HollySys Commissions Smart Power Plant Pilot Project for Fuchun Environmental Protection

HollySys, in collaboration with Jiangsu Fuchunjiang Environmental Protection Heat & Power Co., Ltd., has successfully commissioned and completed performance acceptance for the Phase I pilot project of the Smart Power Plant in Jiangsu, China, covering Unit #2 of Boiler #3. All project targets were achieved as planned, earning strong recognition from the client.

Project Background

The thermal power plant operates three 110 t/h high-temperature, high-pressure circulating fluidized bed (CFB) boilers, along with two 15 MW back-pressure turbine generator units. The plant adopts a header-based steam supply mode, delivering process steam to industrial park users after temperature and pressure reduction through back-pressure units. Due to fluctuating and uncertain steam demand from downstream enterprises, the plant has long faced operational challenges, including significant boiler load variations, low automatic control engagement, and high operator workload. In addition, stable operation has been highly dependent on individual experience and manual intervention. To enhance the stability and reliability of steam supply, Fuchun Environmental Protection selected Unit #2 of Boiler #3 as a pilot for optimization and control system upgrades. Following comprehensive site evaluations and technical assessments, HollySys was chosen as the project partner to jointly advance energy efficiency and intelligent operation.

HollySys' Solution

The project leverages HollySys’ Intelligent Optimization Control System (HiOC) to implement a full-process intelligent upgrade across Unit #2 of Boiler #3. The solution covers key facilities including boiler combustion, steam-water, boiler-turbine coordination, deaeration utilities, and environmental protection systems. Based on in-depth site investigations and process analysis, the HollySys team tailored the solution to actual operating conditions, integrating proprietary time-series prediction models with advanced technologies such as data mining, model training, reinforcement learning, and intelligent human-like operation simulation. Combined with core functions including self-optimization and alarm navigation, the solution enables dynamic load optimization and coordinated control, allowing rapid response to external demand fluctuations.

Customer Value

Improved Efficiency

Leveraging core technologies such as self-optimization and soft sensing, the solution integrates precise control with coordinated optimization to overcome operational difficulties, ensuring the boiler consistently operates at high efficiency.

Higher Stability

Following commissioning, the stability of key process parameters has improved by 40%, enabling smoother and more reliable operation.

Increased Automation and Intelligence

Following commissioning, the boiler’s air–fuel–water and environmental protection systems have achieved fully automated and intelligent operation, with the intelligent optimization system maintaining an automatic engagement rate of 95%+. Stable autonomous operation is ensured under significant external steam demand fluctuations across a wide load range of 50%–110%, with reduced load response lag. In addition, real-time dynamic optimization of the air–fuel ratio has been realized.

Operational Safety

Operator workload has been significantly reduced, minimizing the risk of human error and strengthening overall operational safety.

Energy Saving & Emission Reduction

Steam output per ton of coal has increased by 1%+, while ammonia consumption per ton of flue gas has been reduced by 3%+.

Trend curves of key operating parameters after the commissioning of HiOC

The project marks the completion of Fuchun Environmental Power’s first intelligent boiler optimization upgrade, and provides a scalable and replicable benchmark for the digital and intelligent transformation of the energy sector. Moving forward, HollySys will continue to focus on the intelligent upgrade needs of the thermal power industry, advancing its technologies and solutions to help customers reduce energy consumption, improve efficiency, and achieve smarter operations, empowering sustainable development across the energy sector.