Smelt Spout Cleaning Robot Boosts Safety and Productivity at Pixelle Mill

Pixelle Specialty Solutions has taken a significant step forward in enhancing mill safety and productivity by installing North America’s first smelt spout cleaning robot at its Spring Grove, Pennsylvania facility. Manufactured by Valmet, a leading developer in pulp and paper technology, the robot addresses the critical and hazardous task of smelt spout cleaning in recovery boilers.

On July 20, 2023, Pixelle officially commissioned the new smelt spout cleaning robot, celebrating with an event that highlighted the collaboration between Pixelle and Valmet. The introduction of this robot marks a milestone for North American pulp and paper mills, which have been slower to adopt this technology compared to their European counterparts due to the challenges associated with retrofitting older boilers.

Smelt spout cleaning is essential for maintaining boiler efficiency but poses significant risks to operators, who are exposed to molten smelt, hot gases, and potential repetitive-motion injuries. By automating this task, the new robot significantly reduces these risks. It operates on a six-servo motor, FANUC M-900 series, and can clean multiple ports efficiently without manual intervention. The robot’s pre-programmed sequences and onboard camera allow operators to control and monitor the process remotely, further enhancing safety and efficiency.

The robot performs cleaning cycles every 30 minutes, twice as often as manual cleaning, and each cycle takes approximately 15 minutes. When not cleaning, the robot rests in a safe, out-of-the-way position. This increased frequency and consistency in cleaning have improved the boiler’s liquor quality, with significant improvements in green-to-black liquor standard deviation and smelt standard deviation.

The installation required a $1.4 million investment from Pixelle. The process involved retrofitting the existing boiler with Valmet smelt spouts and overcoming structural challenges to mount the robot’s linear rail system. This innovative approach avoided major boiler alterations, ensuring a smoother integration of the robotic system.

Ross Bushnell, President and CEO of Pixelle, emphasized the company’s commitment to operational excellence and innovation, noting that the new technology positions Pixelle to drive greater mill safety, productivity, and quality. Jeff Forry, Director of Pulp and Utilities at Pixelle, highlighted the robot’s role in protecting workers and allowing them to focus on other critical tasks. Drew Humphries, Vice President of Pulp & Energy at Valmet, expressed excitement about the potential impact of this industry-first installation on North American pulp and paper operations.

The successful implementation of this smelt spout cleaning robot at Pixelle sets a precedent for other North American mills to follow. As the industry increasingly recognizes the benefits of automation, similar investments are expected to enhance safety and productivity across the sector.

The introduction of Valmet’s smelt spout cleaning robot at Pixelle Specialty Solutions represents a significant advancement in pulp and paper mill operations. By automating a hazardous and labor-intensive task, the robot not only improves safety and efficiency but also sets a new standard for innovation in the industry.