Maintaining efficient operations in mechanical pulp production involves overcoming significant challenges, particularly those related to scaling and inorganic deposits. High calcium and sulfate deposit formation in evaporation units, combined with reduced condensate production and increased cleaning costs, strain operational performance and water balance within mills. Through advanced and collaborative solutions, significant improvements can be achieved in minimizing these challenges.

Problem

Mechanical pulp production plants facing recurring issues of:

• High formation of inorganic deposits, particularly calcium and sulfate, within evaporation plant units
• Reduced efficiency in condensate production
• Increased fouling potential, leading to costly and frequent cleaning efforts
• Difficulties in maintaining optimal water balance across the mill processes

These conditions elevate operational costs and disrupt mill efficiency, necessitating proactive remediation.

Solution

A comprehensive solution was developed by integrating targeted inorganic deposit control with cutting-edge tools and expertise across multiple domains:

• Custom Chemical Solutions: Precise chemical treatments tailored to reduce deposit formation and scaling
• Advanced Analytics and Modelling: Real-time system evaluations powered by data analysis and predictive algorithms to forecast future behaviour
• Collaborative Expertise: Combining knowledge in chemistry, analytics, modelling, and process optimization to deliver a synchronized approach

Results

Implementing these solutions led to measurable and impactful outcomes:

• Condensate production increased by 5%
• Cleaning and detergent costs were reduced by 13%
• Condensate output became 20% more efficient relative to cleaning chemical consumption
• Process behaviour became easier to predict, enabling proactive system optimization

Benefits

The results translated into multiple tangible benefits for pulp mills:

• Enhanced Efficiency: Improved condensate production and reduced fouling ensure smoother operations
• Cost Optimization: Savings in cleaning and chemical expenditure lower operational costs
• Confidence in Planning: Predictive insights enable mills to anticipate and mitigate future challenges effectively
• Sustainability Gains: Reduced chemical consumption and enhanced water balance positively impact environmental goals

By leveraging these advanced solutions, mills can create sustainable, cost-effective systems while achieving greater operational reliability