Valmet Installs first ever Smelt Spout Robot in North America

Any recovery boiler operations superintendent knows that smelt spout maintenance is a messy, risky, and time-consuming task. In addition to the risks involved in cleaning spouts, doing so takes time away from a variety of other recovery boiler operations. Enter the Valmet Smelt Spout Cleaning Robot. The robot is a master of all trades: using the mounted camera, operators can safely and comfortably examine operating problems, shatter jet performance, and cleaning outcomes. Depending on the arrangement of your boiler spout deck, the robot is available in a standing or hanging position and can travel laterally on a sliding rail system to clean all spouts. The pre-programmed cleaning routines can be run frequently, enabling operators to concentrate on their other activities in the mill such as checking air ports, changing nozzles on liquor guns, maintenance rounds, and more.

Overcoming obstacles with collaboration and expertise

Originally introduced to the market on a new European boiler in 2008, Smelt Spout Robots haven’t been as quickly adopted in North America.  The reason is due to the lack of new boiler installations in North America. The dearth of new boilers means that robots need to be retrofitted and steel needs to be added to make the mill robot friendly. 

Before Smelt Spout Robots can be installed, a boiler needs Valmet Smelt Spouts to be installed. In the case of Pixelle Specialty Solutions in Spring Grove, Pennsylvania, it had competitor spouts that needed to be removed. During an outage in June of 2022, the team set the stage for the robot by putting Valmet Smelt spouts on the boiler while Product Manager Dan Morrison started working on a proposal for the Smelt Spout Robot purchase and installation.  Unfortunately, the installation was not without its challenges. 

The first step was a scan, so we knew where everything was exactly. We were trying to get the robot installed on a rail overhead, but there were several piping and steam lines that were in the way and would have to be moved. Also, the floor beams were not oversized, meaning that we’d have to install new beams to be able to support the robot.” 

Dan Morrison, Product Manager, NA Pulp & Energy, Recovery

Once it was determined that the typical method of installation wasn’t feasible, Dan and the team began to look at alternative options. Their solution was to remove the rail from the boiler and attach it to a support system of free-standing legs. The innovative solution meant that the mill could avoid significant boiler alterations while still taking advantage of the rail system that allowed for the cleaning of multiple ports with one robot. 

A cause for celebration On July 20th, 2023 Pixelle Specialty Solutions hosted a celebration to officially commission their new smelt spout robot and debut it to the public.  The event began Pixelle's CEO Tim Hess speaking to guests gathered in mill’s conference room about how well the project went and the collaboration between Pixelle Specialty Solutions and Valmet. Shortly after, Valmet Director of Recovery for North America, Dave Gadai presented an award to Tim Hess to commemorate the successful installation and operation of the first smelt spout robot in North America. The last speaker was Dan Morrison, Product Manager, Pulp & Energy, Recovery who presented the robot capabilities and a review of the entire retrofit project at Pixelle Spring Grove.

Once the presentations were completed, attendees proceeded down to the spout deck for the ribbon cutting ceremony. Afterwards the protective fencing was closed, and the robot was run in auto mode so that all attendees could watch it in operation. The event ended with a quick tour of the control room to watch the smelt spout robot in operation through its on-board camera system.

Moving our customers performance forward

The quick work and practical solution resulted in not only the first Valmet Smelt Spout Robot in North America, but a very happy customer as well. 

The newly installed Valmet Smelt Spout Cleaning Robot is a game changer for the safety of our Recovery Boiler Operating personnel and for the future of all North American Pulp and Paper Mills. Pixelle’s partnership with Valmet on this project paid dividends right from the start with detailed planning, engineering, construction management, and commissioning that resulted in a well-orchestrated startup. Retrofit projects are not always ideal. However, the outcome of this project looks like a project installed from day one. I am personally grateful to the Valmet Team and ecstatic with the project outcome.”

 Jeff Forry, Director, Pulp & Utilities, Pixelle Specialty Solutions