2022 is a very bleak year for the cement industry. In 2023, the cement market demand in Zhejiang will continue to be depressed, and the market will continue to show the characteristics of "low peak season, weaker off-season". Under the background of two-way extrusion of falling cement volume and price and rising cost, the profits of Zhejiang cement enterprises will continue to decline.
Technological upgrading and transformation, elimination of backwardness, capacity integration, transformation and upgrading are the most discussed topics for every cement worker in the past two years. On March 30, 2023, six departments, including the Department of Economic and Information Technology of Zhejiang Province, jointly issued the Notice of the Action Plan for High-quality Development of Cement Industry and Carbon Peak in Zhejiang Province (2022-2025) (hereinafter referred to as the Action Plan), which came into effect on June 1, 2023. The release of the
Action Plan is very timely, which points out the development direction of Zhejiang Cement. The following is an analysis report on the high-quality development of Zhejiang Cement Industry based on the current situation of Zhejiang Cement.
1. The overall
goal of the Action Plan is to continuously improve the level of clean energy utilization and green manufacturing in the cement industry, guided by the goal of carbon peak and carbon neutralization, focusing on reduction replacement, energy-saving transformation and digital empowerment, and to implement ten tasks and four safeguards. Accelerate the green and low-carbon transformation of the industry and comprehensively promote the high-quality development of the cement industry.
2. Current situation
of cement industry in Zhejiang Province According to the Survey Data of Cement Industry in Zhejiang Province (2022), in 2022, the total output of cement in China will be 2.130 billion tons, of which the output of cement in Zhejiang Province will be 129 million tons, which is 5.
Zhejiang Province has a total of 132 cement enterprises, 33 new dry process enterprises and 45 clinker production lines, including 22 clinker production lines with a daily output of more than 5,000 tons and 23 clinker production lines with a daily output of less than 2,500 tons (inclusive). The clinker production lines are mainly concentrated in the west and north of Zhejiang Province, mainly in Hangzhou, Huzhou, Quzhou, Jinhua and other places. The design capacity of clinker production line in Zhejiang Province is 51.52 million tons, including 13 enterprises with mines and 31 million tons of clinker design capacity, accounting for 60% of the annual clinker design capacity of 51.52 million tons.
The average scale of Zhejiang cement enterprises is 1.03 million tons, the average scale of new dry process enterprises is 1.6 million tons, and the average scale of grinding enterprises is 830,000 tons. There are 20 cement enterprises with more than 2 million tons, 8 enterprises with more than 4 million tons and 40 enterprises with less than 300000 tons.
In terms of transformation, upgrading and capacity removal (based on the capacity of the public list in 2021), eight production lines of 2500t/d and below have been publicly announced for capacity replacement, of which Xukou South (2500t/d) and Ningbo Kehuan (2500t/d) have been shut down one after another. Zhejiang Huying Cement Co., Ltd. (2500t/d), Quzhou South 2000t/d, Jiangshan South 2000t/d, Zhejiang III" Analysis
of the high-quality development of the cement industry in Zhejiang Province 1. The Action Plan on the measures
to reduce the production capacity of the cement industry clearly requires that by the end of 2025, the total output of cement in Zhejiang Province should be controlled at 1.
The demand for cement in different regions is not balanced. As mentioned earlier, the production lines of Jike in Zhejiang Province are mainly concentrated in the west and north of Zhejiang Province. In terms of capacity reduction, in addition to the closure of clinker production enterprises, Zhejiang Province is actively planning to complete the reduction and replacement of eight clinker production lines of 2500 tons per day or less, merger and reorganization, and demolition and construction of the original site by the end of 2025. At the same time, it is strictly forbidden to put on record and build new cement clinker projects to expand production capacity. The replacement ratio of general cement clinker withdrawal capacity and construction capacity is from 1.
Zhejiang Province has also taken a number of other measures to reduce production capacity. In recent years, the cement enterprises in Zhejiang Province have strictly implemented the "Three-year Action Plan for Winning the Blue Sky Defense War in Zhejiang Province" and the "Implementation Plan for Peak-staggering Production in Zhejiang Cement Industry" formulated by the competent authorities and industry associations, and adhered to the peak-staggering production measures, which have made great contributions to the orderly development of Zhejiang Cement.
We actively encourage enterprises to consider the situation of local limestone resources, and suggest that enterprises without limestone mines, with high production costs and long-term losses, with high comprehensive energy consumption per unit product of clinker after technological transformation, or with enterprises that are still unable to meet ultra-low emissions after technological transformation, should carefully consider reduction replacement, merger and reorganization.
2. To improve the efficiency of energy utilization and rectify the high-consumption and low-efficiency cement enterprises
, the Action Plan clearly States that by the end of 2025, the comprehensive energy consumption per unit product of clinker will be reduced by 5%. From 106.9 kg standard coal/ton to 101.
According to the provisions
of the Energy Consumption Quota for Cement Unit Products (GB16780-2021) implemented on November 1, 2022, according to the Survey Data of Cement Industry in Zhejiang Province (2022), Only two companies in Zhejiang Province will reach the first level of comprehensive energy consumption per unit product of clinker in 2022, namely Jiande Southern Cement Co., Ltd. (98.8 kgce/t) and Huzhou Huaikan Southern Cement Co., Ltd. (99. Suggested measures to be taken by each enterprise:
each cement enterprise shall continue to adopt technical measures and technological transformation, introduce new technologies, new equipment and new processes, and actively study and adopt alternative fuels to effectively reduce the comprehensive energy consumption per unit product of clinker.
We will support the promotion of single second-generation technological transformation for energy conservation and emission reduction, such as low-nitrogen combustion technology for cement clinker production lines and final grinding technology for roller presses, and encourage the implementation of comprehensive technological transformation projects for energy conservation and carbon reduction in cement enterprises.
For high-consumption and low-efficiency enterprises, through merger and reorganization, overall evacuation, relocation into the park, transformation and upgrading, the "one enterprise, one plan" is implemented to upgrade the standard and achieve the standard sales number.
3. To strengthen the implementation of "three products" project
in cement enterprises, it is suggested that enterprises should continue to study and explore the variety, quality and brand of cement, and implement the "three products" implementation plan of raw material industry.
(1)
According to the Survey Data of Zhejiang Cement Industry (2022), there are 9 cement varieties produced by Zhejiang cement enterprises. They are: ordinary Portland cement (accounting for 70.33%), masonry cement (accounting for 19.02%), composite Portland cement (accounting for 6.31%), Portland cement (accounting for 2.1%), steel slag Portland cement (accounting for 0.96%), pozzolanic Portland cement (accounting for 0.6%), A-type slag Portland cement (accounting for 0.18%), white Portland cement (accounting for 0.09%) and marine Portland cement (accounting for 0.09%).
Masonry cement is the main variety of low strength grade. Masonry cement has the disadvantages of less clinker content, more admixture and poor durability, which has potential safety hazards to the structure. Not to be used for structural work under normal conditions. Cement enterprises are
encouraged to continuously develop and produce special cement to meet the needs of new infrastructure construction, new urbanization construction and major construction projects such as transportation and water conservancy, focusing on the development of new low-carbon cement such as low-calcium cement clinker, low-clinker coefficient cement and new carbon-fixing cementitious materials, so as to enrich the cement product system.
(2) In terms
of quality improvement, according to the Survey Data of Zhejiang Cement Industry (2022), Zhejiang Cement Grade 42.5 and above accounted for 79
. Encouraging the increase of 42.
(3) Brand
creation In terms of brand creation, cement enterprises are encouraged to be world-class, aim at the international advanced level, bravely climb the peak of cement technology, and encourage enterprises to introduce brand cultivation management system. We will accelerate the creation of a number of brand enterprises in the cement industry, such as "Pinzibiao", "single champion", "Little Giant" and "invisible champion".
4. Increase the utilization
of clean energy in the cement industry The Action Plan specifies that by the end of 2025, the cement industry will make room for more than 750,000 tons of standard coal; the total installed capacity of clean energy (solar photovoltaic) will reach more than 135 MW.
5. Increase the intelligent construction
of the cement industry. Now is the era of industrial informatization and intelligent explosion. The informatization and intellectualization of the cement industry have been developing vigorously and become the inevitable development trend of the industry.
In recent years, Southern Cement, Conch Cement and Red Lion Cement have been building intelligent factories in the cement industry. These factories have built intelligent equipment and intelligent manufacturing systems with functions of self-perception, self-learning, self-decision-making, self-execution and self-adaptation.
We encourage enterprises to accelerate the exploration of the integration of cement industry and "5G + Industrial Internet", and to build the whole process of cement manufacturing through the integration of new generation information technologies such as 5G, Internet of Things, cloud computing, big data and artificial intelligence. Equipment system intellectualization, production and operation informationization, process data visualization and collaborative management intellectualization realize intelligent management of product life cycle, create more typical application scenarios, promote the construction of a number of intelligent mines and factories that integrate intelligent production, intelligent operation and maintenance, and intelligent management, so as to realize intelligent production. So as to improve working conditions, reduce manual intervention, improve management efficiency, reduce product energy consumption, improve product quality, and help the transformation and upgrading of the cement industry.
6. Fully implement the green transformation
of cement The Action Plan requires that by the end of 2025, the proportion of grade A in the air pollution prevention and control performance of cement clinker production enterprises in the province should be increased to more than 50%, and the rest of cement clinker production enterprises should be increased to grade B or above. On November 12, 2020, the Department of Ecology and Environment
of Zhejiang Province issued the Implementation Plan for Ultra-low Emission Transformation of Cement Industry in Zhejiang Province (hereinafter referred to as the Plan). By the end of 2022, the emission concentrations of particulate matter, sulfur dioxide and nitrogen oxides in flue gas of cement kiln and kiln tail waste heat utilization system will not be higher than 10, 50 and 100 mg/m3, respectively; By the end of June 2025, the emission concentrations of particulate matter, sulfur dioxide and nitrogen oxides in the flue gas of cement kiln and kiln tail waste heat utilization system shall not be higher than 10, 35 and 50 mg/m3 respectively.
The existing clinker production lines have successfully passed the acceptance of the first phase of the Plan, while most enterprises still have a lot of gaps from the requirements of the second phase, and enterprises need to continue to study and invest in technological transformation. In less than two years, the cement kiln and the waste heat utilization system at the kiln tail will strive to meet the requirements of the Plan. While promoting the construction of cement clinker production line co-disposal of hazardous waste and other solid waste projects, and smoothly and orderly promoting the capacity replacement of 2500 tons/day and below production lines,
Zhejiang Province pays special attention to the effective link of new cement kiln co-disposal projects to ensure the co-disposal capacity and disposal safety of hazardous waste and other solid waste. We will encourage the comprehensive utilization of fly ash, tailings and construction waste, promote a green manufacturing system, build a number of green factories and green product certification enterprises, accelerate the implementation of the implementation plan of ultra-low emission transformation in the cement industry, and implement the whole process of ultra-low emission transformation for raw material mining, cement (clinker) manufacturing and bulk material product transportation. Greatly reduce the emission of air pollutants, and comprehensively improve the level of air pollution prevention and control in enterprises.
4. Basic conclusions and judgments of the analysis report:
1. At present, the high-quality development of Zhejiang cement industry is at the national advanced level as a whole, and some enterprises are at the national benchmark level.
2. On the basis of the current situation, we will strive for another two years or so to fully complete the high-quality development goals and tasks of energy conservation and environmental protection proposed in the action plan, which are expected to be achieved through efforts.
3. Under the current severe situation facing the industry, the whole industry has to make arduous efforts to achieve the goal of high-quality development.
4. It is of great significance for Zhejiang Province to take the lead in introducing the action plan for high-quality development of cement in the whole country. It is suggested that relevant government departments continue to vigorously support and promote the implementation of the action plan.
5. The Cement Association will further deepen its work and provide all-round services for the high-quality development of enterprises.
6. With the help of the Action Plan, enterprises should identify the weak links, make up for the shortcomings as soon as possible and improve the overall level according to the ten tasks and requirements put forward in the document.
At present, although Zhejiang cement industry is at a low ebb, we are confident that it is an era of flourishing research and development, new technologies and new resources utilization. Conch Cement, Southern Cement and Red Lion Cement have been far ahead of China's cement industry in terms of new technology, fine management, energy saving and emission reduction, intelligent construction, solar power generation, and co-disposal of fly ash from domestic waste incineration in cement kilns. It has made great contributions to the high-quality development of Zhejiang cement.
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