Pyrolysis boilers burn biomass highly efficiently – when they run optimally. However, without continuous monitoring, inefficiencies remain invisible: Too low combustion temperatures lead to energy losses, suboptimal oxygen supply results in incomplete combustion. This monitoring system captures over 300 data points per minute from Siemens S7 controllers and transmits them via MQTT and SparkplugB into a Unified Namespace. InfluxDB stores the time-series data, while Grafana dashboards provide real-time visualization and alerting. The result: Transparent operations management, optimized combustion, and centralized administration of multiple facilities across locations.
Pyrolysis boilers burn biomass highly efficiently - when they run optimally. But without continuous monitoring, inefficiencies remain invisible:
My monitoring system makes these parameters visible - in real time, centrally, scalably.
For the precise monitoring of pyrolysis boilers, I rely on the tried-and-tested MQTT and SparkplugB protocols. These enable reliable data acquisition and transmission in real time.
With MQTT (Message Queuing Telemetry Transport) as a lightweight, reliable protocol, sensor data can be collected efficiently and sent to a central control unit.
The use of SparkplugB, an MQTT-based protocol for industrial automation, ensures interoperability between the various components of the monitoring system.
A special feature of my system is the Unified Namespace (UNS), which makes it possible to manage a large number of systems in a standardised data space. By integrating all pyrolysis boilers into the UNS, operators can obtain a holistic view of their systems and make effective decisions to optimise operating processes.
Initial Situation: Biomass pyrolysis boilers at different locations. No central overview, manual on-site readings required.
Solution:
uns/location/boiler/parameterCaptured Parameters (per boiler):
Result:
Scalable: One UNS, any number of boilers - no separate integration per system
Open: MQTT + SparkplugB = manufacturer-independent, no vendor lock-ins
Real-time: Sub-second latency between sensor and dashboard
Maintainable: Standard protocols, open-source stack, no black box
Future-proof: Expandable to other assets (buffer storage, solar thermal, etc.)
The combination of MQTT, SparkplugB and the Unified Namespace not only provides efficient data collection and transmission, but also enables a scalable and flexible solution for monitoring pyrolysis boilers and other assets in different environments.
Planning a similar monitoring project?
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