Project Information
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End UserHubei Century Xinfeng Leishan Cement Co., Ltd.
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LocationHubei, China
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Scope of SupplyDCS
Overview
The client's factory has been in operation for nearly 20 years with outdated equipment and low automation level. The on-site control electrical components are from various brands with incompatible protocols. The client urgently needed a comprehensive solution to integrate various on-site equipment, improve automation, reduce energy consumption, and enhance enterprise management capabilities.
Solutions
Hollysys provided the factory with DCS and an upgrading solution. The HOLLiAS MACS-K system supports international standard protocols such as OPC and MODBUS, allowing convenient integration with the raw material quality system (QCS), weighbridge system, and the main substation protection system. Using the Profibus_DP bus protocol, it directly connected with the vertical mill PLC, grate cooler PLC, transducer, intelligent motor controllers, and intelligent PA instruments without additional software or hardware, saving cables, costs, and making maintenance more convenient and control safer.
Results
Without altering the original equipment protocols and operation, the solution enabled the networking of the entire plant's equipment for centralized control, facilitating centralized management, equipment automated notifications, and maintenance, significantly reduced the impact of unexpected equipment shutdowns. It enhanced management efficiency and reduced costs. For specific equipment, the preheater temperature control was automated, with the normal temperature deviation being less than 6°C. This solution stabilized the cement kiln burning zone temperature and grate cooler pressure control, optimized the rotary kiln and preheater control systems, reduced the energy consumption of the burning system by 2%-3%, and improved mill load control, saved 3%-5% on electricity. Overall, the company achieved a total cost saving of 1.3% with our solution.