaic power generation technology on environmental protection [9].

Photovoltaic power generation is a technology that uses the photovoltaic effect of a semiconductor surface to directly convert light energy into electrical energy. The promotion and application of this technology will get rid of the dependence of traditional power generation methods on coal energy.

The vigorous development of the world's photovoltaic industry and market makes photovoltaic power generation occupy an increasingly important position in the world's energy consumption. According to the prediction of the European Union Joint Research Center, solar photovoltaic power generation will not only replace some conventional energy sources in the near future, but also become the main body of the world's energy supply.

Although various new concept solar cells continue to emerge and efficiency continues to rise, the solar cells entering the civilian sector at this stage are mainly crystalline silicon solar cells, accounting for more than 90% of current production, and it can be determined that this situation will not occur in the short term. Fundamental change.

Solar cells produced from silicon wafers can directly convert solar energy into electrical energy, which is a great revolution in human development of new energy sources. Monocrystalline silicon is a relatively active non-metallic element with a substantially complete lattice structure of crystals. It is a good semiconductor material. The purity requirement is 99.9999%, which is used to manufacture photovoltaic solar cells.

Monocrystalline silicon is usually produced by first obtaining polycrystalline silicon or amorphous silicon, and then growing rod-shaped single crystal silicon from the melt by a Czochralski method or a suspension zone melting method.

Polycrystalline silicon is a form of elemental silicon. When molten elemental silicon solidifies under supercooled conditions, the silicon atoms are arranged in a diamond lattice form into a plurality of crystal nuclei. If the crystal nuclei grow into crystal grains with different crystal orientations, the crystal grains are combined and crystallized into polycrystalline silicon. . The difference between monocrystalline silicon and polycrystalline silicon is mainly manifested in physical properties.

Silicon wafers made of monocrystalline silicon or polycrystalline silicon are an important process, including: (1) crystal growth; (2) slicing (wire cutting); (3) leveling (grinding or grinding); (4) marking; 5) polishing; (6) cleaning. It has a significant impact on silicon performance and photoelectric conversion efficiency.

The development of the photovoltaic industry has brought another huge business opportunity for China's diamond tool manufacturing industry. From the recently collected Jiangxi Jinkui Energy Technology Co., Ltd., the world's most advanced diamond wire saw cutting technology was used to test and produce solar monocrystalline silicon wafers. It is pointed out that it is three times faster than the traditional mortar cutting technology, and the hydropower consumption is reduced by two-thirds compared with the traditional mortar cutting technology, and the silicon powder produced after cutting can be completely recycled, which is energy-saving and environmentally friendly. It has far-reaching significance for upgrading the level of domestic industry [10].

The Securities Times said that Yu Diamond entered the field of photovoltaic processing because wafer cutting is a key part of the solar photovoltaic cell manufacturing process. With its high efficiency and long life, diamond cutting lines can help downstream companies effectively reduce costs. At present, there is a precedent for large-scale application of diamond cutting lines overseas. Asahi Diamond, a leading Japanese diamond tool company, launched diamond wire products in 2006, and achieved large-scale sales in Japan and Taiwan in 2009 [11].

Yu Diamond plans to start production of the project within one and a half years, and the production capacity will reach 14.4 million km/year for 0.33mm photovoltaic diamond wire for cutting silicon ingot; 0.12mm diamond wire for 132,000km/year for cutting Information such as silicon wafers is evidence!

6. Dedicated to the development of the electronic information industry

The electronic information industry has developed into the first pillar industry of China's national economic and social development, and the basic industry of the electronic information industry is the integrated circuit (IC) industry. At present, more than 95% of semiconductor devices and more than 99% of integrated circuits (ICs) are made of silicon materials, so the production and processing of silicon materials plays a major role in the production of semiconductors and integrated circuits.

Silicon is a very hard and hard and brittle material, and it is also a good semiconductor material. In wafer (chip) processing, diamond tools must be used for high-precision machining at different stages, see the table below.

Diamond tool for semiconductor wafer (chip) processing applications

The diamond tool for semiconductor processing is a high-precision machining tool. It uses ultra-fine diamond, ultra-thin cutting edge, ultra-high-speed grinding and sawing, and requires high processing precision. Therefore, it is difficult to manufacture and has high technical threshold. Currently, it is mainly for foreign diamonds. Controlled by tool manufacturers, this has given new challenges, new topics, and new directions to diamond tool manufacturers in China [12].

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