Intelligent Soot-Blowing
Intelligent Soot-Blowing
Rapidly Turning $133 kUSD into $396 kUSD
We implemented Intelligent Soot-Blowing(ISB) and adaptive excess-air control on the recovery boiler at a long-servingkraft mill. The optimisation project increased net-steam by 6 t/h,raised boiler efficiency by 3.6 %, and eliminated six unplannedwater-wash shutdowns per year. Finance verified recurring savings of ≈ USD396 000 per year, with a project pay-back of ≈ 4 months.
400 kTon Bleached Softwood Pulp Mill
For more than forty years, this coastal Southern-Hemisphere kraft complex converts plantation softwood into ≈400 000 t of bleached pulp per year, supplying packaging markets across theAsia–Pacific. Its single recovery boiler drives a 25 MW back-pressure turbine, exporting surplus electricity to the grid.
Inefficient Cleaning, High Downtime and Lost Steam
When the client reached out to us they had multiple challenges
- Wholesale power prices have climbed > 80 % since 2020, magnifying every lost megawatt.
- Ageing evaporators raise liquor-solids variability, increasing fouling risk.
- Corporate ESG targets mandate a 15 % CO₂-intensity cut by 2030 with minimal capital outlay.
Fixed soot-blowing intervals wasted steam and failed to prevent fouling on the most critical surfaces. Unplanned water-wash shutdowns wiped out turbine revenue gains and increased operator workload.
Some of their key pain points were
- Six unplanned water-wash shutdowns per year.
- ≈ 4 % steam lost to over-cleaning.
- No live fouling index — operators flying blind until efficiency dropped.
Anssum's Three Step Solution Framework
To tackle the client’s mill challenges, we applied Anssum’s three-step framework:
- Data-Driven Discovery: Pinpointing issues with clear data.
- Collaborative Design: Building solutions together with the client.
- Straightforward Integration: Delivering results with ease.
Implementation Process
$396 kUSD Annual Gain
FinancialSummary – ≈ USD 396 000/year verified savings; project pay-back ≈ 4 months; value-to-cost ratio ≈ 3 : 1.
Key Takeaways
Adaptive cleaning beats fixed intervals — fouling is dynamic; cleaning must be too.
Operator co-design secures adoption — front-line input sets risk limits everyone trusts.
Controls over cap-ex — optimisation of existing equipment delivered sustained steam gains and CO₂ cuts.
Strategic roadmap unlocked — freed steam and stable boiler operation enable future turbine uprate and ESG progress.
