Boilers and Heat Recovery for the Paper Industry

In the paper and cardboard industry, thermal energy consumption in the form of process steam directly determines economic viability and operating costs per metric ton produced. The drying section is one of the most energy-intensive stages in the entire process industry, requiring high availability and a thermodynamically stable supply of steam.

AITESA designs, manufactures, and integrates advanced heat transfer and energy recovery solutions for the paper industry: high-efficiency boiler economizers, heat recovery boilers (HRSG / WHRB coupled with cogeneration), air-cooled condensers and air-cooled evaporators for effluent condensation, and shell-and-tube heat exchangers.

Our technologies capture the residual enthalpy from flue gases and wet steam streams, reducing fuel consumption, stabilizing the steam distribution network, and modernizing facilities without disrupting production.

Do you need to improve thermal efficiency at a paper mill? Tell us about the steam system, the gases, or the equipment involved.

Challenges Facing Paper Mills

Heat recovery in a paper mill does not allow for standard solutions. The feasibility of the equipment requires overcoming severe operational constraints:

• High enthalpy humidity and latent heat recovery: The exhaust gases from drying plants contain large amounts of latent heat in the form of water vapor. The design must manage controlled condensation without suffering corrosion or fouling.

• Presence of cellulose fines and unburned material: Continuous carryover of suspended fibers and particles that can clog the heat exchange surfaces. This requires selecting tube geometries or fins with a wide pitch and integrating automatic cleaning systems (blowers / wash ramps / shot blasting systems / hammering systems).

• Integration into cogeneration and steam cycle systems: Optimization of heat recovery steam generators (HRSGs) coupled with gas turbines or engines, coordinating the pressure of the steam produced with the medium- and low-pressure headers required by the plant.

• Continuous availability without unscheduled shutdowns: A paper machine shutdown results in costs running into the millions. Thermal equipment (economizers, heat exchangers, air-cooled condensers) must be designed to maximize the mean time between failures and allow for maintenance using a gas bypass.

AITESA is involved in every stage of the project: from thermodynamic studies and detailed engineering to supply, revamping, or turnkey EPC execution. We analyze the plant’s hydraulic and thermal balance to ensure that every kilowatt recovered translates into real fuel savings.

Why Choose AITESA for Paper and Cardboard?

Heat recovery in a paper mill does not allow for standard solutions. The feasibility of the equipment requires overcoming severe operational constraints:

AITESA has participated in projects involving heat recovery, thermal equipment, and energy-efficiency solutions for paper and cardboard mills in various industrial settings.

Success stories

Paper

Cardboard

Do you need to improve thermal efficiency or modernize critical equipment at a paper or cardboard mill?

Please briefly describe your needs or the equipment involved. Our technical team will review the initial information and guide you toward the most appropriate solution.