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A Large Cement Enterprise Introduces Pipeline Self-Discharging Iron Remover, Saving Over 260,000 Yuan in Maintenance Cos

2025-11-21

A 1.2 million-ton annual output grinding system production line of a cement plant has long been plagued by iron impurities in raw materials. Previously, traditional manually cleaned iron removers were used, which not only required special personnel to be on duty for cleaning every 2 hours but also caused severe wear of subsequent grinding equipment due to incomplete iron removal. The maintenance cost per ton of finished cement reached 0.45 yuan, with annual maintenance expenditure exceeding 540,000 yuan. In early 2024, the enterprise introduced a pipeline self-discharging automatic iron remover, which was installed at key nodes after the classifier and at the feed pipeline of the roller press to realize full-process automatic iron removal.

After the equipment was put into use, it realized unattended operation with its continuous automatic iron discharging function, reducing 2 full-time operators per production line and saving 120,000 yuan in labor costs annually. More importantly, the equipment increased the iron impurity removal rate of materials to over 98%, effectively reducing the wear degree of grinding equipment. The maintenance cost per ton of finished cement dropped to 0.2 yuan, directly reducing annual maintenance costs by 265,000 yuan. As of October 2025, the equipment has operated stably for 22 months, with a magnetic field attenuation rate of only 2.8%, and there has been no production line shutdown caused by iron removal problems. At present, the enterprise has fully promoted this equipment in its 8 production lines, increasing the annual comprehensive benefit by over 3 million yuan.

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