在港股上市的华润水泥（01313.HK）近期公告，董事局建议由“华润水泥控股有限公司”变更为“华润建材科技控股有限公司”。
“2022年以来，集团积极把握机会，在上述四大业务板块均取得突破，非水泥业务占比逐年提高。董事局认为，‘水泥’已不能完全涵盖集团业务类型，通过更改公司名称将实现经营范围与公司名称的名实相符，准确诠释公司定位，更好呼应企业愿景。”公司称。
21世纪经济报道记者还从华润水泥了解到，公司旗下的田阳水泥参评“灯塔工厂”已经进入申报评审阶段，最终结果预计在今年冬季达沃斯论坛发布。 数字化转型网www.szhzxw.cn
所谓“灯塔工厂”项目，是指数字化制造和工业4.0的先行者。据公司介绍，这需要在四个方面实现榜样意义：一是规模影响，为业界和企业带来运营模式、产品、服务、商业模式的颠覆性创新；二是业务用例，大规模部署、整合多个第四次工业革命用例；三是赋能要素，在重要赋能要素上的最佳实践，如拥有目标清晰的第四次工业革命战略、积极的员工参与、能力建设和敏捷用例开发等；四是技术平台，可以部署第四次工业革命技术的规模化技术平台。
“数智化转型始于2017年，先开始是做顶层设计和整体规划，2018年启动建设工作。”华润水泥总裁景世青介绍称，选择田阳水泥主要由于当时精益运营各项指标表现突出，是华润水泥获得集团“六星级标杆工厂”的第一家生产基地，预期通过数智化转型使田阳水泥持续提升竞争力。
经过数字化改造后，田阳水泥实现二氧化碳排放下降24%，人均水泥产量提升105%，设备非计划停机下降56%，质量稳定性提升25%。 数字化转型网www.szhzxw.cn
一、生产全流程“数智化”
华润水泥（田阳）公司2008年成立，2010年12月建成投产，拥有一条日产5000吨新型水泥熟料生产线，年产水泥200万吨。
产能规模在华润水泥内部不算特别突出，但是在智能化运用上却处于行业一线梯队，并将主要用例成功推广至华润水泥超过30个生产基地。
“2018年创建智能化工厂后，拥有更稳定的产品质量和更高的生产效率，区域竞争力很强。”田阳水泥相关责任人介绍称，通过优化配料方案、积极使用替代原燃材料，优化生产工艺等措施不仅可实现节能降碳，还将促进公司实现系统成本最低，区域市场领先。
需要指出的是，水泥行业是实打实的传统产业，其数智化转型本身的诉求和动力显著低于其他制造业。
而就田阳水泥而言，如今却实现了从矿山开发到窑磨生产，再到质量、设备和物流全流程的数智化改造。
以矿山生产环节为例，便至少包括了配矿、调度和物流三项工作。
此前，主要是依靠人工经验配矿生产，这使得矿石质量波动大、废料量相应增加，资源利用率较低。
“我们运用数字孪生和三维建模技术，制作了一个储量7100万吨的虚拟仿真矿体模型，考虑产量、配矿质量要求、挖掘机和矿车效率等多维度变量约束，利用混合整数规划算法构建配矿优化模型，进而自动生成当班的采矿点位和采矿量组合最优配置方案，实现了矿石资源零浪费。”田阳水泥矿山负责人介绍称。
矿车方面，田阳水泥原来使用的9台柴油矿车，需要18名司机分两班驾驶，全年人工、能耗和维护成本等合计高达400万元，车队每年燃烧柴油产生的二氧化碳排放量达450吨以上。
数智化改造后，公司采购5台纯电动矿车进行替代，并对电动矿车进行无人驾驶技术改造，实现智能配速、交汇停车、车队跟车、让行/绕行避障、自动泊车等功能，协同装料、运输及卸料的物流全流程达到无人化。 数字化转型网www.szhzxw.cn
同时，经过挖卡协同优化、协同卸料优化改造，公司生产效率提升和成本下降十分明显。
上述矿山负责人给出的数据显示，田阳公司目前无人驾驶物流效率，比同行业标准方案下的物流时间缩短22%，矿车年度运营成本下降83%，矿车年度二氧化碳排放量下降68%。
再如窑磨生产环节，公司便利用自主研发窑磨先进控制模型，结合大数据分析和AI算法。
在水泥生产的石灰石破碎、原料粉磨、熟料烧成、煤粉制备、水泥粉磨的100%关键工艺环节，部署了27个先进过程控制回路，实现窑关键参数的滚动寻优和108项关键参数的自动调整，规模化使用5种以上可替代燃料，化石燃料年度CO2排放降低31%，中控操作员数量降低55%。
以上只是田阳水泥数智化升级的缩影。厂区内几乎每个环节都设有“中控室”，已实现了水泥生产全流程的智能化制造。
二、从华润“灯塔”到行业“灯塔”
“（田阳水泥）已经成为华润水泥内部的‘灯塔’。”景世青评价称。
他指出，田阳项目成熟的智能化应用会快速推广到华润水泥其他的生产基地，以提升公司整体的数字化转型。
以“润丰智慧”工业互联网平台为例，2022年6月正式上线，全面服务于华润水泥30多家水泥生产基地，现已接入各类设备及采集终端近4.7万个，日采集数据量超200G，运行算法达26大类100多种。
经过数字化、智能化改造，工厂生产效率提升，运营成本、能耗和排放降低，这更多代表的是企业先进制造的水平，而田阳水泥却并未止步于此。
2022年11月，国家发改委、住建部等五部门联合印发了《国家发展改革委关于加强县级地区生活垃圾焚烧处理设施建设的指导意见》。
意见指出，推进城镇生活垃圾焚烧处理设施建设是强化环境基础设施建设的重要环节和基础性工作。对没有焚烧处理能力的县级地区，可在确保稳定处理的基础上按照相关政策要求利用水泥窑协同处置生活垃圾。 数字化转型网www.szhzxw.cn
水泥窑协同处置生活垃圾有一定优势，一是处置温度高，停留时间长，燃烧过程充分，焚烧状态易于稳定，能较好地消纳入炉垃圾；二是固化垃圾中的重金属离子，无废渣排放，在可控范围内，水泥产品质量和生产不受影响；三是我国有巨大的水泥生产能力，可以在特定区域解决垃圾污染问题，实现节能减排。
反观田阳水泥，早在2017年起便陆续建成利用水泥窑协同处置城乡生活垃圾项目。
厂区内建有一栋建筑，外表看起来平平无奇，却暗藏乾坤，内部可容纳多达8000吨生活垃圾。
“水泥窑内温度可以达到1400度，垃圾经脱水后焚烧产生的热量虽然不及煤炭，同时会呈季节性波动，但是焚烧所产生的热能也可以直接用于水泥生产。”田阳水泥相关负责人表示。
据他介绍，目前其整体处置能力为单日500吨，这可以满足整个百色市的生活垃圾处置需求。
而除了广西外，华润水泥在广东、云南多地也建有水泥窑协同处置城市生活垃圾或市政污泥项目。据公司估算，每年减少使用标煤约8.5万吨。 数字化转型网www.szhzxw.cn
“近年来公司在减碳、绿色产品开发、清洁能源、协同处置、ESG管理方面下了很大功夫，节能减排方面目前处于行业中领先地位，上半年熟料产品单位综合能耗再次取得历史性突破。”景世青介绍称。
近期召开的第六届中国企业论坛上，公司水泥窑协同处置城市生活垃圾项目也入选了ESG领域优秀案例，而华润水泥则以第21名的成绩入围“央企ESG先锋100指数”。
这些工作无疑也为华润水泥田阳公司参评“灯塔工厂”带来了更多加分项。
翻译：
China Resources Cement (01313.HK), which is listed on the Hong Kong stock exchange, recently announced that the Board of Directors proposed to change “China Resources Cement Holdings Limited” to “China Resources Building Materials Technology Holdings Limited”.
“Since 2022, the Group has actively seized opportunities and made breakthroughs in the above four business segments, and the proportion of non-cement business has increased year by year. The Board believes that ‘cement’ no longer fully covers the Group’s business type and that changing the company name will enable the business scope to match the name of the company, accurately interpret the company’s positioning and better match the corporate vision.” The company said.
The 21st Century Economic Report reporter also learned from China Resources Cement that the company’s Tianyang Cement has entered the assessment stage of the “lighthouse factory”, and the final results are expected to be released at this year’s Winter Davos Forum.
The so-called “Lighthouse Factory” project refers to the pioneer of digital manufacturing and Industry 4.0. According to the company, this needs to achieve model significance in four aspects:
First, scale impact, bringing disruptive innovation of operation model, product, service and business model to the industry and enterprises.
Second, business use cases, large-scale deployment and integration of multiple fourth Industrial Revolution use cases. 数字化转型网www.szhzxw.cn
Best practices on key enablement elements such as having a clearly targeted Fourth Industrial Revolution strategy, active employee engagement, capacity building, and agile use case development; The fourth is the technology platform, which can deploy the fourth industrial Revolution technology at scale.
“The transformation of digital intelligence began in 2017, starting with top-level design and overall planning, and starting construction work in 2018.” Jing Shiqing, president of China Resources Cement, said that the choice of Tianyang Cement was mainly due to the outstanding performance of lean operation indicators at that time, and it was the first production base of China Resources Cement to obtain the group’s “six-star benchmark factory”, and it was expected that Tianyang Cement would continue to enhance its competitiveness through the transformation of digital intelligence.
After the digital transformation, Tianyang Cement achieved a 24% reduction in carbon dioxide emissions, a 105% increase in per capita cement production, a 56% reduction in unplanned equipment downtime, and a 25% improvement in quality stability.
“Number intelligence” in the whole production process
China Resources Cement (Tianyang) Co., Ltd. was established in 2008 and put into operation in December 2010. It has a new cement clinker production line with a daily output of 5,000 tons . And an annual output of 2 million tons of cement.
The scale of production capacity is not particularly prominent within China Resources Cement, but it is in the first echelon of the industry in intelligent application. And the main use cases have been successfully promoted to more than 30 production bases of China Resources Cement.
“After the creation of the intelligent factory in 2018, it has more stable product quality and higher production efficiency, and the regional competitiveness is strong.” The relevant person in charge of Tianyang cement said that by optimizing the mixing scheme, actively using alternative raw materials, optimizing the production process and other measures can not only achieve energy saving and carbon reduction, but also promote the company to achieve the lowest system cost and lead the regional market.
It should be pointed out that the cement industry is a solid traditional industry. And its digital intelligent transformation itself is significantly lower than other manufacturing industries.
As far as Tianyang cement is concerned, it has now realized the digital intelligent transformation of the whole process from mine development to kiln grinding production, and then to quality, equipment and logistics. 数字化转型网www.szhzxw.cn
Taking the mining production link as an example, it includes at least three tasks: ore blending, scheduling and logistics.
Previously, the production mainly relied on manual experience, which made the ore quality fluctuate greatly. The amount of waste increased correspondingly. And the resource utilization rate was low.
“We used digital twins and three-dimensional modeling technology to make a virtual simulation ore body model with 71 million tons of reserves. Considering the constraints of multi-dimensional variables such as output, ore allocation quality requirements, excavator and car efficiency, we used mixed integer programming algorithm to build a ore allocation optimization model, and then automatically generated the optimal allocation plan for the combination of mining location and mining volume on duty. Zero ore waste is realized.” Tianyang cement mine person in charge said.
In terms of mining vehicles, the nine diesel mining vehicles originally used by Tianyang Cement require 18 drivers to drive in two shifts, and the total annual labor, energy consumption and maintenance costs are as high as 4 million yuan, and the carbon dioxide emissions generated by the diesel burning of the fleet are more than 450 tons per year. 数字化转型网www.szhzxw.cn
After the intelligent transformation, the company purchased 5 pure electric mining vehicles for replacement, and carried out driverless technology transformation of electric mining vehicles to achieve intelligent speed matching, intersection parking, team following, lane/bypass obstacle avoidance, automatic parking and other functions, and the logistics process of collaborative loading, transportation and unloading reached unmanned.
At the same time, through the collaborative optimization of card mining and collaborative unloading optimization, the company’s production efficiency has been improved and the cost has been reduced significantly.
According to the data given by the person in charge of the above mine, the current unmanned logistics efficiency of Tianyang Company is 22% shorter than the logistics time under the standard scheme of the same industry, the annual operating cost of the mine car is reduced by 83%, and the annual carbon dioxide emissions of the mine car is reduced by 68%.
In the production process of kiln grinding, the company uses its own research and development of advanced control models for kiln grinding, combined with big data analysis and AI algorithms.
In the cement production of limestone crushing, raw material grinding, clinker firing, pulverized coal preparation, cement grinding 100% of the key process of the deployment of 27 advanced process control loops, to achieve rolling optimization of key kiln parameters and 108 key parameters automatic adjustment, large-scale use of more than 5 alternative fuels, annual CO2 emissions of fossil fuels reduced by 31%. Number of central control operators reduced by 55%.
The above is just the epitome of Tianyang cement’s intelligent upgrade. Almost every link in the plant has a “central control room”, which has realized the intelligent manufacturing of the whole process of cement production. 数字化转型网www.szhzxw.cn
From China Resources “Lighthouse” to the industry “lighthouse”
“[Tianyang Cement] has become a ‘beacon’ within CR Cement.” Jing Shiqing evaluation said.
He pointed out that the mature intelligent application of the Tianyang project will be quickly extended to other production bases of China Resources Cement to enhance the company’s overall digital transformation.
Taking the “Runfeng Wisdom” industrial Internet platform as an example, it was officially launched in June 2022, fully serving more than 30 cement production bases of CR Cement, and has access to nearly 47,000 various types of equipment and collection terminals, with a daily data collection volume of more than 200G, and more than 100 kinds of running algorithms in 26 categories.
After digital and intelligent transformation, factory production efficiency is improved, operating costs, energy consumption. And emissions are reduced, which more represents the level of advanced manufacturing of enterprises. And Tianyang cement does not stop here.
In November 2022, the National Development and Reform Commission.
The Ministry of Housing and other five departments jointly issued the “National Development and Reform Commission on Strengthening the construction of county-level domestic waste incineration treatment facilities”.
The opinions pointed out that promoting the construction of urban solid waste incineration treatment facilities is an important link and basic work to strengthen the construction of environmental infrastructure. For county-level areas without incineration treatment capacity, cement kilns can be used to coordinate the disposal of domestic waste in accordance with relevant policy requirements on the basis of ensuring stable treatment.
The collaborative disposal of domestic waste in cement kilns has certain advantages. First, the disposal temperature is high, the residence time is long, the combustion process is full, the incineration state is easy to be stable, and the waste in the furnace can be absorbed well. The second is to solidify the heavy metal ions in the waste, no waste residue discharge, within the controllable range, the quality and production of cement products are not affected; Third, China has a huge cement production capacity, which can solve the problem of garbage pollution in a specific area and achieve energy conservation and emission reduction. 数字化转型网www.szhzxw.cn
In contrast, as early as 2017. Tianyang Cement has successively built a project to use cement kilns to coordinate the disposal of urban. And rural domestic waste.
There is a building inside the factory, which looks ordinary on the outside, but has a hidden meaning, and can hold up to 8,000 tons of domestic waste.
“The temperature in the cement kiln can reach 1,400 degrees, and although the heat generated by the incineration of waste after dehydration is not as good as that of coal, it will fluctuate seasonal, but the heat generated by incineration can also be directly used in cement production.” The person in charge of Tianyang cement said.
According to him, its overall disposal capacity is currently 500 tons per day. Which can meet the needs of domestic waste disposal in the entire Baise city.
In addition to Guangxi, CR Cement has also built cement kilns in many places in Guangdong and Yunnan to coordinate the disposal of municipal solid waste or municipal sludge projects. According to the company’s estimates, the annual reduction in the use of standard coal is about 85,000 tons.
“In recent years, the company has made great efforts in carbon reduction, green product development, clean energy, collaborative disposal, ESG management, energy conservation and emission reduction is now in the leading position in the industry. And the comprehensive energy consumption per unit of clinker products has once again made a historic breakthrough in the first half of the year.” Jing Shiqing introduction said. 数字化转型网www.szhzxw.cn
At the sixth China Enterprise Forum recently held, the company’s cement kiln collaborative disposal of municipal solid waste project was also selected as an excellent case in the ESG field, and China Resources Cement was listed in the “ESG Pioneer 100 Index of Central Enterprises” with the 21st place.
These work undoubtedly also brought more items for CR Cement Tianyang Company to participate in the evaluation of “Lighthouse Factory”.
本文由数字化转型网（www.szhzxw.cn）转载而成，来源于灯塔工厂；编辑/翻译：数字化转型网小汤圆。
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