domestic cement industry, cost control ability has become the core competitiveness of enterprises. Faced with the continuous pressure of the market side, intelligent technology is becoming the key to break the situation-by reconstructing the production process and optimizing the allocation of resources, promoting the transformation of the industry from "scale expansion" to "quality and efficiency", and realizing the industrial upgrading of "weak capacity clearance, superior capacity breakthrough".
1. Intelligent technology: the "golden key"
to solve the dilemma of overcapacity Intelligent technology realizes the precise optimization of the whole production process through data-driven and automatic control, and comprehensively improves the production efficiency of cement enterprises. For example, the intelligent production management center of Qilian Mountain Cement in Chengxian County has realized the whole process of "one screen control" through the integration of intelligent scheduling, process control, equipment health management and energy carbon tube. Its intelligent laboratory introduces fully automatic robot and X-ray fluorescence instrument, which shortens the detection cycle by nearly half, improves the qualified rate of clinker quality to 99.5%, and truly realizes the closed-loop of "detection-control".
Conch Cement relies on Huawei Yunpangu model to build a "AI + industry" deep integration system. The prediction deviation of cement clinker strength at 3 days and 28 days is less than or equal to 1 MPa, and the accuracy is more than 85%.Through the global optimization of the burning system in the field of production optimization, the standard coal consumption is reduced by 1% on the basis of the first-class energy efficiency, and the annual carbon dioxide emission of the 5000t/d production line is reduced by more than 4500 tons. The driverless mine car system in Wuhu mining area has increased the daily ore transportation by 50%, and the electromechanical failure rate has decreased by more than 20% annually. These cases show that intelligent technology can not only reduce energy consumption and labor costs, but also directly transform into market competitiveness through quality improvement and efficiency optimization.
2. Cost control revolution: From "experience-driven" to "data-driven"
, the core value of intelligent technology lies in systematic cost reduction. In Huaikan South 7500 t/d clinker production line, intelligent optimization control system and large data AI algorithm collaborative control platform, a total of 30 AI algorithms of four types have been developed and deployed, covering the whole process of cement production, such as raw material grinding, coal powder preparation, clinker delivery, limestone crushing, auxiliary material crushing, cement grinding, etc. "APC Big Data AI Algorithm" integrates big data analysis and algorithm model to realize one-key start-stop, process intelligent control and automatic processing of abnormal conditions. Through intelligent control, the labor intensity of operators is reduced by more than 90%, the long-term operation rate of the system under all working conditions is 98.7%, the AI substitution rate is more than 98%, and the recognition rate of abnormal working conditions is more than 90%, which basically meets the conditions of unmanned driving.
The more far-reaching change lies in the synergy of the whole industry chain. Tianyang Intelligent Factory, built by Huarun Cement in cooperation with SIEMENS, uses technologies such as Internet of things, advanced analysis and unmanned driving to promote the significant improvement of personnel efficiency, equipment efficiency and product quality, and achieves a 24% reduction in carbon dioxide emissions, a 105% increase in per capita cement production, a 56% reduction in unplanned equipment downtime and a 25% increase in quality stability. This mode of "equipment health management + energy optimization" enables enterprises to shift from single link cost reduction to full life cycle cost control.
3. With the iteration of technology, the intellectualization of the cement industry will present three major directions:
the digitalization of the whole chain: the digitalization of the whole process from mining to product delivery, such as the "Conch Intelligent Mine" driverless system of Conch Cement, which has landed in more than 10 provinces in China. Seamless connection of "mine-factory-logistics" data.
AI is deeply integrated into production decision-making: AI big model will shift from single parameter optimization to global intelligent scheduling. For example, Conch Cement's "1 + 6" intelligent system promotes product quality by 20% and human efficiency by 35% through visual, predictive and NLP models. Coordinated development of
green and intelligence: the industrialization of low-carbon products such as low-calcium cement and solid waste cementitious materials will be accelerated. For example, the cementitious materials of Jidong Cement will eliminate millions of tons of urban solid waste annually, and the production cost will be lower than that of traditional cement, so as to achieve win-win economic and ecological benefits.
Intelligent technology is reshaping the competitive logic of the cement industry-from "competing for capacity and price" to "competing for efficiency and innovation" . Driven
by both the policy and the market, the enterprises that have taken the lead in completing the intelligent transformation have shown significant advantages: the average profit margin of the enterprises that have completed the transformation is 7.3%, which is 5.8 percentage points higher than that of the traditional enterprises, and the capacity utilization rate is expected to increase from 50% to 65% -70%. This efficiency revolution is not only a technological upgrade, but also a reconstruction of industrial ecology. In the future, only by taking intellectualization as the engine and promoting the comprehensive innovation of "production mode-product structure-business model", can we open up a blue sea of sustainable development in the Red Sea market with excess capacity.
At present, the cement industry is facing the double test of energy saving, environmental protection and industrial intelligence upgrading. In order to implement the relevant policy requirements and accelerate the green low-carbon transformation and high-quality development of the cement industry, China Cement Network is scheduled for September 23-24. The 14th China Cement Energy Conservation and Environmental Protection Technology Exchange Conference and the 6th Intelligent Summit Forum were held in Zibo, Shandong Province. This conference will bring together industry experts, enterprise representatives and many industry stakeholders to gather group wisdom and promote energy-saving, environmental protection and intelligent transformation and upgrading of the cement industry.
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