Your pyrolysis boiler is running. The flame is burning. But how efficiently?

Without monitoring, you don't know. This solution collects 50+ data points per minute - and visualizes them in real time.

Why Monitoring for Pyrolysis Boilers is Critical

Pyrolysis boilers burn biomass highly efficiently - when they run optimally. But without continuous monitoring, inefficiencies remain invisible:

• Combustion temperature too low → energy loss
• Oxygen supply not optimal → incomplete combustion
• Ash buildup → missed timely maintenance

My monitoring system makes these parameters visible - in real time, centrally, scalably.

Architecture: MQTT and SparkplugB in the Unified Namespace

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.

MQTT: Lightweight and Reliable

With MQTT (Message Queuing Telemetry Transport) as a lightweight, reliable protocol, sensor data can be collected efficiently and sent to a central control unit.

SparkplugB: Industrial Interoperability

The use of SparkplugB, an MQTT-based protocol for industrial automation, ensures interoperability between the various components of the monitoring system.

Unified Namespace (UNS): Scalable and Central

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.

Technologies Used

Hardware & Control:

• Siemens S7 PLC (data acquisition at boiler)
• Sensors: Temperature, Pressure, Oxygen, Flow

Industrial IoT Stack:

• MQTT Broker (Mosquitto/HiveMQ)
• SparkplugB Protocol Specification
• Unified Namespace Architecture

Data Logging & Visualization:

• InfluxDB (Time-Series Database)
• Grafana (Dashboard & Alerting)
• NodeRED (Data Processing & Workflows)

Integration:

• Siemens S7 MQTT Connector
• SparkplugB Client Libraries

Practical Example: Multiple Pyrolysis Boilers in the Unified Namespace

Initial Situation: Biomass pyrolysis boilers at different locations. No central overview, manual on-site readings required.

Solution:

• Each boiler gets a SparkplugB-capable PLC (Siemens S7)
• All publish to a central MQTT broker
• Unified Namespace grouped by: uns/location/boiler/parameter
• InfluxDB stores all metrics
• One central Grafana dashboard for all systems

Captured Parameters (per boiler):

• Combustion temperature (multiple zones)
• Exhaust gas temperature
• Oxygen content
• Boiler water temperature
• Flow/Return heating circuit
• Buffer storage status
• Fuel supply

Result:

• Real-time monitoring from anywhere
• Early warning on deviations (alerting)
• Historical analysis (efficiency comparison)
• Data-driven maintenance intervals

Advantages of This Monitoring Solution

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.)

Summary

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?

I support you from concept to commissioning:

• Requirements analysis & architecture design
• PLC programming & MQTT integration
• Dashboard development & training

Contact: info@te-c.net