Use less energy to make better products

To improve its production, Qilianshan Cement needed to address:

• High energy usage and costs
• High labor intensity and skill requirements
• Poor process control stability due to human error

Plant operators at Gansu Qilianshan Cement Group Co., Ltd. could not tell exactly how much their equipment operation affects production and energy consumption. Achieving that visibility to create an energy-efficient process was one of the key challenges for the company to overcome.

Apps, Analytics and Services: Energy Management System (EMS), AVEVA’s* Advanced Process Control (APC)
Edge Control: Modicon PLCs
Connected Products: Altivar Process drives, LV products

• The EMS at the Hongda Building Materials plant enables operators to visualize energy management and serves as the basis for improvement. It uses big data analysis technology to mine data through quality, production, and process parameters, allowing operators to understand energy consumption data in real-time and enabling lower energy consumption during normal operation of the equipment.
• AVEVA’s APC solution at the Zhangxian plant enables optimization of the cement kiln’s operational parameters, as well as boosting safety and reliability.

* The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company. The Schneider Electric and Life is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.

Schneider Electric process and energy optimization solutions in the smart manufacturing pilot projects at two plants (Zhangxian and Hongda Building Materials) delivered:

• Almost €600,000 in electricity costs saved in one year at Hongda Building Materials
• Standard coal consumption at the Hongda plant reduced to less than 100kg/ton
• 99% online rate of APC system at Zhangxian
• Improved production stability and efficiency
• Reduced labor requirements