In the past, through technological transformation and equipment optimization, the actual production capacity of some enterprises far exceeded the record production capacity by 20% -40%, forming a large number of "invisible supply". Although this kind of overproduction behavior improves the efficiency of enterprises in the short run, it aggravates the overcapacity and vicious competition of the industry in the long run, and ultimately damages the healthy development of the whole industry. Nowadays, with the implementation of the new regulations and the improvement of the regulatory system, the overproduction space will be completely compressed-the daily output accounting adopts the double verification of raw clinker conversion coefficient method and inventory change method, the monthly output is introduced into the inventory correction mechanism, the annual output is checked through the material balance, and the data is connected to the unified management platform of clinker output monitoring built by the government. Any overproduction behavior will be nowhere to hide.
It is understood that Hubei Province has established more detailed provincial standards, and the supervision platform of Hubei Province has been set up, and the data of some cement enterprises such as Huaxin Building Materials has been connected to the provincial supervision platform of Hubei Province.
Two, the "compliance list" at the technical level: What should we do? As technicians, we need to act immediately:
1. It is recommended that physical calibration be carried out at least once a quarter, and calibration should be carried out immediately in case of abnormalities.
Clinker metering equipment: check the operation status of the clinker silo level meter, belt weigher and other equipment to ensure the continuity and accuracy of data acquisition. The level gauge is recommended to use non-contact measurement such as radar or ultrasonic wave to reduce the influence of hanging materials.
Energy metering instrument: electric energy meter, coal consumption metering and other equipment shall meet the requirements of GB/T 35461, and the accuracy level shall not be lower than
1.2.
Data backup and traceability mechanism shall be established to ensure that the storage period of original data is not less than 3 years to prevent data loss or tampering. The unique coding management of
measuring equipment is carried out to realize "one machine, one file", which is convenient for data traceability and supervision and verification.
(2) Mastery and verification
of accounting methods The new standard establishes a three-level accounting system of "day-month-year". Technicians need to:
1. Scientifically determine the conversion coefficient according to the actual working conditions of the enterprise, so as to avoid the deviation caused by experience.
Monthly inventory correction: perform manual or intelligent inventory at least once a month to correct the accumulated deviation caused by the error of the level gauge and the hanging material. This is the key link to improve the accuracy of data.
Error analysis capability: When the deviation between the two accounting methods exceeds 5%, it is necessary to have the ability to quickly locate the source of error-is it the failure of metering equipment, improper parameter setting, or process fluctuation? Carry out "blind sample test" or "cross validation"
regularly to verify the accuracy of the metering system with materials of known weight.
Establish an early warning mechanism for abnormal data, and start the investigation immediately when the daily output fluctuates by more than 10% or deviates significantly from the historical data.
(III) Fine adjustment of process operation — — core key: reducing production without increasing consumption
, which is the most realistic challenge faced by many enterprises at present. In the past, through technical transformation, the actual capacity of the kiln line has far exceeded the record capacity, and the equipment system and operation habits have been adapted to high-load operation. If the daily output is simply and roughly reduced to the compliance range without optimizing the process parameters, it is likely to lead to the increase of energy consumption index and quality fluctuation of the system. Therefore, compliance production is not as simple as the word "production reduction", but a set of technical adjustments.
1.
Optimization of operating parameters: Under low load conditions, it is necessary to re-optimize the kiln speed, decomposition furnace temperature, secondary air temperature and other key parameters. For example, after reducing the feeding amount, the kiln speed can be reduced appropriately, but it is necessary to avoid too low to cause too long retention time of materials in the kiln; the temperature of the decomposition furnace can be reduced appropriately, but it is necessary to ensure the decomposition rate of raw materials.
Pay attention to system balance: pay close attention to the balance of wind, material and coal in the system during production reduction to prevent system fluctuation caused by mismatch of wind and material. According to the production capacity of the record, find out the appropriate process parameters, so as to revise the operation instructions.
2.
Burner adjustment: adjust the proportion of internal and external air of the burner and the position of the coal injection pipe according to the low load condition to ensure the full combustion of the pulverized coal and avoid the heat loss caused by incomplete combustion. Matching of
waste heat power generation system: the waste heat power generation will decrease after production reduction, so it is necessary to adjust the operating parameters of the steam turbine to maintain the system efficiency. Optimization of
equipment operation: under low load, frequency conversion regulation can be considered for some fans and water pumps to reduce power consumption.
3.
Establish a quality early warning mechanism under low load conditions, and immediately start the adjustment plan when the key indicators show abnormal trends.
Three, the deep logic of overproduction management: Why must compliance?
Some technicians may ask, "In the past, it was all right to overproduce. Why is it suddenly strict now?"?
In 2025, the utilization rate of cement clinker production capacity in China will be less than 50%, which is seriously lower than reasonable level of 75%. Overproduction further aggravates the imbalance between supply and demand, leading the whole industry into a vicious circle of "price war-loss-lower price". In 2025, many listed companies suffered serious losses, and industry profits fell by more than 85% compared with 2021. If production capacity is not strictly controlled, the whole industry will face a survival crisis.
Second, the policy combination has been formed.
The new standards are only part of the regulatory system. The Work Program for Steady Growth of Building Materials Industry jointly issued by six departments in 2025 clearly requires that "overproduction is strictly prohibited". The cement industry has been incorporated into the carbon market, and overproduction cement enterprises will face higher carbon quota costs by 2027. In addition, environmental protection, energy consumption, quality and other "five rulers" standards are also continuing to tighten. It can be said that the space for overproduction has been "surrounded on all sides" by the policy.
Third, the ability of data supervision has been upgraded.
In the past, supervision mainly relied on self-reported data or spot checks by enterprises, and there was a problem of "information asymmetry", which was urgently rectified after being exposed by environmental protection supervision. Now, the new standard provides technical support for the government to establish a unified clinker production monitoring platform, which may realize "online monitoring, real-time early warning and remote verification" in the future. The progress of technological means makes violations nowhere to hide.
4. Technical dividends of compliance production: from "passive coping" to "active benefit"
Some technicians may regard compliance production as a "burden", but in fact, strict implementation of standards can also bring technical dividends:
1. Enterprises can obtain real and accurate output data, and provide reliable basis for production scheduling, cost accounting and market analysis. For example, through accurate energy consumption data, we can find the potential point of energy saving and consumption reduction.
2. After the implementation of standardized measurement management in an enterprise, the unplanned downtime of equipment decreased by 30%.
3. Although compliance production may "lose" part of its output in the short term, it avoids greater compliance risks.
5. Action suggestions
for technical personnel In the face of new standards and requirements, it is suggested to take immediate action from the following aspects:
1. Standard preparation experts or third-party organizations can be invited to conduct training to ensure accurate understanding and implementation.
2.
3. It is suggested to hold a special meeting on compliance production once a month to analyze data deviation and make continuous improvement.
4. It is suggested that a special working group led by the technical director be set up to clarify the responsibilities of various departments and ensure that the standards fall to the ground without dead ends.
Conclusion
In 2026, the cement industry is at the crossroads of transformation. In the past, the mode of overproduction and low-price competition has come to an end, and in the future, we must rely on technological upgrading, management optimization and compliance management to achieve high-quality development. As front-line technicians, we are not only the executors of standards, but also the promoters of industry transformation. Strict compliance production is not a "magic spell" to restrict us, but a "talisman" to protect the healthy development of the industry.
Let's take the implementation of the new standard as an opportunity, start from the technical details, start from the strict calibration of measuring instruments, and truly put compliance production into practice. This is not only responsible for the enterprise, but also for the industry and our own career development.
浙公网安备33010802003254号