Application case of energy management system in 
a cement enterprise in Hunan

As a cement enterprise in the high-energy consumption industry, how to keep up with the times and achieve green economy and low-carbon development has become a difficult problem. The application and implementation of Nanjing Kaisheng energy management system in a cement enterprise in Hunan makes the energy consumption problem of the factory invisible, helps the enterprise identify and tap the energy-saving opportunities in the production process and make correct decisions.
        A Cement Co., Ltd. in Hunan has an old 5000t / d clinker production line, with an actual annual clinker production capacity of 1.5 million tons and an annual cement production capacity of more than 1.6 million tons. The main energy medium consumption is electricity, coal, gas and water. The comprehensive power consumption of clinker is 50kwh / t, the standard coal consumption of clinker is 103kwh / T, and the comprehensive power consumption of comparable cement is 95.68kwh/t, which is less than the national limit, However, it has not reached the advanced value of national cement enterprises. The production quota is more than 200, with surplus personnel. In response to the national requirements for energy conservation and emission reduction, adapt to the fierce market competition, achieve cost reduction and efficiency increase, and ensure that the production line maintains a leading index level and management level in the industry, the plant is constructed in Nanjing Kaisheng International Engineering Co., Ltd

Project background

High energy 
consumption
 cement industry
Intelligent
 transformation
 of 5o0ot / d 
clinker old line
Excess production
 personnel
The index is not 
advanced
National policy call
Market competition
 pressure

Customer pain points

The power consumption of the equipment is abnormal, which cannot be manually checked and handled in time. There are great potential safety hazards and equipment failure risks.

Abnormal power consumption and
 potential safety hazards

Extensive management and vague energy flow

Relying on manual copying, the calculation is cumbersome and can not be approved. The energy consumption of single product is not clear and can not be analyzed as a whole.

Excessive energy consumption 
and high energy cost

Enterprises do not have much energy consumption, large output and complex production line. The monthly energy consumption cost is too high and the energy efficiency ratio is low

Manual operation and maintenance,
 low management efficiency

Without information and visual management system, comprehensive energy consumption monitoring and fine management cannot be carried out.

Project content

Transformation of data 
acquisition system and 
measuring instrument

Network system 
optimization and 
transformation

Customization, deployment
 and commissioning of 
energy management
 system

Research on energy saving
 application of system

Implementation process

Project research
Collect relevant drawings
Site investigation
Demand consultation
Confirmation range
Necessary information collection
Meter installation
Meter, communication,
 network and server debugging
System deployment
Acquisition and network 
equipment installation
Detailed research
software function

conceptual design

project 
implementation 

technical standard
Functional parameters
Hardware selection
Implementation plan
Data correctness verification
Data stability verification
Equipment stability verification
Network stability verification
Software stability verification
Software functional verification
Project verification
System operation
Acceptance and handover
Regular maintenance
Expert services
Operation report

Project results

After the energy management system independently developed and implemented by Nanjing Kaisheng was officially put into operation, each workshop began to use the visual analysis method to analyze the energy-saving space, found and tap a lot of energy-saving potential, and achieved good energy-saving results. In addition, remarkable achievements have been made in reducing staff, increasing efficiency and efficient operation.

Direct economic benefits

The comprehensive power consumption of clinker in the old line reaches 49kwh / T, a decrease of 1kwh / T or 2% compared with that before the implementation of the project. The annual production lasts 280 days and the annual power consumption cost is saved by 427000 yuan

Streamlining personnel and institutions

Reduce 2 report statisticians and 1 energy patrol inspector. According to the average financial cost of personnel of 90000 yuan / year, 270000 yuan of direct economic cost can be saved every year

Management and awareness improvement

The depth and quality of management have been improved by leaps and bounds, the awareness of active exploration and energy conservation has been enhanced, and the quality of personnel has been greatly improved

Project summary

         Nanjing Kaisheng energy management system has been in stable operation on site for more than half a year. The cement enterprise has achieved very good benefits in reducing energy consumption, improving efficiency, ensuring operation, reducing personnel and enterprise management. It not only strengthens the paperless digital office efficiency of energy audit management, but also changes the passive data analysis mode of energy management in an all-round way, Let the comprehensive diagnosis and analysis function in the era of big data be practically applied to all links of energy conservation, from passive analysis of data to active data analysis and active management strategy implementation, so as to find out the family background and control the energy-saving indicators. At the same time, due to the good energy-saving effect of the energy management system, it has received good social effect.

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