HARMAC Boosts Efficiency and Safety with Lower Furnace Rebuild
Oct 22, 2024
HARMAC, a Northern Bleach Softwood Kraft pulp mill located on Vancouver Island's East Coast in Nanaimo, BC, has achieved a remarkable milestone with its recent lower furnace rebuild. This extensive project not only revitalized their aging boiler system but also established new benchmarks for operational efficiency, safety, and sustainability in the pulp and paper industry.
About the customer
HARMAC's current ownership structure was established in 2007-2008. The structure, which is unique to the pulp and paper industry, combines employee and investor stakes, with employees holding an equity share. This model fosters a culture of adaptability and competitiveness, enabling HARMAC to focus on optimizing operations while maximizing profitability. The model also helps promote efficient decision-making that aligns with a central component of HARMAC’s company culture – the commitment to sustainability.
The company focuses on reducing its carbon footprint through advancements in chemical recovery, efficient steam production, and reduced water usage. By utilizing black liquor and hog fuel as alternatives to fossil fuels, HARMAC aims to minimize costs and enhance the reliability of its operations. These efforts reflect the company’s dedication to both economic and environmental goals.
Excellence in efficiency, safety, and collaboration
The decision to select a partner for the boiler rebuild project was driven by a strong reputation in the industry and the ability to deliver modern designs that align with HARMAC’s goals for efficiency, safety, and environmental sustainability. A crucial aspect of the choice was the commitment to providing comprehensive on-site support from project initiation to completion. Additionally, collaboration with industry leaders ensured a smooth and professional project experience, highlighting the ability to work effectively within a high-performing team. With a global presence, deep expertise across process industries, and a proven history of continuous improvement, Valmet was ideally suited to enhance the production capabilities at the mill while minimizing environmental impact.
The Need for Modernization
"Our older boiler system was paired with outdated air systems, which presented several challenges. During an audit, it became clear that modernizing the lower furnace from a sloped floor towards the front wall to a decanting style was essential, but it was also necessary to update the primary, secondary, and tertiary air systems, as well as install a new tertiary air fan. These changes were crucial for drastically improving boiler performance. I believe the modeling Valmet conducted accurately predicted the performance improvements, particularly addressing issues such as insufficient primary air velocities,” — said Mason Rowat, Area Supervisor – Recovery & Steam Plant Operations at HARMAC.
Operational Benefits
The rebuild delivered significant improvements across various aspects of mill operations including:
- Increased Efficiency: The new air systems and furnace design resulted in improved combustion efficiency, consistent spout flows, and reduced maintenance needs. The time required for water washing the boiler was halved in part due to reduced carryover and fouling with the new air system, from approximately 40 hours to 20-30 hours.
- Enhanced Environmental Performance: The project achieved a 95% reduction efficiency, with sulfur dioxide (SO₂) levels below 5 ppm, carbon monoxide (CO) below 300 ppm, and particulates exiting the economizer below 9 grams. These results surpassed internal targets and aligned with HARMAC’s sustainability objectives.
- Reduced Maintenance Needs: The efficiency gains translated to fewer boiler cleanings, reflecting the effectiveness of the new systems in maintaining optimal performance.
Tackling challenges to achieve success
The project’s success was greatly supported by the open communication and collaboration due to all major parties working well together with a common goal. Through proactive problem-solving and effective teamwork, any challenges that arose were quickly and smoothly resolved, underscoring the importance of clear communication in the successful execution of shutdowns and the installation of new equipment.
The positive outcome of the rebuild not only reinforced confidence in the equipment’s sustainable operation but also showcased the exceptional quality of the work performed. Mason Rowat, a key figure in the project, expressed strong satisfaction with the results and recommended Valmet’s services, underscoring the project’s overall success.
The success of HARMAC’s lower furnace rebuild highlights the strength of collaboration between Valmet, the customer, and the installation contractor both remotely and on-site. By integrating Valmet’s technical expertise, our focus on sustainability, and the contractor’s precision, we achieved substantial improvements in efficiency, safety, and performance. This project demonstrated the power of open communication and teamwork, cutting boiler wash time nearly in half and setting a new benchmark for operational excellence in the industry."
HARMAC’s lower furnace rebuild stands as a testament to the impact of innovation, collaboration, and a steadfast commitment to sustainability. This project not only exceeded performance and efficiency expectations—achieving a 95% reduction efficiency and cutting water wash time nearly in half due to reduced carryover—but also demonstrated the critical role of strategic partnerships in achieving long-term operational success. By integrating cutting-edge technology and maintaining open communication throughout the process, HARMAC has significantly enhanced its operational capabilities, setting a new benchmark for excellence in the pulp and paper industry. This achievement positions the company for continued success and leadership in environmental stewardship.
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