Multi-Area Transformation
Multi-Area Transformation
€1.46 MEUR without Capital Expenditure
Over a 24-month programme, we embeddedeleven model-predictive-control (MPC) and soft-sensor applications across thedigester, evaporators, recovery boiler and steam network. The phased roll-outhas delivered ≈ EUR 1.46 million every year in steady-state savings andrevenue uplift. Headline wins include + 53 t/day pulp throughput, + 9 344MWh/yr power export, and a 1.2 % boiler-efficiency lift.
900 kTon Bleached Pulp Mill
Operating for more than six decades, this coastal Australasian kraft complex converts sustainably managed plantation hardwood into ≈ 900 000 t of bleached pulp per year, supplying packaging customers worldwide. A single recovery boiler supplies all site steam and drives a back-pressure turbine that exports green electricity to the grid.
Hidden Bottlenecks & Fragmented Processes
When the client contacted us, they struggled with numerous challenges
- Escalating electricity tariffs – grid prices rose ≈ 80 % in four years.
- Fibre-cost pressure – hardwood indices remain ≈ 27 % above 2019 levels.
- Sustainability mandate – corporate roadmap targets a 10–25 % cut in steam- and water-intensity while lifting output to meet demand.
Isolated fixes merely shifted constraints: speeding up the digester exposed evaporator limits; boiler water-wash downtime erased cycle-time gains. Variable controls, manual soot-blowing and liquor-density swings kept the mill from realising sustained benefit.
Some of their key pain points were
- Digester cook-time buffers masked true capacity.
- Liquor-solids excursions triggered unplanned evaporator drains.
- Fixed-interval soot-blowing wasted steam and forced wash shuts.
- Steam-header pressure spikes throttled turbine generation.
Anssum's Three Step Solution Framework
Facing multiple challenges at the client’s mill, we adopted a targeted approach using Anssum’s three-step solution framework:
- Data-Driven Discovery: Uncovering insights through precise analysis.
- Collaborative Design: Co-creating tailored solutions with the client.
- Straightforward Integration: Implementing seamlessly for lasting impact.
Implementation Process
1.45 MEUR Steady State Gain
Financial Summary – ≈ EUR 1.4million/year steady-state; 6 Month ROI.
Key Takeaways
Iterative Bottleneck Removal – each MPC block frees the next constraint, compounding gains.
Operator-Friendly Integration – running inside the existing DCS secures trust and rapid uptake.
Sustainability Meets Profitability – steam, fibre and power savings align with CO₂-intensity goals.
Holistic View = Greater ROI – treating the mill as a single system outperforms piecemeal fixes.
