1. Project Background: Foreign investment meets high standards, old factories face challenges

As a foreign-invested enterprise, the waste heat power station of a cement enterprise in Sichuan has extremely high standards for its production process, especially regarding safety standards and process control. The original equipment of the plant's steam-water system is outdated, making it difficult to meet the strict standards of foreign-invested enterprises in areas such as boiler steam-water monitoring, chemical water dosing, boiler dosing, and circulating water dosing. The old factory faces issues such as inaccurate monitoring data and unstable dosing control due to aging equipment, seriously affecting production efficiency and product quality, making renovation urgent.

2. Core Project Solution: Tailor-made, Precise Renovation

Mozhidao Measurement & Control tailored a renovation plan based on the actual conditions of a waste heat power station at a cement enterprise in Sichuan, covering four core modules: boiler steam-water monitoring system, chemical water dosing system, boiler dosing system, and circulating water dosing system, fully meeting the high standards of foreign-funded enterprises.

(1) Boiler Steam and Water Monitoring System: High-precision monitoring with reliable data

Advanced sensor layout: At key points of the boiler steam-water system, such as feedwater, steam, and furnace water, high-precision sensors are precisely installed to monitor more than ten key indicators in real time, including conductivity, dissolved oxygen, pH, hardness, silica, sodium ions, alkalinity, and chloride ions. The detection accuracy reaches ±5%, with a data error rate below 0.5%, ensuring water quality data is accurate and reliable, meeting the stringent data accuracy requirements of foreign-invested enterprises.

Intelligent Data Analysis Platform: Builds an intelligent data analysis platform to collect, analyze, and process monitoring data in real time. By setting thresholds, if water quality indicators exceed safe limits, the system immediately issues warning signals to alert maintenance personnel to take timely measures to prevent water quality issues from worsening and ensure safe and stable boiler operation.

Compatibility design: Fully considers compatibility with existing equipment from old factories, using standard communication interfaces (such as RS485, TCP/IP, 4 - 20mA), allowing seamless integration with existing DCS systems, enabling data sharing and centralized management without large-scale equipment replacement, reducing retrofit costs.

(2) Chemical and chemical dosing system: precise regulation, consumption reduction, and efficiency improvement

Intelligent dosing control algorithm: Based on advanced control algorithms, it automatically calculates and adjusts the dosage of scale inhibitors and corrosion inhibitors based on real-time changes in influent quality, achieving precise dosing. Compared with traditional dosing methods, chemical waste is reduced by more than 30%, effectively lowering operating costs and meeting the requirements of foreign-invested enterprises for cost reduction and efficiency improvement.

Efficient dosing equipment upgrades: Existing dosing equipment is upgraded and modified, using new materials that are corrosion-resistant and wear-resistant to improve the equipment's service life and stability. At the same time, optimize equipment structure, improve chemical mixing efficiency, ensure uniform distribution of chemicals, and enhance water treatment effectiveness.

Remote monitoring and operation: Equipped with remote monitoring and operation functions, operation and maintenance personnel can check the operating status of dosing equipment, dosing levels, and other information anytime and anywhere via mobile phones or computers, and remotely control equipment start/stop and adjust dosing parameters, improving operation and maintenance efficiency, reducing on-site inspection workload, and meeting the requirements for efficient management of foreign-funded enterprises.

(3) Boiler dosing system: dynamic balancing and equipment protection

Dynamic dosing strategy: Formulate dynamic dosing strategies based on boiler operating conditions and online monitoring data. Based on changes in furnace water pH value, conductivity, and other indicators, the dosage of phosphates, sodium hydroxide, and other chemicals is adjusted in real time to keep the boiler water quality within the optimal range, prevent scaling and corrosion, protect the safe operation of boiler equipment, and meet the high standards for equipment protection in foreign enterprises.

Safety protection design: Multiple safety protection devices are installed in the dosing system, such as over-temperature and over-pressure protection, power-off protection, and leak alarms, ensuring the equipment can automatically stop operating and trigger alarms in abnormal situations, preventing accidents and ensuring production safety.

Modular design: Adopts a modular design concept, dividing the dosing system into multiple independent modules for easy installation, maintenance, and upgrades. Interfaces between modules are standardized, allowing flexible combinations according to actual needs to improve system adaptability and scalability.

(4) Circulating water dosing system: adapts to complex working conditions and improves circulation efficiency

Strong anti-interference capability: In response to the complex water quality and vulnerability to external interference in old plant circulating water systems, sensors and control equipment with strong anti-interference capabilities are used to ensure accurate monitoring of water quality indicators and stable dosing control even under harsh working conditions.

Intelligent linkage control: Achieves intelligent linkage control between the circulating water monitoring system and the dosing system. When the quality of circulating water changes, the system automatically adjusts the dosing amount, and optimizes dosing strategies based on factors such as the operating status of the circulating water pump and the cooling tower's heat dissipation efficiency to improve the overall operational efficiency of the circulating water system.

Energy-saving and environmentally friendly design: Optimized chemical formulations, selecting environmentally friendly agents to reduce environmental pollution. At the same time, precise dosing reduces chemical consumption, minimizes water waste, and achieves energy conservation and emission reduction goals, aligning with the environmental protection philosophy of foreign-funded enterprises.

3. Project Highlights: High standards and comprehensive guarantees

(1) In-depth research, precise customization

During the early stages of the project, the Modaodao measurement and control project team conducted a comprehensive and in-depth investigation of the waste heat power station at a cement enterprise in Sichuan, thoroughly understanding the old plant's equipment status, process flow, and operational pain points. Based on the research results, customized renovation plans for old factories are made to ensure they meet actual needs, effectively solve the challenges faced by old factories, and meet the high standards of foreign-invested enterprises.

(2) Innovate technology and efficiently transform the market

By adopting a series of innovative technologies and equipment, such as high-precision sensors, intelligent control algorithms, and modular design, efficient upgrades to boiler steam-water monitoring systems are achieved without affecting the normal production of the old plant. The renovation process emphasizes construction safety and quality control to ensure the stable and reliable operation of the renovated system.

(3) Professional team, full-process service

We have a professional project implementation team, with members possessing extensive experience and expertise in renovating old factories. From project planning, design, and construction to commissioning, training, and after-sales, we provide full-process one-stop services. During project implementation, maintain close communication with clients, promptly resolve any issues encountered, ensure smooth project progress, and meet the high requirements of foreign-invested enterprises for project management and services.

4. Project Outcomes: Significant improvement, win-win for all parties

(1) Significant improvement in water quality

After the renovation, the boiler steam-water quality of the waste heat power station at a certain cement enterprise in Sichuan improved significantly, with all indicators stably kept within the qualified range. Scaling rate is reduced by more than 60%, corrosion rate by about 50%, effectively extending equipment service life and lowering maintenance and replacement costs.

(2) Improved operational efficiency

Through precise dosing and intelligent control, boiler thermal efficiency improves by 2% - 3%, unit power generation efficiency by about 5%, and annual power generation increases significantly. At the same time, the operational efficiency of the circulating water system improves, water resource recycling rates increase, and production costs are reduced.

(3) Reduced management costs

The intelligent control system achieves automation and intelligence in water quality monitoring and dosing control, reducing manual operations and on-site inspection workload, and lowering labor costs. At the same time, the system features data recording and analysis functions, providing scientific evidence for operations and maintenance management, and improving management efficiency and decision-making levels.

(4) Meet foreign investment standards and set industry benchmarks

After successful implementation, the project fully met the high safety standards, process control, and other high requirements for a cement enterprise in Sichuan's waste heat power station as a foreign-invested enterprise, providing valuable experience and demonstration cases for the renovation of similar foreign-funded enterprises' old factories, and promoting technological progress and intelligent development in the industry.

5. Customer Evaluation

A relevant person in charge of a waste heat power station at a cement company in Sichuan said: "Mozhidao Measurement & Control customized a boiler steam-water monitoring system upgrade plan for us, precisely solving issues such as outdated equipment and difficult process control at old plants, fully meeting the high standards of our foreign-invested enterprise." After the renovation, water quality stabilized, operational efficiency improved, management costs decreased, and significant economic and social benefits were achieved. We are very satisfied with Mozhidao Measurement & Control's professional capabilities and service attitude, and look forward to more opportunities for cooperation in the future. ”

Mozhidao Measurement & Control—driving development through innovation and leading the future with intelligence, providing one-stop solutions for the renovation of old factories of foreign-funded enterprises