Application Case of the Guangde Xinhang Southern Powder Grinding Intelligent Control System
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Project Overview
Guangde Xinhang Nanfang Cement Co., Ltd. operates a cement grinding station with an annual capacity of 900,000 tons, employing an open‑flow system that combines a 160–180 roller press with a 4.2 × 13 m ball mill. The roller press is part of a closed‑circuit system, while the ball mill operates in an open flow configuration, without a dynamic separator. The design production capacity is 180 t/d. To advance this cement grinding station as a “demonstration project for intelligent and information‑based cement grinding operations,” Guangde Xinhang Nanfang Cement Co., Ltd. (hereinafter referred to as “Xinhang Nanfang”) has commissioned China Materials Bangye (Hangzhou) Intelligent Technology Co., Ltd. (hereinafter referred to as “China Materials Bangye”) to implement an intelligent control system for cement grinding.
Application Effect of the Intelligent Control System
1. APS One-Click Start/Stop: The startup time has been reduced from 10–15 minutes under manual operation to just 3 minutes, effectively lowering the idle running rate of the main equipment and cutting power consumption by approximately 400 kWh. According to statistical calculations, each start-up and shutdown cycle can save around 600 kWh in total.
2. The intelligent control system for cement mills significantly improves operating conditions, achieving an optimal balance among air flow, material throughput, and the work output of the roller press, thereby effectively increasing production while reducing energy consumption.
(1) Reduce fluctuations in key process variables to stabilize cement mill operations.
(2) According to the monthly reports of Xinhang Southern Cement Plant from November 2017 to March 2018, during the three-month periods before and after the commissioning of the intelligent control system, the specific electricity consumption per ton of cement exhibited a clear downward trend, with an average reduction of 1.2% to 1.5%.
(3) According to the reporting data from the Xinhang Southern Cement Plant: in December 2017, the average hourly production of 425‑grade cement was 174 t/h; by March 2018, this had increased to 186 t/h, representing an average increase of 12 t/h. In April, under conditions permitted by auxiliary equipment, peak production could reach 220 t/h for several hours. Electricity consumption per ton of cement improved significantly: in December 2017, electricity consumption was approximately 28.53 kWh/t, while by March 2018 it had decreased to about 27.18 kWh/t, resulting in an average reduction of 1.35 kWh/t.
3. The intelligent control system for cement mills has significantly improved cement quality, effectively reducing the standard deviation of specific surface area from 8.4% to 7%, and increasing the pass rate for specific surface area from 80.36% to 90.24%.
4. The intelligent control system for cement mills is highly adaptable to most on-site operating conditions, enabling stable control of four major cement grades—325, ordinary 425, high-speed rail 425, and 525—and achieving an operational availability of over 95% across all operating conditions.
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