Advanced Series Report
Rooted in the front line: from patrol fitter to process technician
in 2001, Qiu Guangming joined Tapai Group, starting from patrol fitter. Since then, in more than 20 years, he has successively served as central control coal mill operator, vertical mill operator, kiln operator, duty director, deputy director of firing central control, and has grown step by step into a central control director and a second-level technician. Along the way, he has always adhered to the central nervous system of cement production-the central control room, and interpreted the professional spirit of "doing one line, loving one line and specializing in one line" day after day. In addition to his
work, he insisted on studying technology, accumulating operational experience, and gradually grew from a grass-roots fitter to a backbone of technology that is proficient in the whole process of kiln and mill operation. The central control room is the "brain" of cement production, and every instruction of the operator is related to the stable operation and energy consumption level of the kiln system. Qiu Guangming is well aware of the responsibility on his shoulders, and always adheres to the principle of "stability first, step by step, quality and consumption reduction in both directions", leading the team to continuously optimize the blending process and improve the utilization rate of alternative fuels.
Benchmarking and tapping potential: Energy consumption indicators have been refreshed
year after year to reduce costs and increase efficiency, and Qiu Guangming has focused on the "big head" of coal consumption. In 2025, under his meticulous control, the coal consumption of Tapai in Fujian dropped sharply from 103.52 kgce/t in 2024 to 90.83 kgce/t, down 12.69 kgce/t; The comprehensive energy consumption of clinker was reduced from 105.68kgce/t to 93.43kgce/t, a decrease of 12. Behind this series of figures is the meticulous operation and unremitting efforts of him and his team for countless days and nights.
In 2026, facing the annual target of "92kgce/t of standard coal consumption per ton of clinker and 12% of alternative fuel substitution rate" put forward by the company, Qiu Guangming led the central control team to face difficulties. Under the severe situation of implementing "double control" of daily and annual production capacity control and superimposing coordinated kiln shutdown and peak staggering production, the clinker production capacity has been greatly reduced, but he has realized that the energy consumption per ton of clinker has not increased but decreased in the operation of production reduction. From January to July, the average standard coal consumption of clinker is 90.36kgce/t, which is 0.47kgce/t lower than that of 90.83kgce/t in 2025, and the total coal replacement rate is 12.14%, which is 0 higher than that of 11.68% in last year. This "one drop and one rise" is a real benefit.
Precise control: Benefit
from every gram of coal. "Only when the operator has clear thinking and unified direction, can system be balanced and stable." This is what Qiu Guangming often talks about. On the center console, the dense curves on the screen are their battlefields. Combining with the real-time operation status of the system, he dynamically combs and formulates reasonable "process control parameters" for the operation of each system from time to time, such as the outlet temperature of the decomposition furnace, the amount of head coal, the current of the kiln, the oxygen content of the smoke chamber, etc., and tracks the implementation of the operation. We will vigorously promote the application of MFA automatic control system and its unified and stable operation. Through data-driven and standardized operation, key data such as temperature, pressure, load and air volume are tracked in real time, and parameters are fine-tuned in advance according to material changes and equipment status. Unified operation ideas, unified adjustment direction, eliminate blind operation, make every effort to maintain the balance and stability of the kiln system, and lay a solid foundation for improving the amount of alternative fuel blending. Operation is not behind closed doors, they take the initiative to link up with the quality department, implement the "combination of blending and burning", keep a close eye on the working conditions in the kiln, clinker weight per liter, free calcium and other key indicators, timely optimize and adjust the three rate values of grinding raw materials, adapt to the production conditions of a large proportion of alternative fuels from the source of ingredients, so as to achieve stable production, stable quality and coal reduction.
Tackling alternative fuels: gnawing down the "hard bone"
of crusting and blocking, and increasing the use of alternative fuels is a key measure to reduce coal consumption. Qiu Guangming put forward the goal of "leaping from" being able to use "to" being good and multi-purpose ". On the basis of ensuring the stable operation of the kiln system, he led the team to increase the consumption of dry and wet black ash, biomass flocs and RDF as much as possible, and steadily improve the substitution rate of alternative fuels.
However, this road is not smooth, behind the brilliant achievements, there are many realistic tests. A large number of alternative fuels also enrich the harmful components of the kiln system. Technological problems such as blockage of preheater, long secondary kiln skin in kiln, ring formation and fluctuation of clinker quality come one after another. A slight deviation in the central control operation will cause fluctuations in working conditions, which will not only affect the stability of production, but also cause a rebound in energy consumption. In the face of contradictions, the team firmly adheres to the working principle of "stability first, step by step, stability, quality and consumption reduction in both directions", and takes the stability of the kiln as the premise of all work. Fine operation is far from enough, they jump out of the traditional operation thinking, take the initiative to "embrace" technological innovation, and use technological innovation to crack the pain points caused by mixed burning. In view of the risk of skinning and material accumulation caused by alternative fuels, air cannons, anti-skinning microcrystalline materials and acoustic soot blowers are applied to key parts prone to skinning, such as smoke chamber slopes, necking, discharge pipe flap valves and material scattering boxes, to alleviate the hidden dangers of material accumulation and collapse in preheaters; Pay close attention to the commissioning and operation of the two-line bypass ventilation project, strictly control the chloride ion of the hot raw material entering the kiln below 2%, and curb the circulation and enrichment of harmful components; optimize the kiln brick masonry process in the transition zone, adopt the spiral masonry method, and focus on solving the persistent problems of long secondary kiln skin and ring formation in the transition zone, so as to ensure the long-term stable operation of the kiln system. If the kiln condition is stable, the alternative fuel can be added, used and used well, and the solid waste resources can be transformed into the real benefits of saving coal and reducing costs.
Lead the team and educate people: cultivate a central control team
that "understands technology and is good at operation". As the director of the central control room, Qiu Guangming not only has excellent skills, but also pays more attention to team building. They can play a leading role in their work, dare to take on the responsibility and be good at mobilizing the enthusiasm of the team. In terms of technology inheritance, he unreservedly imparts his operational experience accumulated over the past 20 years to young employees, and constantly improves the overall technical level of the team. At the same time, he promotes the standardization of central control operation, through unified operation ideas and directions, so that the team can respond quickly and coordinate in dealing with complex working conditions.
Colleagues' evaluation of Qiu Guangming is highly consistent: "Steady, meticulous, and resourceful." The square-inch central control console connects the whole production line. There are no bold words, only concentration and perseverance in front of the screen. There is no magnificent feat, only the parameter adjustment of sticking to the market day after day and striving for excellence. In the adversity of reducing production and staggering peak and complex working conditions, we should keep the system stable and tap the potential of cost reduction, and interpret the role of "coal saving pioneer" with a group of continuously optimized energy consumption data.
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