Power plants face downtime, high fuel consumption, poor heat rate, and operational instability. Inefficiency arises from combustion losses, auxiliary power wastage, enthalpy loss, and leakages. AI-driven data collection provides diagnostics and prescriptive analytics for operations and maintenance
Continuous monitoring of boilers, turbines, condensers, cooling towers, BFPs, and heat exchangers
Automated identification of efficiency losses, anomalies, and root causes
Prescriptive insights enabling proactive operations and maintenance actions
AI operational intelligence to optimize bed combustion and minimize unburnt carbon losses
Auxiliary Power Analytics
Efficiency tracking and recommendations for BFP, ID/FD fans, and cooling tower performance
Heat Exchange Analytics
Performance tracking for HP/LP heaters, deaerators, and superheaters with maintenance alerts
Advanced Anomaly Detection
Early detection of process deviations with root cause analysis to prevent operational failures
Soot Blower Optimization
AI-scheduled soot blowing to optimize heat exchange and reduce steam consumption and fouling
Condenser-Tower Circuit Optimization
Maximize power output by optimizing exhaust enthalpy, vacuum, and dryness fractions
Real-time KPI Tracking
Continuous monitoring of NHR, LOI, and FEGT with instant insights when parameters drift out of range
Varied Configuration Support
Customized solution logic for AFBC, CFBC, and PF boilers across all turbine configurations
Why Faclon Labs
Distinct strengths enabling successful AI-driven power plant optimization
Advanced AI and LLM Use Cases
Leveraging machine learning for anomaly, diagnostic, and prescriptive operational analytics
Deep Subject Matter Expertise
Access to expert consultants with decades of experience in complex power plant operations
Unique SME-AI Hybrid Solution
Combining cutting-edge data science with specialized engineering knowledge for high precision
Cybersecurity Compliant Architecture
Meets necessary OT and IT cybersecurity standards for sensitive industrial data protection
Tailor Made Deliverable Design
Solutions customized based on specific plant configurations and stakeholder preferences
Focus on Actionable Insights
Prioritizing clear recommendations for O&M teams to act on immediately for performance gains
CASE STUDY - POWER PLANT NHR REDUCTION
AI-Driven Heat Rate Optimization at a Leading 21 MW Paper Power Plant
The project integrated boiler combustion data and thermal cycle parameters for a 21 MW power plant at one of India’s largest pulp and paper mills. This system digitized the monitoring of NHR, LOI, and auxiliary power, creating a unified system of records for enterprise-grade efficiency tracking. The solution provided real-time prescriptive analytics to optimize the heat rate and stabilize operations across the facility
ROI Achieved in Under 6 Months: The system paid for itself rapidly through significant fuel savings and improved process stability
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