Green manufacturing is the way to realize the green development of industry. Green Manufacturing, also known as Environmentally Conscious Manufacturing, Manufacturing for Environment, is a modern manufacturing mode that comprehensively considers environmental impact and resource efficiency. That is to say, in the whole life cycle of products from design, manufacturing, packaging, transportation, use to scrap disposal, the impact on the environment (negative effects) is the smallest, the utilization rate of resources is the highest, and the economic and social benefits of enterprises are maximized as far as possible.
Reducing the carbon emissions of high energy-consuming manufacturing industry is an important link to achieve green manufacturing. Data show that in 2022, global cement carbon emissions will be about 2.7 billion tons, accounting for 7% of global energy-related carbon emissions. Cement production has a long way to go to reduce carbon emissions.
In the composition of carbon emissions from cement clinker production, process carbon emissions from carbonate decomposition account for about 65%, and energy-related carbon emissions account for about 35%. The core of green low-carbon is to change the traditional mode of production and introduce new technologies and equipment, but the process carbon emissions produced by carbonate decomposition are recognized as the most difficult to decarbonize in the world.
Therefore, under the existing conditions, the main direction of carbon emission reduction in cement industry is the carbon produced by energy consumption. The most important way of energy consumption is to use alternative energy, but the use of alternative energy also faces many challenges. Li Yeqing, Party Secretary and President of Huaxin Cement, said that the traditional production mode faces four major problems: first, the calorific value of alternative fuels in low-carbon cement manufacturing fluctuates greatly, there are many interference factors, and it is difficult to control the production; second, there are many kinds of alternative fuels with different characteristics, and it is difficult to prepare, store and homogenize the fuel; Third, alternative fuels are complex in composition and different in quality, the frequency of raw material composition matching adjustment is high, and the quality control of cement products is difficult; fourth, alternative fuels are highly corrosive, the deterioration of production equipment is accelerated, and the safety supervision of equipment and site is difficult.
In Huaxin Wuhan Changshankou Environmental Protection Factory, domestic waste from Jiangxia District, Hongshan District, Wuchang District, Donghu High-tech Zone and other areas of Wuhan began a "recycling journey". Crushing, drying, sorting.. After ecological pretreatment, these domestic wastes are converted into derived fuels to replace coal, and then transported to the cement plant of Huaxin Cement Company for co-disposal in cement kilns.
By the end of 2022, Huaxin Cement has used more than 15 million tons of waste derived alternative fuels, and the average TSR (fuel substitution rate) of the company's kiln line plants has reached 15. Among them, the TSR of Huangshi 10,000-ton line plant has reached more than 40%, which has become the lowest carbon emission per unit clinker production line in China. "By 2030, Huaxin Cement's carbon emissions per unit of product output value will be reduced by more than 70% compared with 2005; by 2060, it will eventually achieve net zero emissions." Li Yeqing said.
In order to solve the technical problem of unstable production caused by the large proportion of refuse derived fuel (RDF), Huaxin Cement has designed an intelligent and innovative application solution for low-carbon manufacturing based on its own experience in carbon reduction, which enables the green development of cement manufacturing industry. HIAC (Huaxin Intelligent Advanced Contro), a domestic advanced control system for low-carbon cement manufacturing, significantly reduces coal consumption and carbon emissions on the basis of ensuring stable operation of cement production; HOQC (Huaxin Online Quality Control), an intelligent online quality control system for cement, uses data to drive production, solves the problem that production quality is difficult to guarantee when fuel quality fluctuates greatly, and realizes high-quality and low-carbon production; The intelligent equipment monitoring and optimization system — — HERO (Huaxin Equipment Reconnaisance Optimization) realizes the real-time monitoring, fault prediction and intelligent early warning of cement production equipment, improves the equipment operation rate and ensures the safe operation of production.
, digitalization and intellectualization are the "cutting-edge tools" for Huaxin Cement to practice the concept of green development. "In recent years, Huaxin Cement has accelerated digital transformation and intelligent upgrading, insisted on independent innovation and independent research and development, and took the lead in https://price.ccement.com/brandnewslist-1-1000554.," said Li Yeqing. In 2021, based on Alibaba Cloud Industrial Control Optimization Platform (AICS), Huaxin Cement built a set of intelligent advanced control system for low-carbon cement manufacturing, which successfully realized the stable control of working conditions during large-scale environmental co-disposal, and further improved the coal substitution rate and quality stability. At present, Huaxin Cement is promoting this system in all domestic cement production lines, and plans to apply it to overseas production lines, so that domestic self-developed intelligent control system can go abroad. Every stage of the whole
industry chain life cycle carbon reduction
life cycle has carbon emissions. In the next step, Huaxin Cement will follow the principle of "whole industry chain, whole life cycle energy saving and carbon reduction", and further promote the development of green manufacturing from four aspects.
Firstly, Huaxin Cement will promote the research and development of green and low-carbon products, give priority to the research and development and production of mixed cement, high-performance cement and energy-saving and environmental protection building materials, and reduce the proportion of single ordinary Portland cement; At the same time, we should make full use of digital technology and artificial intelligence technology to create a modern green cement comprehensive system with efficient utilization of resources, low environmental pollution, energy saving and high waste recovery rate.
Fourthly, we should implement large-scale production line waste co-disposal and emission reduction management measures, strengthen the recycling of different materials such as grinding, paper stone pulp and machine-made sand, and improve the recycling value of green low-carbon waste resources.
Through the above measures, Huaxin Cement will promote enterprises to achieve green and low-carbon development of the whole supply chain in the process of product design, raw material procurement and production.
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