Sootblowing and Combustion Optimization to Improve Boiler Efficiency and Reduce Failure Rates using Pulse

Overview

In industrial boiler operations, attaining and maintaining the optimal efficiency level is crucial in minimizing emissions, lowering energy consumption, and decreasing operational costs. Fouling and suboptimal combustion are a few reasons for boiler inefficiencies, especially when dealing with fluctuating fuel quality. The Pulse Intelligent Digital Twin solution delivers real-time optimization for soot blowing cycles and combustion processes, driving enhanced efficiency, reduced equipment failures, and increased longevity for critical boiler components.

Discovery

Boiler operators face continuous ash and soot accumulation issues on heat exchange surfaces. The burning of inconsistent types of fuels, such as lignite, coal, or biomass aggravates this issue. The accumulation of fouling materials increases the value of Furnace Gas Exit Temperature (FGET), reduces heat transfer rates, and raises energy utilization. In addition, the use of different kinds of fuels introduces complexity in maintaining optimum combustion that leads to poor performance and even breakdown of equipment parts such as boiler tubes ad more. In most cases, since standard monitoring platforms cannot recognize occurrences such as fan stalls and mill chokes, and other parameters that give early warning signs efficiently, circumstances such as the timing of sootblowing or combustion adjustment are compromised.

Challenges

The client faced many critical operational hurdles while managing a diverse global fleet of boilers with capacities ranging from 30 TPH to 3000 TPH. Some of them are-

  • Fuel Variability:Inconsistent air-fuel ratios led to inefficient combustion, increased emissions, and energy losses.
  • Delayed Sootblowing Response:Inefficient sootblowing cycles increased FGET, reduced the efficiency of heat transfer, and increased operational costs.
  • Frequent Equipment Failures:The lack of early detection of combustion inefficiencies resulted in unplanned outages and increased costs during maintenance.
  • Data Overload:It was difficult for operators to extract meaningful insights from vast amounts of operational data, which led to issues in identifying early warning signs, including tube leaks and mill chokes.
  • Slow Operational Responses:Delayed reactions to operational inefficiencies led to increased costs of operations and a larger environmental footprint.



Approach

To overcome these challenges, the Intelligent Digital Twin solution of Pulse was seamlessly deployed in the client's boiler systems; this created a robust framework for real-time monitoring and analysis. The solutions delivered to the client were the following:

Smart Sootblowing Optimization:

Using real-time FGET and fouling data, Pulse was able to dynamically adjust sootblowing schedules. This ensures cleanliness and optimization of heat exchange surfaces at peak performance levels, thereby minimizing energy losses.

Advanced Combustion Tuning:

Pulse continuously optimized the air-fuel ratio using multivariate predictive models tailored to fluctuating fuel quality, significantly reducing emissions and improving combustion efficiency across a range of fuel types.

Data-Driven Insights:

Real-time dashboards provide actionable insights, enabling operators to make informed decisions regarding mill loading, fuel distribution, and auxiliary equipment performance. This allowed for rapid responses to inefficiencies before they escalated.

Comprehensive Boiler Risk Assessment:

Pulse’s automated diagnostics tracked critical parameters such as thermal profiles, water chemistry, erosion, and fatigue, enabling preemptive measures to prevent equipment failure and extend boiler life.

Impact & Learnings

The implementation of Pulse’s Intelligent Digital Twin sootblowing and combustion optimization solution yielded substantial benefits for industrial boiler operations:

Improved Boiler Efficiency:

By optimizing combustion and sootblowing, overall boiler efficiency increased by up to 0.75%, leading to reduced dry flue gas losses and lower operational costs. This efficiency gain also minimized auxiliary power consumption and significantly reduced overheating-related tube failures.

Reduced Equipment Failures:

Pulse’s predictive maintenance capabilities led to a 20% decrease in boiler tube failures and auxiliary equipment breakdowns, minimizing unplanned outages and maintenance costs.

Optimized Operational Performance:

Dynamic setpoint recommendations and timely sootblowing schedules reduced FGET and improved heat transfer, ultimately extending the lifespan of critical boiler components and improving reliability.

Sustainable Energy Generation:

These improvements not only enhanced operational efficiency but also supported sustainable energy production by lowering emissions and reducing energy waste.

These outcomes highlight Pulse’s ability to transform industrial boiler operations, demonstrating the power of predictive analytics and real-time optimization in driving measurable improvements in efficiency, reliability, and sustainability.



Conclusion

Pulse’s Digital Twin solution for sootblowing and combustion optimization empowers power plant operators with real-time insights, enabling them to make informed, data-driven decisions that enhance boiler performance. By addressing key challenges such as fuel quality variability, data overload, and inefficiencies in response times, Pulse helps power plants achieve significant reductions in operational costs, minimize equipment failures, and extend the lifecycle of critical assets. With its advanced predictive capabilities, Pulse is redefining operational standards in the power generation industry, ensuring long-term sustainability and reliability.

Unlock the full potential of your Boiler Systems with Pulse Digital Twin

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