BoilOptAI
AI-driven boiler efficiency optimisation platform enabling low-carbon, data-driven industrial operations without invasive hardware or PLC control.
Why BoilOptAI Matters
Industrial boilers are among the most energy-intensive assets in manufacturing, yet many still operate with static control settings, limited feedback, and legacy monitoring approaches.
This results in avoidable fuel waste, higher operating costs, increased carbon emissions, and reduced equipment reliability— particularly for SMEs lacking access to advanced optimisation tools.
BoilOptAI addresses this gap with a software-first, non-intrusive AI platform that continuously analyses existing boiler data to deliver explainable optimisation insights—without interfering with safety- critical systems or requiring capital-intensive upgrades.
BoilOptAI Workflow
BoilOptAI ingests real-time operational data from existing boiler sensors, including fuel flow, flue gas temperature, oxygen levels, pressure, load cycles, and ambient conditions.
The data is cleaned, time-aligned, and validated before being analysed by a hybrid AI intelligence layer combining combustion physics and machine-learning models.
The system detects inefficiencies, abnormal behaviour, and optimisation opportunities, translating insights into actionable advisory recommendations such as fuel-air ratio optimisation, maintenance indicators, and load scheduling guidance.
Software Architecture & Operational Intelligence
BoilOptAI is built on a modular, industrial-grade software architecture designed for retrofit deployment, scalability, and safe operation across diverse boiler systems and manufacturers.
Lightweight data connectors interface with existing sensors and control outputs without invasive hardware changes or direct PLC control, ensuring compatibility while preserving safety-critical system integrity.
At the intelligence layer, hybrid AI models combine combustion physics with machine-learning techniques to deliver robust, interpretable optimisation insights that adapt continuously through operational feedback.
These insights are delivered through a secure, web-based operational dashboard that provides real-time visibility into boiler efficiency, system health, optimisation recommendations, and risk indicators—enabling confident, data-driven decision-making without overriding control systems.
Deploy BoilOptAI
BoilOptAI enables industrial operators to reduce fuel consumption, emissions, and operational risk without invasive hardware changes or capital-intensive upgrades.