Steam and power networks are the energy backbone of process industries: yet they are often operated reactively, leaving significant savings ...
Steam and power networks are the energy backbone of process industries: yet they are often operated reactively, leaving significant savings ...
Overview
Steam and power networks are the energy backbone of process industries: yet they are often operated reactively, leaving significant savings on the table. AhilyaSoft deploys advanced optimization solutions that model your entire steam and power network (boilers, turbines, letdown stations, headers, condensate systems) and continuously compute the optimal load allocation and operating strategy to minimize total energy cost while meeting all process demands.
Methodology
Comprehensive thermodynamic model of your complete steam and power network: boilers, turbines, headers, letdown stations, deaerators, and condensate system.
Real-time efficiency curves for each piece of equipment, continuously updated from plant data to reflect actual performance including degradation.
Mixed-integer nonlinear optimization that determines optimal boiler loading, turbine extraction, letdown usage, and power import/export to minimize total energy cost.
Optimized setpoints pushed to DCS/APC for automatic implementation, with continuous re-optimization as demands, ambient conditions, and prices change.
What You Gain
Measurable results within weeks, not quarters.
Reduce fuel costs by 5–12% through optimal boiler and turbine loading
Maximize power export revenue in cogeneration facilities
Balance steam headers automatically across varying process demands
Identify and eliminate steam venting, letdown losses, and condensate waste
Support what-if analysis for capital investment decisions (new boiler, turbine, etc.)
Deployed across industries where milliseconds and margins matter.
Applications
Sugar cogeneration: maximize bagasse utilization and power export
Refinery utility plant: optimal fuel allocation across multiple boilers and turbines
Pulp & paper: recovery boiler and power boiler load optimization
Chemical complex: multi-header steam network balancing
District energy systems: optimal heat and power dispatch
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