Steam Header Management

Managing the industrial powerhouse to minimize the costs of electricity and steam requires constant attention and a great deal of information management.

Typically, significant manual intervention occurs as operations personnel are continuously multi-tasking and making critical process control decisions.

Our steam header and energy management optimization system is used to stabilize steam header operations and reduce the total cost of energy in a mill by automating critical decision making and process adjustment.

The steam header system automatically coordinates all boilers, PRVs, steam turbines, and vents in a prioritized manner to stabilize steam headers during upsets and maintain a proper thermodynamic balance. The Energy Management System (EMS) then optimizes energy costs and generation by employing facility-specific models and rule sets to continually determine the optimum setpoints for all powerhouse process units.

Proven Results

Our fellow Emerson Impact Partner implemented a steam header and Energy Management System (EMS) at a pulp mill in British Columbia. With the new solution in place, steam header variability was reduced and upsets were handled more consistently, leading to fewer boiler trips. Further, electrical generation was maximized, resulting in an average 2 MW increase in power production. This resulted in over $2,000,000 in savings for the Customer to date.

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