On May 11, the "Seventh Census" data was released, showing that my country's population over 60 years old was 264 million (18.7%), of which the population over 65 years old had reached 191 million (13.5%).
A problem that accompanies an aging society and causes headaches for all companies is that it is too difficult to recruit workers. Specific to our ceramics industry, how difficult is it to recruit workers? Miao Bin, president of the China Building and Sanitary Ceramics Association, revealed: "Some companies have a staff shortage rate of more than 20%."
Not only is it difficult to recruit workers, but the national goal of "carbon peaking and carbon neutrality" has also issued a four-word transformation and upgrading instruction to ceramic companies: intelligent manufacturing.
Only 30 people, international advanced level
Raw material preparation has always been a "long-standing problem" in the ceramic industry. There are five reasons: non-standardized raw materials, large number of people employed, high energy consumption, poor environment, and low degree of automation. In particular, the low degree of automation is a key factor, which directly leads to more employees, poor environment and high energy consumption.
Currently, a traditional ceramic tile wet powder making workshop requires 60-80 people to operate, and it is dusty, noisy, and requires high work intensity. Zhang Boqing, executive director of the Mechanical Energy Saving and Environmental Protection Branch of the China Building and Sanitary Ceramics Association and professor at Jingdezhen Ceramics University, said bluntly that the raw material preparation link is the bottleneck for ceramic tile factories to achieve automation and intelligence. How to get through this last mile is a topic facing all enterprises. .
How to break through the bottleneck of raw material preparation automation? Zhang Baiqing has discovered a solution, which is continuous ball milling. And he believes that the company that leads the ceramic industry in continuous ball milling is undoubtedly Bohui.
▲The "sliding shoe type continuous ball milling system" developed by Bohui
On November 29, 2019, Dongpeng’s most intelligent production base was put into operation in Yongchuan, Chongqing. The production base has achieved true full-line automation, which means that not only the press and its back-end kilns and mills Throwing, packaging and other links, as well as a complete set of raw material preparation systems at the front end of the press, are all intelligent.
This raw material preparation system is the "intelligent wet milling system" developed by Bohui and Dongpeng. It is currently the only one in the world. Liang Haiguo, general manager of Guangdong Bohui Huasheng Technology Co., Ltd., said that the system integrates visual data into the entire raw material preparation process from pre-crushing, raw material homogenization and storage, continuous ball milling, spray drying tower, and powder storage.A central control platform and hundreds of sensors feeding back data in real time ensure the accurate and stable production of raw materials.
▲Liang Haiguo introduces the "intelligent wet milling system" to customers
Currently, the first phase of the "intelligent wet milling system" project supplies raw materials to Dongpeng's two production lines, requiring only 30 workers to manage and operate them. Zheng Yonghan, deputy general manager of Guangdong Bohui Huasheng Technology Co., Ltd., said that after the other two production lines to be built are ignited and put into operation, the raw material workshop only needs to add 9 more people to meet the production management of the second phase of the project. This means that an average of 10 people per production line can manage the raw material preparation process.
Due to its outstanding technical level, the "intelligent wet milling system" has been successfully approved as "a powder crushing method and device (201611219444.X), a slurry management method and system (202011036389.7), a Ceramic slurry production system (202022159875.
Recently, at the scientific and technological achievements appraisal meeting organized by the China Building and Sanitary Ceramics Association, "Intelligent Wet Powdering System" (the official name of the appraisal meeting is "Research and Application of Key Process Technologies and Digital Equipment for the Preparation of Building Ceramic Raw Materials" ) project was unanimously identified as “internationally advanced level” by experts and scholars.
First in three industries, saving 80% in labor costs
Bohui's "Intelligent Wet Powdering System" runs through the entire raw material preparation process from pre-crushing to powder storage, so its connotation is very rich, including nine aspects in total, three of which are industry firsts.
First, mud selection and slurrying system. The main function is to remove quartz sand and wood residue and improve the purity of the mud. This is helpful for the stability of the formula and the low-temperature firing of the kiln. Intelligent batching is used to turn the mud into measurable mud, realizing digital management, and its output reaches more than 60 tons per hour.
Second, the raw material pre-crushing system. Use new crushers and high-pressure roller crushers to crush raw ore materials into particles with a particle size of ≤3mm.And only one forklift was used in the whole process. The dry and wet ingredients form a small formula, which effectively reduces dust and helps the homogenization system to discharge materials smoothly. Its single set output is not less than 100 tons per hour.
Third, the raw material homogenization library system is the first industry initiative. The intelligent homogenization process of tiled direct extraction completely solves the problem of raw material component fluctuations. The three-dimensional warehousing improves site utilization and the reserve can reach 20,000 tons (12 days).
Fourth, sliding shoe type continuous ball milling system. In the ceramic industry, continuous ball milling is nothing new, but Bohui has innovated this technology and upgraded the ball mill from the end cover type to the sliding shoe type, which avoids the risk of cracking and breaking the shaft of the end cover type ball mill. The sliding shoe type continuous ball mill system is not only safe, reliable and easy to maintain, but the weight and moisture of the slurry in the slurry tank are automatically monitored online. Due to the continuous, refined and automated batching, the slurry performance is very stable.
Fifth, feldspar iron removal (bluestone purification) deep processing system. Through the industry's leading strong magnetic iron removal machine, the whiteness of the feldspar raw material can be increased from 3.5 degrees to 30 degrees at one time, and the raw material loss can be reduced to ≤10%. What's even more rare is that the system's sewage does not flow out, but is recycled internally, achieving zero discharge.
Sixth, large-capacity energy-saving spray tower system. The tower is 15 meters high and its daily output reaches 1,700 tons. A special spray gun structure is configured for special particles. It adopts high-pressure Huayan pump, automatic knocking gun system, double-fan design, double-layer tower frame, and automatic moisture monitor. It is safe, efficient, energy-saving, and durable.
Seventh, intelligent powder storage system. Adopting digital precision management, the inventory of material boxes can be displayed in real time, and fully automatic and intelligent entry and exit of the warehouse eliminate the need for manual operation. In addition, it is equipped with a new unorganized emission dust treatment system, which is the second industry first to achieve clean production.
Eighth, intelligent digital production system for ceramic glazes. There is no dust, the fully automatic batching is fast and accurate, and reports are automatically generated for real-time monitoring, saving two-thirds of manpower.
Ninth, the intelligent digital central control system is the third industry first. It is highly intelligent and digital, providing accurate real-time data and seamless connection for big data management and equipment diagnosis of the entire factory. It uses central control management to automatically monitor each process, eliminating manual errors, reducing the scrap rate, and ensuring It ensures high-quality and stable flexible production of the production line, and has the foundation of disruptive innovation.
Bohui's "intelligent wet milling system" is the industry's first set of mechanical equipment that runs through the entire raw material preparation process. Liang Haiguo is very proud of this. He pointed out that Yongchuan Dongpeng's raw material workshop has saved 80% of labor costs and 15% of electricity consumption compared with traditional raw material workshops. More importantly, Bohui and Dongpeng have joined hands with Dongpeng through "intelligent "Wet milling system" fills the gap in the raw material workshop that cannot be fully automated, and contributes to the transformation and upgrading of the industry and the move towards Industry 4.0.
Clean production improves employee happiness
At the "Intelligent Wet Milling System" seminar, Zhong Baomin, general manager of Dongpeng Innovation Center, said that due to working in an environment with less dust, less noise, and less labor intensity created by automation and intelligence, The happiness of employees in the raw material workshop of Yongchuan Dongpeng has been greatly improved. He also believes this is a system that can benefit the industry.
This is not Zhong Baomin’s preference alone. In fact, as long as one has seen the “Intelligent Wet Powdering System”, it is difficult not to praise it, especially for ceramic people who have experienced the traditional raw material preparation workshop environment.
Zhang Baiqing pointed out that the "intelligent wet milling system" successfully ensured that "materials do not fall to the ground" in all aspects, including the automatic measurement of water and internal circulation consumption, achieving clean production, especially the homogenization link is remarkable. points, leading the industry.
Li Ying, Vice President of Nobel, expressed her love for the "intelligent wet milling system". She hopes that Nobel's new factories in the future can use this equipment in the raw material preparation process.
Huo Jianrong, general manager of Shuncheng Group's Best Production Base, also said that compared with the previous continuous ball mill, the "intelligent wet milling system" is "really one day at a time". Not only are the electricity and labor costs lower, but the working environment is also improved. Better. He believes that this system will be the future development trend.
As the world's largest producer and consumer of ceramic tiles, my country does not match the world's number one status in terms of automation and intelligence of production. It is still exploring the path of intelligence or even automation. With the advent of irreversible objective national conditions such as aging, rising labor costs, and peak carbon emissions, ceramic companies will also have to save themselves, and the best way to save themselves is undoubtedly to shift to greener, low-carbon, and low-cost smart manufacturing. .
Faced with the turbulent market competition environment and the wave of industry polarization, it is already self-evident what kind of enterprise we will belong to in the future.
