Innovation and excellence define the way we approach energy management. Our commitment to efficiency, sustainability, and operational excellence has led us to adopt cutting-edge technologies that push boundaries and set new industry benchmarks. One such milestone is the implementation of Model Predictive Control (MPC) in our captive power plants, an achievement that is revolutionising the way we generate and optimise power.
MPC is more than just an upgrade, it is a game-changer. By bringing intelligence, automation, and predictive capabilities into our operations, we have redefined efficiency across five fuel gas-fired boilers and five steam turbine generators (STGs), while seamlessly managing 30 air-cooled condenser (ACC) fans. This transformation ensures stable and optimised energy production, allowing us to operate with greater precision and reliability.
At the heart of this initiative is the Hexa-Pilot system, a technological marvel that dynamically adjusts ACC fan speeds based on real-time cooling demands, maximising heat rejection and minimising energy waste. Our boilers now operate at peak efficiency, with advanced combustion control that optimises the fuel-air mix, driving down emissions while enhancing performance. The impact extends to our STGs, where adaptive control strategies balance power output and stabilise high-pressure steam headers, critical for the seamless functioning of turbine-driven pumps that power our production operations.
The results speak for themselves. By leveraging MPC, we have significantly reduced fuel gas consumption, strengthened operational stability, and unlocked new levels of efficiency. With power output now maximised through intelligent automation, we have eliminated manual intervention, enabling a smoother, more reliable energy supply. The ability to analyse real-time calorific values has further refined combustion strategies, making decision-making smarter and more effective than ever before.
This initiative is not just about cost savings, though the $1 million annual savings are a testament to its impact. It is about setting new standards, leading the way in energy innovation, and proving that with the right technology and vision, we can achieve remarkable breakthroughs. We don’t just adapt to change, we drive it. Our success with MPC reflects our unwavering pursuit of excellence, cementing our position as industry leaders in sustainable, intelligent power management.
Contributed by Anoushka Ailawadi
