Waste-to-Energy : Data-driven boiler optimisation
Explosion Power addresses this challenge through tailored boiler analysis. Rather than focusing on individual values, the company examines operating data and its correlations over multiple operation periods. This makes the heat exchange process easier to understand, allowing clear measures and actions to be defined, and identifying where Shock Pulse Technology can be applied to improve efficiency and reliability.
Shock Pulse Generators are mounted on the outside of the boiler wall, with the outlet nozzle leading through a connection piece or a manhole into the boiler interior. The sudden combustion of a mixture of combustible gas and compressed air generates a shock pulse that is introduced into the boiler and causes the flue gas flow and the heating surfaces to vibrate briefly, generating a structure-borne sound vibration within the deposits. These simultaneously acting mechanisms efficiently clean the deposits and improve the heat exchange.
From drawings to a digital twin
Based on measurements, schematics and boiler drawings, a digital twin of the boiler is created. This model records tube bundle types, arrangements and geometry, as well as the relevant measurement points. The resulting data streams are stored and visualised on a dedicated cloud platform, enabling plant operators and analysts to work with the same information in real time.
This structured evaluation creates a strong foundation for dialogue and improvement. Operators can see the actual impact of cleaning, track performance developments transparently, and adapt the use of Shock Pulse Generators to the specific operating mode of their plant.
A success story at Konin Waste to Energy Power Plant in Poland
After the installation of a Shock Pulse Generator Type SPGr10 in December 2024, all main process parameters stabilized and remained within limits, making previous manual cleaning activities unnecessary. The installation location was selected to address earlier challenges with flue gas pressure drop, flue gas temperatures, and superheater heat transfer. Based on in-house boiler analysis, Explosion Power provides operators with recommendations that can be adapted as needed.
Find out more: Case Studies from our customers – Explosion Power
Towards continuous improvement
By combining digital modelling with systematic operational data analysis, Explosion Power makes boiler operation more transparent, measurable and optimisable. The result is not just validation of cleaning measures, but a pathway to continuously improving performance in complex, real-world conditions.
Interested in optimising your boiler operation? Visit Our technology platform – efficient solutions for your boiler to learn how a data-driven approach can support your plant.
In cooperation with Explosion Power.