I. Urban problems that can be solved
???? Samcheok Cement Plant of Sampyo Group has been operated for decades, with relatively old equipment, backward management mode and production line with poor operation stability. In this situation the plant is in an urgent need to change the current situation, and Kisen International’s cement plant intelligent scheme becomes the best choice for the owner.
II. Core technologies and advantages of the case
????The project is an intelligent modification project of the top of silo processing raw material into clinker of line 6 and 7 of Korea Sampyo Plant. By modifying and upgrading the hardware and software systems, with the expert system, the stability of the whole production line is improved, the output is increased and the heat consumption is reduced. Through production operation and maintenance management system, evaluation system and other intelligent systems, the production process is predicted and the host equipment is predictably maintained, so that the all-round optimization of quality, equipment and production of the whole production line is ensured. In this way, the labor intensity of operators and equipment maintenance cost are reduced, and the quality and output of clinker are improved.
???? The project is divided into two stages: the first stage includes remote monitoring system, data interface, energy management system, platform integration, equipment management system and evaluation system. In the second stage, the operation data is obtained from the automated digital platform of the system, and a complete data chain of power consumption, quality and production process is constructed, so that the original automation function and optimization module are improved, realizing intelligent optimization control.
????The specific contents of the project mainly include 3 parts:
????Part 1: hardware upgrading
???? It mainly includes: intelligent electricity meter, network layout, secondary wind temperature measurement equipment, kiln head fire temperature measurement, grate cooler material layer and boiling monitoring, free calcium online analyzer, etc. Through hardware upgrading, the key data in production can be obtained to provide data basis for the implementation of intelligent modification.
????Part 2: management system
???? It mainly includes: remote monitoring system, energy management system, equipment management system, quality system interface and integrated intelligent platform.
???? With these management systems, the real-time monitoring of production status, statistical analysis of energy consumption of the whole plant, management of equipment inspection, maintenance and lubrication, as well as the data communication between intelligent system and plant LIMS, ERP and other systems are fully realized, and the working mode and management process of the plant are comprehensively optimized.
????Part 3: expert system
???? It mainly includes: raw material grinding mill expert system, kiln expert system, coal mill expert system and evaluation system
???? The production line is comprehensively optimized and controlled through the expert system, realizing the intelligent control and reducing the workload of operators while saving coal and electricity. The evaluation system models the main process sections and host equipment of the whole plant and predicts their operation status, which plays a certain guiding role in production and reduces unplanned shutdown of equipment and production line.
III. Application scenarios and landed projects of the case
????The project is an intelligent modification project of the top of silo processing raw material into clinker of line 6 and 7 of Korea Sampyo Plant, including supply of material, installation, and hardware and software debugging. By modifying and upgrading the hardware and software systems, the quality, equipment and production capacity of the production line are optimized, and the labor intensity of operators, equipment maintenance cost and energy consumption are reduced, so as to realize the intelligent green upgrading of the enterprise.
IV. Official and media evaluation
???? It has been nearly two years since the implementation of the intelligent system, during which all systems run stably, and it achieves a result of general excellence in the customer satisfaction survey.
