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 Smelt Spout Robots Enhance Safety and Productivity in North American Pulp and Paper Mills

Valmet: Robotics Adopted for Smelt Spout Cleaning in North American Paper Mills

Automating Smelt Spout Cleaning in North American Paper Mills: Enhancing Safety and Efficiency

Recovery boilers, crucial investments in the pulp and paper industry, endure for decades with proper maintenance. However, upkeep poses challenges: messy, risky tasks often necessitate full or partial shutdowns, impacting productivity and safety.

Among these tasks, smelt spout cleaning stands out. Vital for boiler efficiency, manual cleaning exposes operators to molten smelt, green liquor, and heat, risking injury. Recruitment, training, and retention of operators compound these challenge

To mitigate risks and boost productivity, automated robotic solutions now tackle smelt spout cleaning. Although available since 2008, adoption in North American mills was hindered by space constraints and few new boiler installations.

Now, retrofitting existing boilers with robotic systems addresses these challenges. Innovative designs, such as robots adaptable to tight spaces with standing or hanging mounts on linear rail assemblies, facilitate safe, efficient cleaning cycles. Protective measures like fencing ensure operator safety, streamlining operations.

As North American mills embrace these advancements, they enhance both safety and operational efficiency, underscoring the transformative potential of robotic technology in industrial maintenance.

Valmet: Integrating and Deploying Robots to Alleviate Worker Strain

Field-Proven Smelt Spout-Cleaning Robots

In June 2023, Valmet introduced its inaugural smelt spout-cleaning robot in North America at the Pixelle Specialty Solutions mill in Spring Grove, Pennsylvania. Operating at intervals of 30 minutes—twice the frequency achievable manually—the robot completes each cleaning cycle in just 15 minutes. Between cycles, it safely repositions to a designated home position.

Safety measures include physical barriers that halt the robot if breached, enhancing operator protection. Operators remotely manage cleaning schedules via pre-programmed sequences, facilitated by an onboard camera for real-time monitoring and troubleshooting from the control room.

Automation of smelt spout cleaning not only boosts operator safety but also optimizes productivity by freeing them for other critical tasks. Furthermore, the robot has significantly improved liquor quality and standard deviations in green-to-black liquor and smelt.

Key to successful integration is collaboration with experienced automation designers, ensuring tailored solutions that minimize disruptions to existing structures and operations during installation or retrofitting of smelt spout cleaning robots.

Symbiotic Relationship Between Technology and Human Operators

Contrary to the assumption of replacing human labor, smelt spout cleaning robots exemplify technology working in concert with boiler operators to enhance safety and efficiency. By automating repetitive tasks, these robots enable operators to focus on other critical functions within the recovery boiler system.

This collaborative approach not only enhances operator safety but also broadens their job scope, potentially easing recruitment and retention challenges faced by pulp and paper manufacturers. By leveraging automation alongside skilled personnel, manufacturers can bolster productivity across various operations, validating investments in robotic retrofits.