Robotic Technology Enhances Safety and Productivity in Pulp and Paper Industry

Robotic technology is revolutionizing maintenance tasks in the pulp and paper industry, particularly the challenging process of smelt spout cleaning in recovery boilers. While critical for operational efficiency, manual cleaning of smelt spouts poses significant risks to operators, including exposure to molten smelt, green liquor, and hot gases.

Recently, North American paper mills have started integrating automated smelt spout cleaning robots to mitigate safety hazards and boost both operator and boiler productivity. The adoption of robotics has been slower in the region due to space constraints, but retrofit solutions now offer opportunities to enhance existing recovery boilers.

One of the main obstacles to deploying smelt spout cleaning robots in pulping operations has been the limited space available for the robot’s movement around the spout deck. Automation designers have addressed this challenge by introducing flexible mounting options, such as standing and hanging mounts, along with linear rail assemblies to facilitate precise robot positioning.

In June 2023, Valmet, a major automation solutions provider in the industry, unveiled its first smelt spout cleaning robot at the Pixelle Specialty Solutions mill in Spring Grove, Penn. This advanced robot conducts cleaning cycles every 30 minutes, doubling the frequency compared to manual operations, while ensuring operator safety through physical barriers and remote control functionalities.

Collaboration with experienced automation designers during robot installation is crucial for seamless integration into existing recovery boilers. Designers must analyze the operational environment, consider structural requirements, and optimize the placement of the robot to minimize disruptions to the spout deck and surrounding components.

Contrary to the misconception that automation excludes human labor, smelt spout cleaning robots are designed to work alongside operators, enhancing their safety and efficiency. By relieving operators of risky cleaning tasks, robots enable them to focus on other critical boiler maintenance duties, ultimately improving overall productivity in pulp and paper manufacturing.