In steel plants, dust removal fans are major power consumers, accounting for 30% to 40% of the total plant energy consumption. A medium-sized steel mill consumes 200 million kWh of electricity annually, and a single 2000kW fan incurs annual electricity costs of 6 to 7 million yuan.

Three major energy consumption pain points — drastic load fluctuations, slow manual adjustment and rough automatic control — not only cause massive energy waste, but also impair dust removal efficiency and endanger on-site environment and workers’ health.

Energy conservation and consumption reduction are extremely urgent, and the bottom line of environmental protection must be strictly observed. At the 2nd Iron & Steel Equipment Cooperation and Development Exchange Conference of the 15th Five-Year Plan Period and the 2026 (3rd) Iron & Steel Industrial Internet + Intelligent Manufacturing Collaborative Innovation Forum, Luculent accurately targeted industry pain points and proposed targeted solutions. The Sunshine Intelligent Energy Consumption Optimization Control System breaks industry bottlenecks efficiently and gains widespread recognition across the sector.

Tailored to actual enterprise demands, the system integrates AI, Internet of Things and big data technologies to activate data-driven operation and algorithm-based decision-making, featuring five core advantages:

1. Intelligent Optimization for Automatic Optimal Parameter Setting

Adopting the dual-drive mode of mechanism model and data-driven algorithm, it continuously establishes and optimizes models based on historical equipment operation and energy consumption data. It dynamically locks the optimal control parameters balancing stable production and minimum energy consumption, seamlessly connects with original control systems and automatically adjusts key parameters. Free from reliance on manual experience, it enables more efficient and stable equipment operation.

2. Independent Evolution for Rising Energy-saving Efficiency

The AI model keeps iterating along with changing working conditions. It captures real-time condition changes and automatically calculates the optimal parameter range with self-evaluation and self-upgrade capabilities. It can precisely adapt to production schedule adjustments and equipment status fluctuations, timely optimize control strategies, and maintain steady and growing long-term energy-saving effects.

3. Safety Closed-loop Control for Unattended Reliable Operation

Optimized commands are directly delivered to control systems with second-level response and full-automatic closed-loop operation requiring no manual intervention. Equipped with heartbeat monitoring, abnormal alarm push, secure data collection and other multi-layer protection mechanisms, it ensures stable fan operation and eliminates potential control risks.

4. Precise Dust Control to Balance Environmental Compliance and Energy Saving

Embedded with dust video recognition model with recognition accuracy over 95%, the system instantly speeds up dust collection once excessive dust is detected to curb dust diffusion and meet environmental standards. It incorporates dust monitoring data into AI iterative learning to realize optimal operation balancing environmental protection and energy conservation. It also supports regular automatic ash cleaning to prevent pipeline ash blockage.

5. Visualized Supervision to Simplify Decision-making

Supported by energy consumption cockpit, comprehensive energy consumption analysis and energy-saving trend dashboard, power consumption status, energy-saving effects and energy efficiency deviations are fully visualized. It facilitates intuitive monitoring, accurate judgment and efficient decision-making for managers at all levels, realizing the transformation from experience-based management to data-based and intelligent management.

This system features no hardware renovation requirement, short implementation cycle of only 2 to 3 weeks, low investment and quick returns. Statistics show that after deployment on a single 2240kW dust removal fan, power consumption can be cut by 5%-15%, saving nearly 300,000 yuan in annual electricity fees, and achieving triple benefits in environmental protection, economic profit and operational safety.

At present, the Sunshine Intelligent Energy Consumption Optimization Control System has become a trusted digital intelligent partner of leading steel enterprises including Baowu Group and Hangzhou Iron & Steel Group. It has also won wide authoritative industry recognition: selected into the 2025 MIIT Intelligent Manufacturing Open Challenge Projects and the Extreme Energy Efficiency Capacity List released by China Iron and Steel Association, and awarded the Technical Characteristic Award in Industrial Internet Competition and Annual Excellent Case by Industrial Internet Industry Alliance.

Notably, this technology is widely applicable to various high-energy-consuming equipment such as fans, water pumps and air compressors. Combined with AI multi-modal intelligent diagnosis technology, it realizes early and accurate equipment fault warning, further improves equipment energy efficiency and reduces maintenance costs. It fully supports enterprises’ green low-carbon transformation and sustainable development, and provides a replicable, promotable and high-efficiency Luculent Sunshine Solution for industrial energy conservation.