With "AI + Data", Empower Smart Plant Construction and Accelerate the Digital Transformation of the Salt Chemical Industry

Jiangxi 92 Salt Industry Co., Ltd. (referred to as "92 Salt Industry"), was established in March 1970. The company owns the Zongtian Salt Mine, with a rock salt reserve of 177 million tons. It has built production facilities with an annual output of 600,000 tons of vacuum salt, 150,000 tons of small packaged edible salt, 300,000 tons of ion membrane caustic soda, 180,000 tons of hydrogen peroxide, and an 18 MW steam turbine generator for combined heat and power generation. This forms an integrated salt-chemical industry chain of "salt + caustic soda + hydrogen peroxide + cogeneration."

In collaboration with SUPCON, 92 Salt Industry is committed to building a new type of smart plant integrated production automation, visualized management, optimized energy consumption, intelligent operations, and remote monitoring and diagnostics. The project was launched in August 2023 and was completed and fully operational in June 2024, laying a solid foundation for the company's digital transformation.

01 Intelligent Control Significantly Improves Production Efficiency

Based on the "1+2+N" Smart Plant Architecture, the upgrade achieved deep integration of automated production processes and enterprise operations. Through the Operation Management & Control System (OMC), standardized operations are achieved, reducing operational thresholds and decreasing manual operation frequency. Ultimately, 92 Salt Industry achieved remarkable operational results -- the effective self-control rate of chloralkali unit loops exceeded 95%, electrolyzer APC controller usage rate reached 100%, ineffective alarms reduced by over 30%, the standard deviation of key parameters decreased by over 50%, 100% product qualification rate for alkali products under normal production conditions, ±0.1% deviation in 32% alkali concentration, and a 2% increase in production output.

02 "AI + Safety" Enhances Integrated Safety Management

92 Salt Industry has established a plant-wide integrated automatic control system and production safety emergency linkage platform based on?industrial operating system. By applying AI video analysis technology to automatically identify unsafe behaviors, the response time for safety warnings was improved by 20%, significantly shortening the time gap between problem detection and action, effectively preventing potential safety incidents. Additionally, the central control room displays a 3D visualization of the site, clearly showing personnel locations, work areas, and hazard locations. It also integrates surveillance video and real-time alarm information, allowing the company to comprehensively grasp the safety status of the production site.

03 Preventive Maintenance Reduces Operational Costs

In equipment management, 92 Salt Industry uses instrument control health management software for predictive maintenance and intelligent diagnostics of control systems and field electrical smart instruments, reducing maintenance workload. SUPCON?also?equipped 50 key rotating equipment with wired vibration sensors, and real-time operational parameters of 1,137 main equipment units are collected and integrated into industrial operating system. This creates a specialized equipment data lake, effectively eliminating information silos at the equipment level. Through the monitoring and fault grading system of rotating equipment, the operating status of key equipment is accurately grasped, problems are detected promptly, and precise diagnostics are provided, thereby improving production efficiency, reducing maintenance costs, and ensuring production stability and safety.

04 Big Data Empowers Lean Management

A unified data foundation was built based on industrial operating system to break down data silos, enabling real-time data collection and display. Access to various business systems was unified, reducing operational processes by over 50% and improving query efficiency by more than 90%. Horizontal collaborative work improved information?transmission efficiency between departments by over 30%, reduced paperwork by more than 50%, decreased data collection and report preparation workload by 80%, and enhanced management efficiency by over 15%.

Through digital methods, paperless office operations were achieved, and electronic record-keeping facilitated data analysis and sharing, enhancing data utilization efficiency, reducing human interference, and ensuring data authenticity and reliability. Managers can monitor key production line indicators in real-time, comprehensively analyze various data, and provide strong support for decision-making.