Burner
An industrial burner in a power plant can be adjusted more precisely using IoT data from the steam network. A burner that produces only as much temperature as needed cuts energy demand without compromising steam quality.
Burner at a glance
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Optimising an industrial burner with live steam network data
The basis is a set of high-temperature sensors retrofitted to the steam pipes, continuously measuring steam temperature at many points in the network. Readings travel via LoRaWAN and MQTT to a platform, and a dashboard shows live temperature curves for every section of the network. A digital twin of the steam networks combines this data and provides the basis for automatically fine-tuning the burner settings in the power plant. Previously, temperatures were recorded only manually and not continuously, so the analysis came too late for timely adjustment.
The solution example comes from the chemical industry and falls under temperature measurement in condition monitoring. CURRENTA operates eight steam networks with three steam grades across its three CHEMPARK sites. Without an overview of live temperatures, the power plant sometimes fed in steam at unnecessarily high temperatures, wasting energy and reducing efficiency. Currenta Conneqtive fitted each network with 10 to 15 high-temperature sensors and transmits the data over its own LoRaWAN. Since then, the live data has provided the basis for automatically fine-tuning the burner settings in the power plant instead of adjusting them late after manual analysis. A further improvement using machine learning is planned as the next step.
Industrial burners: frequently asked questions
How are power plant burner settings adjusted using data?
Burner settings are fine-tuned based on measured steam temperatures in the network rather than on experience. Sensors continuously report the temperature that actually reaches the points of use. If it is higher than required, the burner can be turned down. At CURRENTA, a digital twin of the steam networks supplies this data as the basis for automatically fine-tuning burner settings in the power plant. Previously, manual analysis prevented timely adjustment.
How is industrial burner control linked to process data?
Industrial burner control is linked to readings from the process the burner supplies. At CURRENTA, these are steam temperatures from the networks, captured by retrofitted high-temperature sensors and transmitted via LoRaWAN. A digital twin of the steam networks brings the values together. On this basis, the burner settings in the power plant are fine-tuned automatically instead of being adjusted late after manual analysis.
Why do poorly matched burner settings waste energy?
If the burner is set to a higher temperature than the process requires, it generates heat that nobody uses. At CURRENTA, there was no overview of live temperatures in the steam network, so unnecessarily high temperatures went unnoticed. The result was higher energy demand and lower power plant efficiency. Manual analysis also prevented timely adjustment of the burner settings.
What does an operator need to optimise an industrial burner?
Above all, the operator needs reliable measurement data from the process the burner supplies. At CURRENTA, these are temperatures from the steam networks, captured by retrofitted sensors and transmitted via LoRaWAN and MQTT. A dashboard makes the values visible and a digital twin brings them together. On this basis, the burner settings are adjusted automatically, with machine learning to be added in future.
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