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Experience

Methods from real sites

These projects were delivered by team members at their former organisation. Each lists what was done and the result reported in project materials. Customer identities are anonymised.

Steel · energy dispatch

Balancing gas, steam and air across processes

Northern steel group, 10 Mt/yr capacity

3%energy saving

What was done: The team surveyed supply and demand of gas, steam and compressed air across about ten processes, built at least fifteen energy models including hot-stove staggering guidance, and supported dispatchers in coordinating energy across processes.
Context: Project materials also report blast-furnace and coke-oven gas flaring reduced and output up 1%. Their estimate of total benefit is close to RMB 42 million a year (10 Mt × 1% × RMB 300/t, plus RMB 12 million from energy).

Delivered by team members at their former organisation. Results as reported in project materials.

Manufacturing · utilities

Baselines for every utility, coordinated supply and demand

Central-China cigarette manufacturer

−6.7%comprehensive energy per 10,000 cigarettes

What was done: More than 580 devices and 6,800 real-time points were modelled with 699 baselines and 290 energy-control networks, covering single-unit efficiency, group control and supply–demand coordination.
Context: Project materials report 3,027 tonnes of CO₂ avoided.

Delivered by team members at their former organisation. Results as reported in project materials.

Power · coal-fired generation

Seeing the coal you cannot measure

Eastern coal power plant, two supercritical units

>50%lower probability of unplanned outages

What was done: A unified platform with online soft sensing of coal quality and fly-ash carbon, and health monitoring of the eight major fans.
Context: Project materials also report coal consumption down by more than 1 g/kWh and benefits of about RMB 10 million a year.

Delivered by team members at their former organisation. Results as reported in project materials.

Paper · combined heat and power

Boiler efficiency managed against its baseline

Paper manufacturing base, eastern China

+1.5%boiler efficiency

What was done: Boiler efficiency management, load allocation between units and turbine generation strategy for the site’s heat and power plant.
Context: Project materials report annual benefits of about RMB 9.8 million.

Delivered by team members at their former organisation. Results as reported in project materials.

Special steel · quality

From raw material to inspection, one traceable line

Southern special-steel plant, 3 Mt/yr

+1.6%first-pass inspection yield

What was done: Whole-process quality visibility and online judgement, linking raw-material, process and inspection records so experts can investigate problems.
Context: Project materials also report management efficiency up 20% one year after go-live.

Delivered by team members at their former organisation. Results as reported in project materials.

Mining · equipment

Dust collection that warns before it fails

Eastern mining company, 2.4 Mt/yr aggregate

−50%maintenance cost

What was done: Remote dust monitoring, anomaly warning and fault identification, combined with operation and cleaning control of the dust collectors.
Context: Project materials also report electricity cost down 20% for the dust-collection system.

Delivered by team members at their former organisation. Results as reported in project materials.

Brewing · edge control

Seven kettles, one steam header

International brewer’s plant, central China

Steadiersteam supply and more consistent boils

What was done: One steam header feeds seven wort kettles. AI-assisted PID control of the steam valves ran at the edge, with statistical process control and boil scoring.
Context: Edge control project; scope and results are being confirmed, so no figures are shown.

Delivered by team members at their former organisation. Results as reported in project materials.