Flying dust, gray sky.. When it comes to cement plants, many people's impression is still dusty and "dusty". But the factory area in front of us, surrounded by green trees, red roofs and white walls, is clean and tidy, with strong industrial flavor and green eyes.
Jiangxi Yichun Hongshi Cement Co., Ltd. (Hereinafter referred to as Yichun Hongshi Cement) strives to become a "park-like" green ecological enterprise through intelligent management, precise control of raw material consumption and energy consumption, reduction of resource waste and pollution emissions.
Walking in the production area, the air is fresh and the trees are shady, only to see a cement bulk ash tanker is automatically loading, at the same time, automatic collection of digital laboratory, non-contact online analyzer real-time data acquisition. In the mining area, a number of spray dust trucks work at the same time, from a distance, the only dust only stays around the mining truck, and is quickly knocked down by the spray.
"Since obtaining the mining license in July 2019, the company has continuously increased its investment in the construction of green mines, promoting the construction of green mines with high standards, high requirements and all-round." Huang Yang, Deputy Chief of Electrical Section of Yichun Red Lion Cement, introduced. In 2021, Yichun Red Lion Cement was rated as a provincial green mine by Jiangxi Provincial Department of Natural Resources. Jiangxi Red Lion Cement is speeding up its progress towards high-end, intelligent and green by
reducing costs and increasing efficiency and adding "number" energy storage.
As early as the beginning of the construction of the factory in 2019, Yichun Red Lion Cement was built according to the intelligent standard, so that the traditional cement manufacturing can catch the "digital intelligent express train", realize the intelligent management of the whole process from raw material procurement to product delivery, and set a benchmark for the sustainable development of the cement industry. At present, Yichun Hongshi Cement has an intelligent cement production line which integrates energy saving, environmental protection, circular economy and comprehensive utilization of resources, with a daily output of 4500 tons of cement clinker and an annual output of 2 million tons of high-grade cement.
Now, the digitalization of this cement plant has made new progress.
In Yichun Red Lion Cement Intelligent Production Centralized Management and Control Center, staff are sitting in front of the computer, dragging the mouse, real-time monitoring of multiple modules. "Starting from energy efficiency management, the company launched APC expert optimization control, through the application of advanced sensors, intelligent algorithms, large data modeling and other technologies, integrating the experience of cement industry production equipment experts, to achieve equipment unmanned inspection, maintenance, fault prediction, remote diagnosis, etc., in order to optimize costs, save energy and reduce consumption." Huang Yang introduced that fine management can also give timely production feedback to help enterprises achieve efficient energy use.
Yichun Hongshi Cement adopts the intelligent management mode of "digitalization + intelligent equipment + remote collaboration" in the production process, and gradually realizes the unmanned production site, intelligent process control and digital production management.
Moreover, with the help of digital twin simulation system, Yichun Red Lion Cement constructs a three-dimensional visual digital twin system for cement production workshop, collects field data in real time by using 5G technology, constructs a three-dimensional visual scene, simulates the operation of equipment in production, monitors the driver's operation behavior, and realizes the operation of equipment. It ensures personal safety and production safety while improving work efficiency.
Cement industry is a high energy consumption industry, and intelligent transformation will turn "silly, big, black and rough" into a smart chemical plant. Through intelligent management, the effective operation rate of Yichun Hongshi cement production line equipment reaches 100%, the operation rate of automatic control system reaches 95%, and the energy consumption is expected to be reduced by 3% on the existing basis, resulting in benefits of about 5 million yuan per year.
"In the monitoring room, the cement production process can be controlled in real time, the quality parameters can be adjusted in time, the proportion can be optimized, the production can be instructed by one key, and the whole process can be controlled intelligently, which greatly improves the production efficiency and product stability." Huang Yang introduced that through the application of advanced sensors, intelligent algorithms, large data modeling and other technologies, the company accurately collects real-time production data and precisely controls the whole process of production.
At present, Yichun Hongshi Cement has built 64 types of equipment models, such as fans, belt conveyors, mills and cyclones, in the cement industry, with a system early warning accuracy of 95%, helping enterprises to achieve equipment life cycle management and equipment predictive maintenance. The digitalization process
of Yichun Red Lion Cement is a microcosm of Yichun City's continuous consolidation of enterprise digitalization foundation and acceleration of enterprise digitalization construction. In 2023, Yichun promulgated the "869" Action Plan for the Modernization of the Key Industrial Chain of Yichun Manufacturing Industry (2023-2026), striving to achieve full coverage of the industrial Internet in key industrial clusters and full coverage of the "Intelligent Conversion to Digital Networking" in industrial enterprises through two years, and at the same time, to promote the modernization of the key industrial chains in Yichun. Yichun City allocates 80 million yuan of special funds for technological transformation of industrial enterprises and 60 million yuan of science and technology funds annually, focusing on supporting the digital transformation of manufacturing industry and large-scale equipment renewal. With the support of the
policy, Yichun has made great efforts to build the benchmark of "small lighthouse" enterprises and "digital intelligence factory", and has established a list of relevant enterprises in advance, including 120 "small lighthouse" enterprises and 216 "digital intelligence factory" enterprises; On this basis, we will accelerate the construction of digital transformation service system, publicly solicit and select digital service providers, digital services and products for the public, and identify the first batch of 19 digital service providers and 75 "small, fast, light and accurate" digital services and products.
According to reports, next step, Yichun will make every effort to unveil the "industrial brain" of lithium and electricity new energy, building materials, medicine and textile, support key leading enterprises, and make every effort to build a national industry digital transformation benchmark demonstration.
