Case Study And Customer Feedback on Smart Dust Filter Solution - Cement Industry Chapter

Case Study and Customer Feedback on Smart Dust Filter Solution - Cement Industry Chapter

Existing problems in the working conditions of the cement industry

1. Manual inspection is time-consuming and laborious

Manual inspection is time-consuming, laborious, and labor-intensive. On site inspection, recording, reporting and summarizing after inspection, and manual analysis in the later stage all require a large amount of labor, and the corresponding management personnel and management costs are very high. There are certain safety risks in on-site inspection by inspection workers;

2. Difficulties in standardized management of inspections

Difficulty in standardizing inspection management, unable to conduct timely inspections and effective supervision and assessment of inspection workers according to standard operations;

3. High requirements for personnel skills

High requirements for personnel skills, lack of certain technical abilities and experience, and inability to promptly identify potential hazards on site;

4. The dust collector has been used for too long

The dust collector has been used for too long, resulting in air leakage from the pulse valve of the air bag, rotting of the on-site electrical control box, and disorderly wiring. The fixed hole of the pulse valve on the dust collector air bag has internal thread slippage, and the pulse valve is severely leaking air, resulting in a significant loss of compressed air;

5. Compressed air consumption cannot be counted

The compressed air consumption cannot be counted. Once the pulse valve diaphragm is damaged or malfunctioning, the compressed air consumption will increase sharply;

6. Bag damage without warning or alarm information

There is no warning or alarm information for bag damage. Once a bag is damaged and the emissions exceed the standard, if it cannot be resolved in a timely manner, the bags in the same compartment that are filled with dust will be scrapped.

Intelligent solutions are applied here

Real time comprehensive monitoring of equipment operation to ensure production safety; Preliminarily replacing "workers", utilizing the handheld inspection function to reduce the labor cost of equipment maintenance and significantly improve labor efficiency;

Based on technological means, using new materials and processes to solve problems that require the experience of engineers, replacing "engineers", solving problems such as bag leakage and energy consumption monitoring, truly achieving one-stop integration and recording of all relevant data and information, facilitating data management;

By using scientific algorithms such as big data analysis, intelligent algorithms, and data models to replace expert experience, solve problems, conduct expert diagnosis, life prediction, and energy efficiency analysis, provide more rational and scientific control solutions, reduce equipment failure risks, minimize downtime and unnecessary downtime losses, and extend equipment service life;

Providing intelligent control over the equipment's dust cleaning system ensures the optimal operation of the dust filtration system. To avoid collapse caused by poor dust cleaning effect, safety accidents during manual inspection, and high spraying temperature, ensure stable operation of equipment, save energy, safety, and increase efficiency.

Specific cases of intelligent solutions

Case 1

A large state-owned cement group (Hubei)

A certain cement group: dust collectors for cement mills (96 valves) and kiln tails (288 valves), both of which are old project renovations

Solution: The customer retains the control system and uses Xiechang intelligent valve (AC220V)+collection cabinet+dust cloud cleaning

Implement functions

Palm inspection: real-time detection of pulse valve spraying, response time<5s;

Blowing analysis: Pulse valve spray statistics, unified analysis

Energy consumption analysis: Analyzing the energy consumption of the dust collector's gas source based on the blowing volume

Achieve results

Abnormal diagnosis: In June 2021, the backend diagnosis showed abnormal on-site work; After verification, it was found that there was an abnormal gas leakage on site;

Abnormal diagnosis: The pulse valve worked abnormally in August 2021;

Verified as abnormal in the customer control system

Energy consumption analysis: In April 2021, the delivery site verified that the customer's blowing control was abnormal; After verification, the waste energy consumption of high-pressure gas source is 2.8 times the theoretical value

Case 2

A large state-owned cement group (Guangxi)

A cement group: Dust collector at kiln tail (50 valves), renovated for an old project

Solution: The customer retains the control system and uses Xiechang Intelligent Valve (DC24V)+single valve adapter+distributed collector+pressure transmitter

Implement functions

Palm inspection: real-time detection of pulse valve spraying, response time<5s;

Blowing analysis: Pulse valve spray statistics, unified analysis

Energy consumption analysis: Analyzing the energy consumption of the dust collector's gas source based on the injection volume

Achieve results

Abnormal diagnosis: In June 2022, the backend diagnosis showed abnormal on-site work; After verification, it was found that the on-site spray pipe had fallen off

Abnormal diagnosis: The pulse valve worked abnormally in July 2022; After verification, it was found that the aging and short circuit of the customer's dust cleaning control system cable caused an alarm

Case 3

A large state-owned cement group (Fujian)

A cement group: Dust collector at kiln tail (170 valves), renovated for an old project

Solution: The customer retains the control system and uses Xiechang Intelligent Valve (DC24V)+single valve adapter+distributed collector+pressure transmitter

Implement functions

Palm inspection: real-time detection of pulse valve spraying, response time<5s;

Spray analysis: Pulse valve spray statistics, unified analysis

Energy consumption analysis: Analyzing the energy consumption of the dust collector's gas source based on the injection volume

Achieve results

Abnormal diagnosis: In June 2022, the backend diagnosis showed abnormal on-site work; After verification, it was found that the on-site spray pipe had fallen off

Abnormal diagnosis: The pulse valve worked abnormally in July 2022; After verification, it was found that the alarm was caused by aging and short circuiting of the customer's control system cables

Case 4

A large state-owned cement group (Zhejiang)

A certain cement group: Coal mill (144 pieces) bag dust collector, renovated for an old project

Solution: The customer retains the control system and uses Xiechang explosion-proof valve (AC220V)+single valve adapter+distributed collector+pressure transmitter+single box room differential pressure transmitter+single box room concentration sensor

Implement functions

Palm inspection: unmanned inspection, fault alarm, precise positioning of fault points

Spray analysis: Pulse valve spray statistics, unified analysis

Energy consumption analysis: Analyzing the energy consumption of the dust collector's gas source based on the injection volume

Leakage analysis: algorithm based on the combination of single chamber differential pressure transmitter and concentration mete

Achieve results

Palm inspection: The coal grinding area belongs to the explosion-proof area and cannot be manually inspected; Short downtime for maintenance and high skill requirements for inspection personnel

Abnormal diagnosis: fault alarm, precise location of fault point; Accurately locate the fault point and maximize work efficiency within limited downtime

Energy consumption analysis: statistical analysis of compressed air consumption to prevent leakage points and membrane leakage