[Xingsen Carbon Plant, August 20,2024] Xingsen Carbon Plant has completed the automation and upgrading of core activated carbon production equipment with a total investment of 12 million yuan, promoting the transformation of the enterprise to digitalization and intelligence, and further consolidating its leading position in the field of activated carbon manufacturing.
Automatic upgrade: double improvement of activated carbon production efficiency and quality
The transformation covers the key links of raw material transportation, molding and pressing, high temperature carbonization and finished product sorting in activated carbon production. Through the application of intelligent control system, industrial robot and Internet of things technology, the production process of activated carbon is automated:
- Precise control: the automatic equipment monitors the temperature, pressure and other parameters in real time, reducing the process fluctuation by 40%, and the qualified rate of activated carbon products is increased from 88% to 95%;
- Human resource optimization: the number of operators in a single activated carbon production line was reduced from 15 to 3, and employees were transferred to technical operation and maintenance positions, reducing the rate of work-related accidents by 60%;
- Capacity improvement: the comprehensive efficiency of equipment (OEE) is increased from 65% to 85%, the average daily capacity of activated carbon is increased from 50 tons to 75 tons, and the annual output value is expected to increase by 30 million yuan.
Employee empowerment: from operator to activated carbon technology expert
The company invested 2 million yuan to conduct 12 sessions of intelligent equipment operation training for activated carbon, with 85% of frontline employees passing the certification. Zhang Wei, the team leader of the forming workshop, noted that the intelligent system has reduced the fault response time for activated carbon production equipment from 4 hours to 30 minutes. The ‘Automation Innovation Team’ proposed 23 suggestions for optimizing the activated carbon process, which have been implemented, resulting in an annual cost savings of 1.5 million yuan. .
Green intelligent manufacturing: the environmental benefits of activated carbon production are significant
The third party test data show that the automation upgrade of activated carbon production has been realized:
- Energy saving: natural gas consumption per unit is reduced by 18%, and carbon dioxide emission is reduced by 1200 tons per year;
- Dust treatment: the dust recovery efficiency in the process of activated carbon production was increased to 99.5%, and the surrounding PM2.5 concentration decreased by 35% year on year;
- Waste utilization: the recycling rate of waste from activated carbon production is increased from 70% to 90%, and the annual raw material purchase is reduced by 800 tons.
look forward to the future
Mr.Shi, the general manager, announced that in 2025, an additional investment of 8 million yuan will be made to introduce AI visual detection and digital twin technology to optimize the activated carbon production process. The goal is to achieve 100% networking of all activated carbon production equipment in the plant and 80% predictive maintenance coverage, continuously consolidating the benchmark position in the activated carbon industry with intelligent manufacturing.
