1. Project Background: The old factory faces difficulties and urgently needs a breakthrough

A thermal power company in northern Anhui, a long-established factory operating for many years, has long faced thorny issues such as outdated equipment and difficult process control in its boiler steam-water system. As the operating years increase, the original monitoring and dosing equipment ages severely, with reduced accuracy and frequent failures, resulting in large fluctuations in water quality, frequent scaling, and corrosion. This not only affects power generation efficiency but also increases maintenance costs and safety risks. At the same time, the complex process flow and spatial layout of the old factory further increased the difficulty of renovation, and traditional renovation plans could not meet actual needs. Against this backdrop, a thermal power company in northern Anhui urgently needs a targeted, efficient, and reliable intelligent management and control system upgrade plan.

2. Core Project Solutions: Tailored and Precise Measures

Mozhidao Measurement & Control tailored a boiler steam-water quality intelligent control system renovation plan based on the actual situation of a thermal power enterprise in northern Anhui, covering four core modules: boiler steam-water monitoring system, chemical water dosing system, boiler dosing system, and circulating water dosing system, comprehensively solving the problems faced by old plants.

(1) Boiler Steam-Water Monitoring System: High-precision insight and real-time warning

Advanced sensor layout: At key points of the boiler steam-water system, such as feedwater, steam, and furnace water, high-precision sensors are precisely installed to monitor more than ten key indicators in real time, including conductivity, dissolved oxygen, pH, hardness, silicon dioxide, sodium ions, alkalinity, chloride ions, etc. Detection accuracy reaches ±5%, with a data error rate below 0.5%, ensuring accurate and reliable water quality data.

Intelligent Data Analysis Platform: Builds an intelligent data analysis platform to collect, analyze, and process monitoring data in real time. By setting thresholds, if water quality indicators exceed safe limits, the system immediately issues warning signals to alert maintenance personnel to take timely action and prevent water quality issues from worsening.

Compatibility design: fully considering compatibility with existing equipment from old factories, standard communication interfaces (such as RS485, TCP/IP, 4~20mA) are used, allowing seamless integration with existing DCS systems for data sharing and centralized management, eliminating the need for large-scale equipment replacement and reducing retrofit costs.

(2) Chemical and chemical dosing system: precise regulation, consumption reduction, and efficiency improvement

Intelligent dosing control algorithm: Based on advanced control algorithms, it automatically calculates and adjusts the dosage of scale inhibitors and corrosion inhibitors based on real-time changes in influent quality, achieving precise dosing. Compared with traditional dosing methods, chemical waste is reduced by more than 30%, effectively lowering operating costs.

Efficient dosing equipment upgrades: Existing dosing equipment is upgraded and modified, using new materials that are corrosion-resistant and wear-resistant to improve the equipment's service life and stability. At the same time, optimize equipment structure, improve chemical mixing efficiency, ensure uniform distribution of chemicals, and enhance water treatment effectiveness.

Remote monitoring and operation: Equipped with remote monitoring and operation functions, operation and maintenance personnel can check the operating status and remaining dosage levels of dosing equipment anytime and anywhere via mobile phones or computers, and remotely control equipment start/stop and adjust dosing parameters, improving operation and maintenance efficiency and reducing on-site inspection workload.

(3) Boiler dosing system: dynamic balancing and equipment protection

Dynamic dosing strategy: Formulate dynamic dosing strategies based on boiler operating conditions and online monitoring data. Based on changes in furnace water pH, conductivity, and other indicators, the dosage of phosphate, sodium hydroxide, and other chemicals is adjusted in real time to keep the boiler water quality within the optimal range, prevent scaling and corrosion, and protect the safe operation of boiler equipment.

Safety protection design: Multiple safety protection devices are installed in the dosing system, such as over-temperature and over-pressure protection, power-off protection, and leak alarms, ensuring the equipment can automatically stop operating and issue alarms in abnormal situations, preventing accidents.

Modular design: Adopts a modular design concept, dividing the dosing system into multiple independent modules for easy installation, maintenance, and upgrades. Interfaces between modules are standardized, allowing flexible combinations according to actual needs to improve system adaptability and scalability.

(4) Circulating water dosing system: adapts to complex working conditions and improves circulation efficiency

Strong anti-interference capability: In response to the complex water quality and vulnerability to external interference in old plant circulating water systems, sensors and control equipment with strong anti-interference capabilities are used to ensure accurate monitoring of water quality indicators and stable dosing control even under harsh working conditions.

Intelligent linkage control: Achieves intelligent linkage control between the circulating water monitoring system and the dosing system. When the quality of circulating water changes, the system automatically adjusts the dosing amount, and optimizes dosing strategies based on factors such as the operating status of the circulating water pump and the cooling tower's heat dissipation efficiency to improve the overall operational efficiency of the circulating water system.

Energy-saving and environmentally friendly design: Optimized chemical formulations, selecting environmentally friendly agents to reduce environmental pollution. At the same time, precise dosing reduces chemical consumption, decreases water waste, and achieves energy conservation and emission reduction goals.

3. Project Highlights: Tailor-made, breakthrough challenges

(1) In-depth research, precise customization

During the early stages of the project, the Modaodao measurement and control project team conducted a comprehensive and in-depth survey of a thermal power enterprise in northern Anhui, thoroughly understanding the old plant's equipment status, process flow, and operational pain points. Based on the research results, customized renovation plans were tailored for old factories to ensure they met actual needs and effectively addressed the challenges faced by old factories.

(2) Innovate technology and efficiently transform the market

By adopting a series of innovative technologies and equipment, such as high-precision sensors, intelligent control algorithms, and modular design, efficient upgrades to the boiler steam-water quality intelligent control system are achieved without affecting normal production at the old plant. The renovation process emphasizes construction safety and quality control to ensure the stable and reliable operation of the renovated system.

(3) Professional team, full-process service

We have a professional project implementation team, with members possessing extensive experience and expertise in renovating old factories. From project planning, design, and construction to commissioning, training, and after-sales, we provide full-process one-stop services. During project implementation, maintain close communication with the client, promptly resolve any issues encountered, and ensure smooth project progress.

4. Project Outcomes: Significant improvement, win-win for all parties

(1) Significant improvement in water quality

After the renovation, the boiler steam-water quality of a thermal power enterprise in northern Anhui improved significantly, with all indicators stably kept within the qualified range. Scaling rate is reduced by more than 60%, corrosion rate by about 50%, effectively extending equipment service life and lowering maintenance and replacement costs.

(2) Improved operational efficiency

Through precise dosing and intelligent control, boiler thermal efficiency improves by 2% - 3%, unit power generation efficiency by about 5%, and annual power generation increases significantly. At the same time, the operational efficiency of the circulating water system improves, water resource recycling rates increase, and production costs are reduced.

(3) Reduced management costs

The intelligent control system achieves automation and intelligence in water quality monitoring and dosing control, reducing manual operations and on-site inspection workload, and lowering labor costs. At the same time, the system features data recording and analysis functions, providing scientific evidence for operations and maintenance management, and improving management efficiency and decision-making levels.

(4) Demonstration and Leading Role

The successful implementation of the boiler steam-water quality intelligent control system renovation project for a thermal power enterprise in northern Anhui has provided valuable experience and demonstration cases for the renovation of similar old plants, promoting technological progress and intelligent development in the industry.

5. Customer Evaluation

A relevant person in charge from a thermal power company in northern Anhui said: "Mozhidao Measurement & Control has tailored an intelligent boiler steam water quality control system renovation plan for us, precisely solving problems such as outdated equipment and difficult process control at old plants." After the renovation, water quality stabilized, operational efficiency improved, management costs decreased, and significant economic and social benefits were achieved. We are very satisfied with Mozhidao Measurement & Control's professional capabilities and service attitude, and look forward to more opportunities for cooperation in the future. ”

Mozhidao Measurement & Control—Driving Development with Innovation, Leading the Future with Intelligence