Pulp and Paper

France

Multi-Effect Evaporator Energy Performance

The APC multi-effect evaporator optimization project delivered a significant reduction in live steam consumption by enhancing heat transfer. The new APC system operates continuously most of the time, improving plant availability and providing operational flexibility tailored to the feedstock processed, while increasing the dry matter percentage fed to the recovery boiler.

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Key Results

Including energy efficiency optimization of the evaporation plant and output solids stabilization.

+4.5 %

Energy Savings

+1.3 %

Average Dry Matter Concentration

-17,000 t/year

Annual Steam Production Reduction (Tons)

-63.5 % Process Variability

Dry Matter Stabilization

+2,700 MW

Annual Electricity Generation

-11 %

Maximum Threshold Exceeded

Challenges

Reduce live steam consumption

by maximizing energy recovery and reuse across the different effects.

Optimize process control

to maintain concentrated product quality while maximizing production throughput.

Reduce the facility’s environmental footprint

by reducing indirect CO₂ emissions associated with steam consumption and improving overall process efficiency.

Ensure reliable and flexible operation

enabling rapid production adjustments to meet operational demand.

Project Overview

Deliver a turnkey energy efficiency project featuring the commissioning of Advanced Process Control (APC) logic for evaporators, pre-evaporators, and concentrators.

With the objectives of:

Stabilize evaporator and concentrator liquid levels
Stabilize boiling temperature
Increase dry matter %
Reduce excursions beyond the upper limit
Reduce production losses
Minimize manual operator interventions

APC Solutions

The commissioned APC solutions achieved a 4.5% annual steam savings alongside a 1.3% increase in dry matter content.

These gains were accomplished while simultaneously improving operational stability and flexibility.

The gains validated on-site following APC commissioning delivered a full return on investment in less than 12 months.

Approach

Instrumentation and loop control performance audit
Dynamic simulation of the evaporation unit
APC logic programming
Simulator-based operator validation and training
Operational and economic performance monitoring
Remote support

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