Evaporator Optimization
Evaporator Optimization
A Yearly $238 kCAD in Steam & Chemicals
We embedded a wash-schedule optimiser and vapour-sharing MPC on a five-effect concentrator set. The optimisation project cut wash water by 30 %, raised steam economy, and eliminated unplanned drain-and-wash downtime. A finance audit confirms ≈ CAD 238 000 in recurring annual savings—achieved with zero hardware cap-ex.
Integrated 420 kTon Kraft Operation
Situated in Northern America, this integrated kraft operation has produced bleached softwood pulp for more than forty years, shipping ≈ 420 000 t per year to packaging and tissue customers across North America and Asia. The concentrator train is the critical link between the fibreline and recovery boiler; any wash event throttles liquor throughput and steam supply.
Fixed-Interval Washing Wastes Steam
When the customer reached out to us they were facing numerous challenges
- Escalating energy costs — natural-gas prices and carbon-tax surcharges have climbed sharply since 2021.
- Stringent water-use permits — every wash must be captured and treated under provincial regulations.
- Fibre-cost pressure — regional log prices remain above their five-year average, squeezing margins.
Conservative time-based washing dumped hot liquor, wasting steam and chemicals. If fouling built faster than the schedule, an unplanned wash shut the line for hours.
Some of their key pain points were
- 4- to 6-hour unplanned washes two to three times per month.
- Steam-economy drift ± 2 %.
- Excess wash water raised effluent-treatment load.
Anssum's Three Step Solution Framework
The client’s mill was grappling with tough challenges, prompting us to deploy Anssum’s three-step framework:
- Data-Driven Discovery: Unlocking insights through smart analytics.
- Collaborative Design: Crafting solutions hand-in-hand with the client.
- Straightforward Integration: Rolling out changes smoothly for maximum impact.
Implementation Process
$238 kCAD Annual Gain
Financial Summary – ≈ CAD 238 000/year verified savings value-to-cost ratio exceeding 10 : 1.
Key Takeaways
Wash-on-need beats fixed intervals – cleaning only when fouling cost outweighs steam cost.
Soft-sensor analytics deliver lab-grade insight without extrainstruments.
Controls over cap-ex – all gains achieved through collaborative partnership.
Water, energy, and CO₂ wins align with ESG commitments and regulatory caps.
