Background and Rationale

In Pakistan, approximately 30% of electricity is generated from coal-based thermal plants. Pakistani coal, however, has a high ash content (30-45%), in contrast to imported coal (10-15%). Consequently, thermal power plants produce significant quantities of fly ash, a byproduct of burning pulverized coal and lignite. The disposal of fly ash necessitates vast land areas and poses environmental risks, including air and water pollution.

The adoption of IIoT technologies in the energy sector offers numerous advantages, including improved environmental management. In this project, the integration of IIoT aims to streamline the collection, storage, and disposal of fly ash, enabling real-time monitoring and enhancing the efficiency of ash utilization.

System Description

Integration and Architecture

At the thermal power plant, FAIZAL implemented an advanced fly ash handling system by integrating IIoT technology with the plant’s existing management software. The system architecture involves the following key components:

1. Data Acquisition Systems (DAQ)
   • Each DAQ system is equipped with an IIoT gateway that can interface with various controllers and devices through industrial communication protocols.
   • The DAQ systems collect parameters from the AHP of Units 1, 2, and 3.
2. Communication Protocols
   • Unit 1 and Unit 2: These units utilize PLCs that support Modbus TCP and Ethernet/IP communication protocols, respectively. The DAQ systems read data directly through these protocols.
   • Unit 3: The MaxDNA Distributed Control System (DCS) at Unit 3 does not support third-party communication protocols. Therefore, data from Unit 3 is obtained through analog signals (4-20mA), which are then integrated into the DAQ system’s Analog Input modules.
3. Cloud-Based Management Software
   • Data collected by the DAQ systems is transmitted to the cloud-based IIoT platform.
   • The platform integrates the collected data into the management software using REST APIs.
   • The management software provides a comprehensive dashboard for real-time monitoring and historical data analysis.

Real-Time Monitoring and Data Analysis

• The IIoT platform enables real-time monitoring of all critical parameters related to the ash handling process.
• Data visualization tools within the software allow operators to view live status, alarms, and operations across all remote sites.
• Historical data is archived in an SQL database, facilitating trend analysis and predictive maintenance.

Results and Benefits

Improved Fly Ash Utilization

The integration of IIoT technology has significantly enhanced the plant’s ability to utilize fly ash effectively. Key benefits include:

1. Environmental Protection
   • The project contributes to environmental sustainability by reducing soil pollution and conserving topsoil.
   • Effective fly ash management reduces the need for large disposal areas, preserving land for other uses.
2. Operational Efficiency
   • Real-time data collection and analysis enable the plant to monitor the ash handling process more efficiently.
   • The system helps in identifying and addressing issues promptly, minimizing downtime and maintenance costs.
3. Enhanced Monitoring and Control
   • The centralized cloud-based system allows for continuous monitoring of ash handling operations.
   • Operators can access real-time data from any location, ensuring better control and decision-making.
4. Sustainable Development
   • The project aligns with sustainable development goals by promoting the efficient use of resources and reducing the environmental impact of coal-based power generation.

By leveraging advanced IIoT technologies, The Lucky Electric Power Company has enhanced its operational capabilities and demonstrated a strong commitment to environmental stewardship and sustainability in its thermal power plant operations. The successful implementation of this project sets a benchmark for other power plants seeking to integrate IIoT solutions for improved efficiency and environmental management.