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Proven Results

Industrial Energy Management System (EMS)

March 26, 2026

The Challenge

Industrial powerhouses depend on multiple boilers, steam headers, turbines, and fuel sources, requiring operators to constantly balance steam supply, fuel selection, equipment loading, and power purchase decisions—often during upset conditions. This manual, multi‑variable decision‑making increases operational risk and makes consistent energy optimization difficult, leading to inefficient equipment operation, missed opportunities to reduce purchased power, and higher overall energy costs.
The Solution

The Solution

Spartan Controls implemented an Industrial Energy Management System (EMS) using facility‑specific models and rule sets to continuously determine optimal operating setpoints across the powerhouse. The EMS coordinates boiler combustion, steam headers, and steam turbine generator controls to maximize efficiency and power generation while respecting process and equipment constraints.

Using model predictive control and expert system logic, the EMS automatically optimizes boiler load allocation, steam turbine loading, and electricity generation versus purchase decisions. The system operates in advisory or full automatic mode and is built on open, real‑time architecture to ensure long‑term stability, maintainability, and seamless integration with existing control systems.

The Value

The EMS delivered measurable economic and operational benefits:
 
  • 5–10% reduction in total energy costs through optimized fuel selection, boiler loading, and power generation decisions
  • Reduced purchased electricity costs by maximizing on‑site generation when economically favorable
  • Improved steam header stability during upset conditions, reducing production risk
  • Lower operator workload, eliminating manual energy trade‑off calculations
  • Improved decision consistency, with real‑time cost and constraint awareness built into control actions
Since deployment, the EMS has remained in continuous operation, delivering sustained energy cost reductions and reliable powerhouse performance.