Entering the Intelligent World of the Cement Industry

In the era of Industry 4.0, “intelligence” has become a buzzword, frequently on everyone’s lips. The widespread adoption of artificial intelligence compels us to confront the profound changes it brings; subtly yet inexorably, we can no longer ignore its impact on advancing society as a whole. The rollout of 5G technology has further ushered in an age of “Internet of Everything,” where connectivity is no longer just a conceptual vision but a tangible reality that has permeated modern industry. Across sectors, companies are embracing smart manufacturing, seeking to seize opportunities and drive industrial transformation and upgrading in this unprecedented wave of innovation.
Recently, the General Office of the Ministry of Industry and Information Technology issued the “Action Plan for Digital Transformation of Intelligent Manufacturing in the Building Materials Industry (2021–2023).” The plan sets the following targets by 2023: to formulate or revise more than 30 standards related to intelligent manufacturing in the building materials sector; to cultivate five information‑technology and intelligent‑manufacturing service providers with annual revenues exceeding RMB 100 million; to establish five innovation platforms for intelligent manufacturing in the building materials industry; to develop 15 system‑level solutions; to achieve breakthroughs in 50 key generic technologies for intelligent manufacturing in the building materials field; to foster 100 building‑materials‑industry apps; to select six benchmark enterprises in intelligent manufacturing; and to build 50 smart factories in the building materials sector.
As a foundational industry underpinning national economic and social development, the building materials sector occupies an exceptionally important position. Accordingly, seizing development opportunities, formulating strategic objectives, taking the lead in driving growth, and advancing the application of intelligent technologies in the cement industry are both the trend of the times and essential for its own sustainable development.
This wave of “heat” is rolling in, sending ripples through the cement industry. Domestic cement companies have achieved impressive results in transforming their plants into smart factories. Next, let’s take a closer look at the智能化 world of the cement industry! In your opinion, which cement smart factory deserves the No. 1 spot in your mind? Share your answer!
Quanjiao Conch Cement Co., Ltd.
 

 
Quanjiao Conch centers on intelligent manufacturing, supported by three core platforms—operations, maintenance assurance, and smart management. It features a digital mine system with an expert‑optimized control system, an intelligent quality‑control system, a supply‑and‑marketing logistics information management system, an equipment management and auxiliary inspection system, and an energy management system, enabling intelligent decision‑making, automated operations, visualized management, proactive fault prevention, and seamless coordination across all elements. Since the commissioning of Quanjiao Conch’s fully integrated, intelligent cement plant, workforce has been reduced by approximately 18%, equipment failure‑related downtime has declined by about 20%, production efficiency has improved by more than 20%, overall resource utilization has increased by roughly 5%, energy consumption has fallen by over 1%, and annual CO₂ emissions have been cut by more than 25,000 tons, yielding significant economic and social benefits.
Taian Zhonglian Cement Co., Ltd.
 
 
Taian Zhonglian is equipped with an automated inspection and metering system for incoming raw and fuel materials, an in‑plant logistics automation system, an intelligent mining system, an online analytical automatic control system, a plant‑wide expert optimization system, an unmanned production‑site management system, and an internet‑based remote terminal monitoring and diagnostics system. The company’s distinctive features—including intelligent mine extraction, non‑homogenized raw material processing, information‑driven production management, automated process control, chromium‑free refractory materials, ball‑free grinding of raw materials, unmanned production sites, and visualized production processes—have established Taian Zhonglian as a model for the integration of informatization and industrialization in the cement industry. It was selected for the Ministry of Industry and Information Technology’s “2015 Smart Manufacturing Pilot Demonstration Projects” and recognized among China’s “Top Ten Green Innovation Achievements.” On its demonstration production line, key technical and economic indicators—such as electricity and thermal consumption, levels of automation, process flow efficiency, and labor productivity—are all at world‑leading standards.
Luoyang Zhonglian Cement Co., Ltd.
 
 
Luoyang Zhonglian, driven by technological innovation, is fully committed to building a smart factory. It has established an intelligent control platform centered on the MES system, encompassing seven major modules: a production management and control system, an expert‑based intelligent control system for cement production, an intelligent cement equipment management system, an intelligent quality control system, an intelligent mining system, a lean manufacturing management system, and a unified card‑based unmanned operation system. By leveraging cutting‑edge technologies such as information technology, the Internet of Things (IoT), 3D simulation, big data analytics, and artificial intelligence, the company has achieved automated plant operations, visualized management, proactive fault prevention, seamless internal–external coordination, and intelligent decision‑making.
Huzhou Huaikan Southern Cement Co., Ltd.
 
 
At Huai’an South, a 7,500 t/d production line serves as a pilot demonstration site, further advancing the research and application of intelligent technologies such as the Internet, cloud computing, and big data in cement manufacturing. The demonstration line is equipped with world‑class technology and features intelligent process management; all stages—including raw material processing, transportation, clinker burning, and packaging—are fully visualized. As a result, the workforce has been reduced from 180 to 60 employees, achieving both workforce reduction and operational efficiency gains.
Yichun Hongshi Cement Co., Ltd.
 
 
Yichun Red Lion is designed in accordance with the standards of a “second-generation, next‑generation dry‑process production line,” as well as smart manufacturing and green environmental protection requirements. It employs internationally advanced dry‑process technology, with digital technologies deeply integrated into every stage, each production step, and every piece of equipment. Its technologies, equipment, and environmental protection systems are sourced from leading domestic and international manufacturers; it utilizes Caterpillar mining equipment from the United States to enable digitized mine extraction, thereby building a green mine to the highest standards. A Danish‑made Smith intelligent laboratory ensures automated quality inspection and control of cement and clinker, enhancing product quality stability. Additionally, proprietary equipment health‑management and expert‑optimization systems are deployed to ensure stable, high‑efficiency operation of the production line. State‑of‑the‑art automated loading and shipping equipment further boosts loading efficiency, reduces labor intensity, and improves the on‑site working environment. Through the integrated application of cutting‑edge processes and technologies, Yichun Red Lion has been developed into a large‑scale, highly intelligent cement plant.
China Resources Cement (Tianyang) Co., Ltd.
 
 
Building a comprehensive, intelligent, and modern cement manufacturing system. The 5G wireless network provides coverage across the Tianyang Park’s main plant area, the grinding station, the mining operations zone, and the mine‑office complex. On‑site monitoring and inspection devices, mobile terminals, vehicle‑mounted equipment, video surveillance systems, and other supporting platforms enable wireless data transmission and integration, while production‑process and quality‑inspection data can be analyzed in real time online. In addition, the park has deployed 5G‑enabled smart remote‑controlled loaders from Guangxi Liugong, allowing remote operation in the stockpiling area and significantly reducing the frequency with which personnel need to enter high‑dust environments. As a result, the Baise Tianyang China Resources Cement Plant has seen a 30% increase in production efficiency, a substantial improvement in safety, and a 20% reduction in labor costs.
Zunyi Saide Cement Co., Ltd.
 
 
The Zunyi Saide Cement Intelligent Laboratory System integrates automated sampling, manual sample delivery, automated sample preparation, and automated analysis into a single platform. Analysis results are automatically transmitted to the quality management system and the expert optimization system, enabling automatic recording, statistical processing, and in-depth data analysis, while also supporting quality‑optimized control of the production process. The production management system collects and aggregates operational data, provides a visual human–machine interface, and conducts data analytics for real-time monitoring and historical trend analysis, ensuring precise oversight of production conditions. A plant‑wide digitalization framework has been established, dynamically generating work orders for inspections, maintenance, lubrication, and overhauls, thereby facilitating equipment condition assessment and predictive maintenance. Furthermore, the system gathers and analyzes the quality of raw materials, semi‑finished products, and finished goods, enabling comprehensive plant‑wide quality analysis, forecasting, and early warning—from material receipt to shipment.
Guizhou Tongren Southwest Cement Co., Ltd.
 
In the era of Industry 4.0, “intelligence” has become a buzzword, frequently on everyone’s lips. The widespread adoption of artificial intelligence compels us to confront the profound changes it brings; subtly yet inexorably, we can no longer ignore its impact on advancing society as a whole. The rollout of 5G technology has further ushered in an age of “Internet of Everything,” where connectivity is no longer just a conceptual vision but a tangible reality that has permeated modern industry. Across sectors, companies are embracing smart manufacturing, seeking to seize opportunities and drive industrial transformation and upgrading in this unprecedented wave of innovation.
Recently, the General Office of the Ministry of Industry and Information Technology issued the “Action Plan for Digital Transformation of Intelligent Manufacturing in the Building Materials Industry (2021–2023).” The plan sets the following targets by 2023: to formulate or revise more than 30 standards related to intelligent manufacturing in the building materials sector; to cultivate five information‑technology and intelligent‑manufacturing service providers with annual revenues exceeding RMB 100 million; to establish five innovation platforms for intelligent manufacturing in the building materials industry; to develop 15 system‑level solutions; to achieve breakthroughs in 50 key generic technologies for intelligent manufacturing in the building materials field; to foster 100 building‑materials‑industry apps; to select six benchmark enterprises in intelligent manufacturing; and to build 50 smart factories in the building materials sector.
As a foundational industry underpinning national economic and social development, the building materials sector occupies an exceptionally important position. Accordingly, seizing development opportunities, formulating strategic objectives, taking the lead in driving growth, and advancing the application of intelligent technologies in the cement industry are both the trend of the times and essential for its own sustainable development.
This wave of “heat” is rolling in, sending ripples through the cement industry. Domestic cement companies have achieved impressive results in transforming their plants into smart factories. Next, let’s take a closer look at the智能化 world of the cement industry! In your opinion, which cement smart factory deserves the No. 1 spot in your mind? Share your answer!
Quanjiao Conch Cement Co., Ltd.
 
 
Quanjiao Conch centers on intelligent manufacturing, supported by three core platforms—operations, maintenance assurance, and smart management. It features a digital mine system with an expert‑optimized control system, an intelligent quality‑control system, a supply‑and‑marketing logistics information management system, an equipment management and auxiliary inspection system, and an energy management system, enabling intelligent decision‑making, automated operations, visualized management, proactive fault prevention, and seamless coordination across all elements. Since the commissioning of Quanjiao Conch’s fully integrated, intelligent cement plant, workforce has been reduced by approximately 18%, equipment failure‑related downtime has declined by about 20%, production efficiency has improved by more than 20%, overall resource utilization has increased by roughly 5%, energy consumption has fallen by over 1%, and annual CO₂ emissions have been cut by more than 25,000 tons, yielding significant economic and social benefits.
Taian Zhonglian Cement Co., Ltd.
 
 
Taian Zhonglian is equipped with an automated inspection and metering system for incoming raw and fuel materials, an in‑plant logistics automation system, an intelligent mining system, an online analytical automatic control system, a plant‑wide expert optimization system, an unmanned production‑site management system, and an internet‑based remote terminal monitoring and diagnostics system. The company’s distinctive features—including intelligent mine extraction, non‑homogenized raw material processing, information‑driven production management, automated process control, chromium‑free refractory materials, ball‑free grinding of raw materials, unmanned production sites, and visualized production processes—have established Taian Zhonglian as a model for the integration of informatization and industrialization in the cement industry. It was selected for the Ministry of Industry and Information Technology’s “2015 Smart Manufacturing Pilot Demonstration Projects” and recognized among China’s “Top Ten Green Innovation Achievements.” On its demonstration production line, key technical and economic indicators—such as electricity and thermal consumption, levels of automation, process flow efficiency, and labor productivity—are all at world‑leading standards.
Luoyang Zhonglian Cement Co., Ltd.

 
 
Luoyang Zhonglian, driven by technological innovation, is fully committed to building a smart factory. It has established an intelligent control platform centered on the MES system, encompassing seven major modules: a production management and control system, an expert‑based intelligent control system for cement production, an intelligent cement equipment management system, an intelligent quality control system, an intelligent mining system, a lean manufacturing management system, and a unified card‑based unmanned operation system. By leveraging cutting‑edge technologies such as information technology, the Internet of Things (IoT), 3D simulation, big data analytics, and artificial intelligence, the company has achieved automated plant operations, visualized management, proactive fault prevention, seamless internal–external coordination, and intelligent decision‑making.
Huzhou Huaikan Southern Cement Co., Ltd.
 
 
At Huai’an South, a 7,500 t/d production line serves as a pilot demonstration site, further advancing the research and application of intelligent technologies such as the Internet, cloud computing, and big data in cement manufacturing. The demonstration line is equipped with world‑class technology and features intelligent process management; all stages—including raw material processing, transportation, clinker burning, and packaging—are fully visualized. As a result, the workforce has been reduced from 180 to 60 employees, achieving both workforce reduction and operational efficiency gains.
Yichun Hongshi Cement Co., Ltd.
 
 
Yichun Red Lion is designed in accordance with the standards of a “second-generation, next‑generation dry‑process production line,” as well as smart manufacturing and green environmental protection requirements. It employs internationally advanced dry‑process technology, with digital technologies deeply integrated into every stage, each production step, and every piece of equipment. Its technologies, equipment, and environmental protection systems are sourced from leading domestic and international manufacturers; it utilizes Caterpillar mining equipment from the United States to enable digitized mine extraction, thereby building a green mine to the highest standards. A Danish‑made Smith intelligent laboratory ensures automated quality inspection and control of cement and clinker, enhancing product quality stability. Additionally, proprietary equipment health‑management and expert‑optimization systems are deployed to ensure stable, high‑efficiency operation of the production line. State‑of‑the‑art automated loading and shipping equipment further boosts loading efficiency, reduces labor intensity, and improves the on‑site working environment. Through the integrated application of cutting‑edge processes and technologies, Yichun Red Lion has been developed into a large‑scale, highly intelligent cement plant.
China Resources Cement (Tianyang) Co., Ltd.
 
 
Building a comprehensive, intelligent, and modern cement manufacturing system. The 5G wireless network provides coverage across the Tianyang Park’s main plant area, the grinding station, the mining operations zone, and the mine‑office complex. On‑site monitoring and inspection devices, mobile terminals, vehicle‑mounted equipment, video surveillance systems, and other supporting platforms enable wireless data transmission and integration, while production‑process and quality‑inspection data can be analyzed in real time online. In addition, the park has deployed 5G‑enabled smart remote‑controlled loaders from Guangxi Liugong, allowing remote operation in the stockpiling area and significantly reducing the frequency with which personnel need to enter high‑dust environments. As a result, the Baise Tianyang China Resources Cement Plant has seen a 30% increase in production efficiency, a substantial improvement in safety, and a 20% reduction in labor costs.
Zunyi Saide Cement Co., Ltd.
 
 
The Zunyi Saide Cement Intelligent Laboratory System integrates automated sampling, manual sample delivery, automated sample preparation, and automated analysis into a single platform. Analysis results are automatically transmitted to the quality management system and the expert optimization system, enabling automatic recording, statistical processing, and in-depth data analysis, while also supporting quality‑optimized control of the production process. The production management system collects and aggregates operational data, provides a visual human–machine interface, and conducts data analytics for real-time monitoring and historical trend analysis, ensuring precise oversight of production conditions. A plant‑wide digitalization framework has been established, dynamically generating work orders for inspections, maintenance, lubrication, and overhauls, thereby facilitating equipment condition assessment and predictive maintenance. Furthermore, the system gathers and analyzes the quality of raw materials, semi‑finished products, and finished goods, enabling comprehensive plant‑wide quality analysis, forecasting, and early warning—from material receipt to shipment.
Guizhou Tongren Southwest Cement Co., Ltd.
 
 
In addition, Tongren Southwest Cement’s 2-million-ton-per-year intelligent production line is currently under intensive construction and, upon completion, is expected to break new ground as a pioneering demonstration project in the cement industry.
Go far by starting close; forge ahead with vigor. The widespread adoption of intelligent technologies in the cement industry remains a long and arduous journey. Fortunately, a dedicated group of pioneers has embraced the principle of “breaking down to build up,” carrying forward the legacy while charting new paths, thus guiding future generations through practical experience. In the years to come, the advancement of intelligence in the cement sector is poised to surge forward like a ship riding the wind, flourishing with unstoppable momentum. China Cement Network will host the “2020 China Cement Intelligent Manufacturing Summit Forum and the 12th International Grinding Summit” in Luoyang on October 28–29, 2020, where we will engage in in-depth discussions and extensive exchanges on key topics such as technological trends in smart manufacturing, cutting-edge applications, and emerging collaboration opportunities. We look forward to advancing together with you—“riding the waves” into the future!
 
In addition, Tongren Southwest Cement’s 2-million-ton-per-year intelligent production line is currently under intensive construction and, upon completion, is expected to break new ground as a pioneering demonstration project in the cement industry.
Go far by starting close; forge ahead with vigor. The widespread adoption of intelligent technologies in the cement industry remains a long and arduous journey. Fortunately, a dedicated group of pioneers has embraced the principle of “breaking down to build up,” carrying forward the legacy while charting new paths, thus guiding future generations through practical experience. In the years to come, the advancement of intelligence in the cement sector is poised to surge forward like a ship riding the wind, flourishing with unstoppable momentum. China Cement Network will host the “2020 China Cement Intelligent Manufacturing Summit Forum and the 12th International Grinding Summit” in Luoyang on October 28–29, 2020, where we will engage in in-depth discussions and extensive exchanges on key topics such as technological trends in smart manufacturing, cutting-edge applications, and emerging collaboration opportunities. We look forward to advancing together with you—“riding the waves” into the future!