The Challenge
A kraft pulp mill relied on conventional regulatory and ratio controls for bleaching chemical addition, with operators manually adjusting targets based on measured brightness. This resulted in inconsistent performance, poor coordination of bleaching stages, and slow response to changes in pulp flow and kappa. Rising chemical costs and tightening margins made bleaching cost per ton a growing concern.
The Solution
Spartan Controls implemented the SpartanPRO™ Kraft Bleaching APC to automatically coordinate reagent addition across bleaching stages based on pulp flow, kappa levels, and final brightness targets.
The solution also strengthened foundational pH and level controls—key drivers of bleaching efficiency. Operators transitioned from manual dosage management to setting target brightness and operating constraints, allowing the APC to continuously optimize chemical usage.
The solution also strengthened foundational pH and level controls—key drivers of bleaching efficiency. Operators transitioned from manual dosage management to setting target brightness and operating constraints, allowing the APC to continuously optimize chemical usage.
The Value
- The APC solution reduced variability and optimized one of the mill’s largest operating costs:
- $2.5M per year reduction in bleaching chemical consumption (chlorine dioxide, caustic, peroxide)
- 20% reduction in final product brightness variability
- 75% reduction in low‑brightness pulp
- Significant reduction in operator workload
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