1、 Topic background

In recent years, the cement industry has shifted from mandatory large-scale and long-term staggered production and kiln shutdowns due to national environmental protection requirements, which has naturally led to an increase in production costs and a reversal of supply and demand balance, resulting in continuously rising cement prices. This situation has become a new operational norm. In this new situation, every cement enterprise is facing new opportunities and difficulties. It is obvious that how to find effective ways to significantly increase the effective capacity of existing cement depots with minimal input and maximum output under limited conditions has become the winner of market competition for enterprises.

As long as the eyes are inward, it is not difficult to see that the efficiency of the finished product reserve operation in the cement warehouse has begun to significantly restrict the profit opportunities of the high price cement market demand. Without a doubt, whoever has more cement shipments and smoother traffic, their net income will be higher.

Due to historical development reasons, the larger the capacity of cement depots, the more problems there are, which seriously restrict the production and sales realization under favorable price situations. Currently, cement depots using pneumatic unloading technology generally have the following problems:

Due to the impossibility of forming a complete flow during unloading in the warehouse, there are often over 30% of the storage capacity of offset dead materials in the warehouse.

2. Due to the high storage position, it is easy to cause the powder material at the bottom of the warehouse to be crushed and blocked, so it is necessary to control the storage position to keep 20% of the storage capacity empty.

3. As the offset and dead material in the warehouse continue to expand and block the material path, the operating efficiency of the Roots blower continues to decrease. Generally, simple open-loop technology is used for unloading, which leads to rough fluctuations in flow control. When collapsed flushing occurs in the warehouse, it is easy to cause overload and blockage in the subsequent transportation and lifting process, leading to chain failures and management and sales conflicts.

4. The continuous growth of dead materials leads to a thorough cleaning and maintenance every 2 years on average, which not only consumes labor and time (more than 200000 yuan per time for a 10000 ton cement warehouse), greatly reduces operating efficiency and increases production costs, but also easily leads to serious cleaning and injury accidents.

2、 Opportunities brought by innovation

Nowadays, a disruptive technological innovation has emerged in the cement industry, specifically targeting and thoroughly addressing the above-mentioned problems, which is powder flow control. The use of powder flow control to renovate old cement warehouses can achieve the following obvious benefits:

1. Due to the ability to form a complete flow discharge for the entire warehouse, dead material deposition is completely eliminated, and 30% more dead material can be released to occupy the storage capacity than before.

2. Due to the unique technology of prioritizing the discharge of hard materials on the storage walls, the full storage period will not form sedimentary blockages, which can release 20% more safe storage capacity than before.

3. Due to the use of intelligent closed-loop control technology, not only can abnormal working conditions such as material cutting be completely eliminated, but also precise control of discharge flow can be achieved to ensure stable operation and matching with subsequent transportation and lifting, approaching the maximum flow rate, thereby greatly improving cement production efficiency.

4.  Due to the use of Tai Chi cone technology at the bottom of the warehouse, the overall flow and discharge of hard materials on the entire warehouse wall are achieved, and there is no longer any dead material deposition or compaction in the warehouse. This can fundamentally eliminate the need for cleaning the cement warehouse and permanently solve the safety problem of cleaning the cement warehouse.

5. Due to the use of unpowered natural material unloading technology, the powder flow control can completely eliminate the high decibel noise interference and power consumption caused by the high-power Roots blower, achieving silent and environmentally friendly production.

3、 About Opportunities and Risks

It is evident from the comparison of innovative benefits of using powder flow control in the above-mentioned cement storage that:

1. The renovation of old warehouses or the application of new warehouses for powder flow control can increase the effective storage capacity by more than twice compared to old technologies, which is much faster and more effective than the laborious and costly expansion of new warehouses.

2. The intelligent closed-loop control of powder flow control can enable remote unmanned digital quantitative unloading control of cement storage in one step.

3. Complete the most headache inducing comprehensive requirements for safety, energy conservation, environmental protection, and noise reduction in cement depots in one go.

For many years, we have always said that innovation is necessary for development. Now that cement storage technology has achieved innovative results, do we dare to take risks? We cannot always be contemplative and indifferent to action.

Admittedly, there is always a bit of risk in applying new technologies, but Powder Flow Control has successfully applied nearly 50 sets. Over the course of more than three years, a brand new theory of powder dynamics has been fully validated and improved on various powder warehouses of all sizes in various regions. The actual risk has been almost reduced to zero, and it has been highly praised and recognized by experts, designers, and other knowledgeable individuals. After on-site inspection and verification by experts on the users of Powder Flow Control, Powder Flow Control has continuously won the Best Application Technology and Equipment Award from the Cement Expert Alliance in 2016, 2017, and 2018. Rather than saying that powder flow control is a new technology and equipment, it is more accurate to say that powder flow control is a new discovery of powder application laws and has opened up new paths, providing a rare opportunity for cement enterprises to significantly improve efficiency and quality.

Time is money, efficiency is life. In the current situation, for many cement enterprises, either they follow the old and stick to the old, or they dare to give it a try. In fact, the application risk of powder flow control is only a small horse crossing the river. If you use it yourself, you can understand that in the cement market market that has been weak for many years, seizing the opportunity is the best choice to surpass competitors.