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

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

How to ensure the safe and stable operation of equipment has always been a core issue in the production process of steel enterprises. Especially for the inspection of equipment operation process, it is of utmost importance.

Using manual inspection requires high quality, sense of responsibility, and ability from personnel, but it is also difficult to ensure that inspection personnel arrive on time and conduct standardized inspections according to the set standards. It also requires personnel with "engineer" experience to conduct data inspection and analysis, and the data volume is large, cumbersome, and difficult to effectively summarize and statistically analyze.

By investing a large number of personnel and expenses, we ensure stable production. The resulting management difficulties and increasing management costs have led to overcapacity, intense competition, and significant cost increases.

Solutions to the above-mentioned issues

01. Replace the compressed air tank and intelligent pulse valve with new ones, and use the intelligent pulse valve and intelligent edge hardware independently developed by Xiechang  to remotely transmit the real-time working status of the intelligent valve to Xiechang's independently developed "Clean Dust Cloud" big data platform. Through the mobile APP, the "mobile inspection" of the pulse valve can be achieved, allowing the dust collector to be in "palm" mode;

02. Using an information platform to automatically collect sensor detection data, and based on a mobile app to visualize and automate inspections, making the effective energy consumption of equipment visible. The PC end of Clean Dust Cloud completely eliminates the problems of difficult recording, querying, and management of historical operating data of devices, truly realizing the "standardization", "automation", and "unmanned" of device inspection;

03. The automatic alarm function of the "Clean Dust Cloud" mobile app: it alerts immediately upon discovering abnormal equipment operation, hidden dangers, etc., and "actively" pushes information to equipment maintenance personnel, solving the huge production capacity loss problem caused by untimely discovery of hidden dangers and the heavy workload of reporting, summarizing, and analyzing on site, and recovering corresponding economic losses for owners;

04. Xiechang is a professional manufacturer of pulse valves. Intelligent pulse valves can effectively display the real action process to owners through the "clean dust cloud", and optimize system control effectively with the support of data. For example, it is possible to predict the lifespan of valves and prepare parts in advance to avoid affecting the service life of filter bags due to delayed discovery; By cooperating with pressure/differential sensors, concentration sensors, etc. of the dust collector, it helps users intelligently monitor the damage of the filter bag. If the filter bag is damaged, the dust cleaning cloud actively notifies the operation and maintenance personnel in minutes, so that users can stop losses in a timely manner;

05. The intelligent pulse valve can accurately measure the real-time gas consumption of the valve during operation and transmit it to the clean dust cloud. Based on an intelligent algorithm model, the clean dust cloud displays the actual effective energy consumption to the owner in the form of a mobile app, PC monitor, and industrial screen, making the effective operating energy consumption of the dust collector "visible" to assist the owner in effectively optimizing the dust collector's work, extending the use time of the dust collector, and supporting the owner's "dual carbon" strategy;

Specific cases of intelligent solutions

Case 1

A large state-owned steel group (Shandong)

A certain steel group: Dust removal for the bottom material of the 1 # machine head (120 valves), which belongs to the renovation of an old project

Solution: The customer retains the control system and uses the Xiechang 3-inch submerged intelligent valve (DC24V), pressure transmitter, acquisition cabinet, and clean dust cloud

Implement functions

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

Cleaning 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 May 2020, the backend diagnosis showed abnormal on-site work; After verification, it was found that there was a gas leak on site

Abnormal diagnosis: The pulse valve worked abnormally in October 2021; After verification, it was found that the customer's original control circuit had an abnormal open circuit

Energy consumption analysis: In December 2020, the delivery site verified the customer's compressed air consumption; After verification, it has been found that excessive pulse width results in compressed air waste and energy consumption that is 2.3 times the theoretical value

Case 2

A large state-owned steel group (Guangxi)

A certain steel group: Three time (504 valves) dust collectors for steelmaking zone 1, three time (448 valves) dust collectors for zone 2, and three time (448 valves) dust collectors for zone 3, all of which are newly launched projects

Solution: Control the dust collector with a closed-loop controller, using Xiechang Intelligent Valve (DC24V)+pressure sensor+acquisition cabinet+BHK closed-loop controller

Implement functions

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

Cleaning 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 bag analysis: big data calculation based on export dust concentration meter+differential pressure transmitter

Achieve results

Abnormal diagnosis: In March 2022, the backend diagnosis showed that the pulse valve was working abnormally on site; Verified as on-site gas outage

Abnormal diagnosis: Abnormal pressure in the airbag in May 2022; After verification, it was found that the customer's compressed air pipeline leaked air, causing insufficient cleaning pressure and triggering an alarm

Abnormal diagnosis: August 2022 pulse valve abnormality+abnormal airbag pressure; After verification, it was found that the compressed air on site had stuck the airbag membrane with internal organs

Case 3

A large state-owned steel group (Inner Mongolia)

A certain steel group: dust collectors for furnace 4 # (192 valves) in steelmaking zone 2 and furnace 6 # (192 valves) in zone 2, both of which are new projects

Solution: Control the dust collector with a closed-loop controller, using Xiechang Intelligent Valve (DC24V)+pressure sensor+acquisition cabinet+BHK closed-loop controller

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 February 2021, the backend diagnosis showed that all on-site operations were abnormal; Verified as on-site shutdown for major repairs

Abnormal diagnosis: abnormal pulse valve and abnormal airbag pressure in August 2021; After verification, it was found that there was a malfunction in the pressure regulating valve group of the compressed air pipeline on site.

Case 4

A large state-owned steel group (Guangxi)

A certain steel group: desulfurization refining 4 # (66 valves) dust collector, desulfurization refining 5 # (260 valves) dust collector, both of which are new projects

Solution: Control the dust collector with a closed-loop controller, using Xiechang Intelligent Valve (DC24V)+pressure sensor+acquisition cabinet+BHK closed-loop controller

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

Achieve results

Abnormal diagnosis: In September 2021, the backend diagnosis showed that the pulse valve was working abnormally on site; After verification, it was found that the on-site dust collector was temporarily shut down for maintenance of the ash conveying system cage

Abnormal diagnosis: Abnormal pressure in the airbag in June 2022; After verification, it was found that the pressure of the compressed air source on site had decreased.