What is cement production line simulation technology?

The cement production line is a cement equipment production line composed of a series of equipment for producing cement. It mainly consists of processes such as crushing and pre-homogenization, raw material preparation and homogenization, preheating and decomposition, cement clinker burning, cement grinding and packaging.

The national "Online Simulation Technology Exchange Meeting for Energy Saving and Emission Reduction in the Cement Industry" hosted by the Ministry of Industry and Information Technology was held in Wu'an City, Hebei Province. At the meeting, Zhou Changyi, director of the Comprehensive Utilization Department of the Ministry of Industry and Information Technology, said that my country will promote the application of online simulation technology in cement and other industrial fields. It is understood that this technology passed the scientific and technological appraisal of the Ministry of Industry and Information Technology at the end of last year.

According to reports,Cement production online simulation technology establishes a precise mathematical model of the entire physical process based on the design parameters and characteristic parameters of operating equipment and systems, and then enters the model through the real operation distribution control system and database, so that the simulation system directly obtains on-site operating status and operation actions, performs real-time simulation calculations on the current status, and tracks the actual operation of the production line.

The system needs to be customized based on the actual situation of the production line, such as equipment operation status, production management status, and supporting equipment throughout the factory. The implementation cycle of the entire system, including research and development, debugging, data collection, optimization analysis, etc., takes more than a year, and the systems installed in different production lines are different. The installation of the entire system is not done in one go, but the functions of each subsystem are gradually put online. For example, the management system or control system can be put online first, and then other systems of the production line can be gradually put into digital control. This technology is applied in Wu'an Xinfeng Cement Co., Ltd.

It is reported that after the application of this technology, the standard coal consumption per ton of clinker can be reduced by 8.6 kilograms, and the comprehensive power consumption of clinker is reduced by 5 kilowatts per hour. A cement clinker production line with a daily production of 5,000 tons can save about 15,000 tons of standard coal throughout the year, save about 8 million kilowatt-hours of electricity, reduce carbon dioxide emissions by about 30,000 tons, and reduce the cost of cement per ton by more than 10 yuan. Relevant personnel from Guangdong Asia Imitation Technology also said that it costs 25-28 million yuan to equip a production line with an energy-saving control system. The specific price is determined based on the actual production line conditions. Cement companies can recover the cost in about a year.

Compared with cast-in-place concrete, factory-produced precast concrete has many advantages:

Safety: For construction workers, the relatively stable working environment in the factory has a higher safety factor than complex construction site operations;

Quality: The quality and workmanship of building components can be better controlled through mechanized production;

Speed: Standardizing the size and characteristics of prefabricated parts can significantly speed up installation and construction project progress;

Cost: Compared with traditional on-site mold making, molds in the factory can be reused and the overall cost is lower; mechanized production requires less labor. As labor costs continue to rise, the cost advantage of large-scale production of prefabricated parts will become more obvious.

Environment: The workload of construction sites using prefabricated parts is significantly reduced, and dust pollution and noise pollution are significantly reduced.

Disadvantages of prefabs:

The factory requires a large area of ​​storage yard and supporting equipment and tools, and the storage cost is high;

A professionally trained construction team is required for installation;

Transportation costs are high and risky, which determines its market reach is limited.