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Particle size variation negatively impacts combustion efficiency, product quality, yield, and equipment health. Manual sampling is delayed and intermittent, making it impossible to support real-time process control or react to rapid material changes. Faclon Labs uses vision-based analytics to measure particle size distribution continuously and non-intrusively directly from the conveyor-based material flow.
Continuous measurement of particle size directly from conveyor-based material flow.
Early detection of size deviations enabling proactive upstream process adjustments.
Digital visibility into material consistency supporting quality and efficiency goals.
Measured improvements in process efficiency, quality, and material consistency
Core vision-based capabilities enabling real-time particle size monitoring
Key strengths behind accurate and scalable particle size analytics deployments
Faclon deployed a vision-based particle size analysis system at a large thermal power plant to monitor coal quality in real-time before it enters the boiler. This digital transition replaced intermittent manual sieve analysis with a continuous diagnostic hub, providing the operations team with a real-time "size map" of the incoming fuel. The system allows for immediate adjustments to the milling process, ensuring optimal combustion and reducing the losses associated with unburned carbon.
2.5% Improvement in Combustion Efficiency by ensuring consistent coal fineness for the boiler feed.
15% Reduction in Unburned Fuel through precise real-time control of the pulverizer output size.
Real-Time Process Corrections enabled by instant alerts on coal size deviations.
Data-Driven Operational Optimization across the entire fuel handling and milling circuit.
Transition to a proactive reliability strategy. Our platform monitors asset health facility-wide, helping you plan maintenance effectively, reduce unplanned downtime, and protect your critical industrial infrastructure.
