A systems approach for process debottlenecking towards a sustainable pulp and paper industry
Source abstract
Abstract
Increasing the competitiveness of the pulp and paper industry requires an effective optimization of its existing assets in line with a long-term vision for process transformation, production upgrade, and product diversification. Currently, pulp production increase is one of the main sources of additional revenue for the kraft industry. Likewise, energy efficiency is often employed as a cost-effective approach to reduce operating costs, enhancing the possibilities to lower fossil fuel consumption and contributing to a low-carbon economy. On the other hand, reaching higher production targets and facilitating process transformation, such as biorefinery implementation, heavily depend on the status and performance of a mill’s current infrastructure; therefore, a system analysis is needed to assess the new production requirements, the bottlenecks, and the interactions across departments. In order to obtain practical improvement solutions, direct and indirect impacts on process performance and resource utilization should be considered. This work provides an overview of the key challenges that need to be addressed for production increase and energy efficiency improvement. The methodology starts by a scope analysis for debottlenecking and screening capacity limitations vs. mill targets, followed by their ranking (bottleneck ranking diagram). Benchmarking, gap analysis, and root-cause techniques are applied to diagnose system inefficiencies. This mill-wide debottlenecking assessment is then used to guide the selection of a long-term sustainable operation and design a portfolio of improvement projects by avoiding cross effects of the short-term projects on the long term. A case study of a kraft pulp mill is used to illustrate the proposed methodology.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Process Optimization and Integration · Energy Efficiency and Management · Thermochemical Biomass Conversion Processes
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Natural Resources Canada
References (42)
Show source-provided references
1. 1. Korhonen, J., Pätäri, S., Toppinen, A., et al., J. Cleaner Prod. 108(A): 864(2015). https://doi.org/10.1016/j.jclepro.2015.06.003.10.1016/j.jclepro.2015.06.003 ↗
2. 2. Lundberg, V., Bood, J., Nilsson, L., et al., Chem. Eng. Trans. 35: 127(2013). https://doi.org/10.3303/CET1335021.
3. 3. Satini, R., “Digital technologies provide the tools for pulp and paper process optimisation,” World Pulp Pap. 2019: 89(2019).
4. 4. Griffin, P.W., Hammond, G.P., and Norman, J.B., Appl. Therm. Eng. 134: 152(2018). https://doi.org/10.1016/j.applthermaleng.2018.01.126.10.1016/j.applthermaleng.2018.01.126 ↗
5. 5. Oliveira, G., Calisto, V., Santos, S.M., et al., Sci. Total Environ. 631–632: 1018(2018). https://doi.org/10.1016/j.scitotenv.2018.03.072.10.1016/j.scitotenv.2018.03.072 ↗
6. 6. Mongkhonsiri, G., Charoensuppanimit, P., Anantpinijwatna, A., et al., J. Cleaner Prod. 255: 120278(2020). https://doi.org/10.1016/j.jclepro.2020.120278.10.1016/j.jclepro.2020.120278 ↗
7. 7. Brunnhofer, M., Gabriella, N., Schöggl, J.-P., et al., For. Policy Econ. 110: 101882(2020). https://doi.org/10.1016/j.forpol.2019.02.006.10.1016/j.forpol.2019.02.006 ↗
8. 8. Navarri, P., Bakhtiari, B., and Bédard, S., “Process integration in the pulp and paper industry,” IEA Expert Workshop, International Energy Agency, Paris, 2017.
9. 9. Nandakumar, N., Saleeshya, P.G., and Harikumar, P., Mater. Today: Proc. 24(1): 1217(2020). https://doi.org/10.1016/j.matpr.2020.04.436.10.1016/j.matpr.2020.04.436 ↗
10. 10. Subramaniyan, M., Skoogh, A., Muhammad, A.S., et al., J. Manuf. Syst. 55: 143(2020). https://doi.org/10.1016/j.jmsy.2020.02.011.10.1016/j.jmsy.2020.02.011 ↗
11. 11. Torkfar, F. and Avami, A., Process Saf. Environ. Prot. 103(B): 442(2016). https://doi.org/10.1016/j.psep.2016.06.008.10.1016/j.psep.2016.06.008 ↗
12. 12. Zhang, J., Zhu, X.X., and Towler, G.P., Ind. Eng. Chem. Res. 40(6): 1528(2001). https://doi.org/10.1021/ie990854w.10.1021/ie990854w ↗
13. 13. Teng, S.Y., How, B.S., Leong, W.D., et al., Chem. Eng. Sci. 214: 115429(2020). https://doi.org/10.1016/j.ces.2019.115429.10.1016/j.ces.2019.115429 ↗
14. 14. Tahouni, N., Khoshchehreh, R., and Panjeshahi, M.H., Energy 77: 742(2014). https://doi.org/10.1016/j.energy.2014.09.047.10.1016/j.energy.2014.09.047 ↗
15. 15. Li, W. and Hui, C.-W., Comput.-Aided Chem. Eng. 15: 268(2003). https://doi.org/10.1016/S1570-7946(03)80555-2.10.1016/S1570-7946(03)80555-2 ↗
16. 16. Bähner, F.D. and Huusom, J.K., Ind. Eng. Chem. Res. 58(43):20003(2019). https://doi.org/10.1021/acs.iecr.9b03134.10.1021/acs.iecr.9b03134 ↗
17. 17. Yang, Y., Farid, S.S., and Thornhill, N.F., J. Biotechnol. 179: 17(2014). https://doi.org/10.1016/j.jbiotec.2014.03.004.10.1016/j.jbiotec.2014.03.004 ↗
18. 18. Panjeshahi, M.H., Gharaie, M., and Ataei, A., Energy 35(12):5202(2010). https://doi.org/10.1016/j.energy.2010.07.046.10.1016/j.energy.2010.07.046 ↗
19. 19. Koulouris, A., Calandranis, J., and Petrides, D.P., Comput. Chem. Eng. 24(2): 1387(2000). https://doi.org/10.1016/S0098-1354(00)00382-3.10.1016/S0098-1354(00)00382-3 ↗
20. 20. Alshekhli, O., Foo, D.C.Y., Hii, C.L., et al., Food Bioprod. Process. 89(4): 528(2011). https://doi.org/10.1016/j.fbp.2010.09.013.10.1016/j.fbp.2010.09.013 ↗
21. 21. Adham, K. and Buchholz, T., “Debottlenecking high temperature metallurgical plants through modeling and simulation,” in Int. Symp. High-Temp. Metall. Process., Proc. Symp., 8th. (H. Wang, Ed.), The Minerals, Metals, and Materials Series, Springer, Cham, 2017. https://doi.org/10.1007/978-3-319-51340-9_12.10.1007/978-3-319-51340-9_12 ↗
22. 22. Hofmann, C., Staehr, T., Cohen, S., et al., Procedia Manuf. 31:148(2019). https://doi.org/10.1016/j.promfg.2019.03.023.10.1016/j.promfg.2019.03.023 ↗
23. 23. Burelle, R., Wernqvist, A., Stern, R., et al., “Expansion of chemical recovery capacity at Södra Cell Värö Mill,” TAPPI PEERS Conf., TAPPI Press, Peachtree Corners, GA, USA, 2017.
24. 24. Paleologou, M., Ahmad, Z., Xu, C., “Lignin depolymerization pro-cess using chemicals recoverable by the kraft recovery cycle,” U.S. pat. US20200148835A1, 14 May 2020.
25. 25. Axelsson, E., Olsson, M.R., and Berntsson, T., Nord. Pulp Pap. Res. J. 21(4): 485(2006). https://doi.org/10.3183/npprj-2006-21-04-p485-492.10.3183/npprj-2006-21-04-p485-492 ↗
26. 26. Benali, M., Périn-Levasseur, Z., Savulescu, L., et al., Biomass Bioenergy 67: 473(2014). https://doi.org/10.1016/j.biombioe.2013.08.022.10.1016/j.biombioe.2013.08.022 ↗
27. 27. Laaksometsä, C., Axelsson, E., Berntsson, T., et al., Clean Technol. Environ. Policy 11(1): 77(2009). https://doi.org/10.1007/s10098-008-0169-0.10.1007/s10098-008-0169-0 ↗
28. 28. Välimäki, E., Niemi, P., and Haaga, K., “A case study on the effects of lignin recovery on recovery boiler operation,” Int. Chem. Recovery Conf., TAPPI Press, Atlanta, 2010. https://doi.org/10.13140/2.1.1777.5046.
29. 29. Chioua, M., Bauer, M., Chen, S.-L., et al., Control Eng. Pract. 49: 149(2016). https://doi.org/10.1016/j.conengprac.2015.10.011.10.1016/j.conengprac.2015.10.011 ↗
30. 30. Babaei, M. and Patel, M., J. Cleaner Prod. 520: 146109(2025). https://doi.org/10.1016/j.jclepro.2025.146109.10.1016/j.jclepro.2025.146109 ↗
31. 31. Barrios, N., Gonzalez, M., Zabib, N., et al., Resour. Conserv. Recycl. Adv. 29: 200318(2026). https://doi.org/10.1016/j.rcradv.2026.200318.10.1016/j.rcradv.2026.200318 ↗
32. 32. Marshman, D.J., Chmelyk, T., Sidhu, M.S., et al., Appl. Energy 87(11): 3514(2010). https://doi.org/10.1016/j.apenergy.2010.04.023.10.1016/j.apenergy.2010.04.023 ↗
33. 33. Rogers, J.G., Cooper, S.J., and Norman, J.B., Renewable Sustainable Energy Rev. 95: 23(2018). https://doi.org/10.1016/j.rser.2018.06.019.10.1016/j.rser.2018.06.019 ↗
34. 34. Kong, L., Hasanbeigi, A., and Price, L., J. Cleaner Prod. 122: 5(2016). https://doi.org/10.1016/j.jclepro.2015.12.116.10.1016/j.jclepro.2015.12.116 ↗
35. 35. Fleiter, T., Fehrenbach, D., Worrell, E., et al., Energy 40(1): 84(2012). https://doi.org/10.1016/j.energy.2012.02.025.10.1016/j.energy.2012.02.025 ↗
36. 36. Andersson, E. and Thollander, P., Energy Strategy Rev. 24: 229(2019). https://doi.org/10.1016/j.esr.2019.03.004.10.1016/j.esr.2019.03.004 ↗
37. 37. “Revitalizing the pulp and paper industry – One mill at a time,” IMPACT, Magazine by FPInnovations, Pointe-Claire, QC, Canada, 2018. Available [Online] https://web.fpinnovations.ca/wp-content/uploads/2018-2019-impact-english.pdf <17April2026>
38. 38. “Exciting results from the CanmetENERGY energy optimization partnership,” FPInnovations, Pointe-Claire, QC, Canada, 9 June 2020. Available [Online] https://web.fpinnovations.ca/exciting-results-from-the-canmetenergy-energy-optimization-partnership/<23April2026>.
39. 39. Kermani, M., Périn-Levasseur, Z., Benali, M., et al., Comput. Chem. Eng. 102: 238(2017). https://doi.org/10.1016/j.compchemeng.2016.11.043.10.1016/j.compchemeng.2016.11.043 ↗
40. 40. Klemes, J.J., Ed., Handbook of Process Integration (PI): Minimisation of Energy and Water Use, Waste and Emissions, Woodhead Publishing Series in Energy, Woodhead Publishing, Sawston, UK, 2013.
41. 41. Barecka, M.H., Skiborowski, M., and Górak, A., “A methodology for process debottlenecking by process intensification: Application to ethylene oxide production,” AIChE Annu. Meet., American Institute of Chemical Engineers, New York, 2016.
42. 42. Amazouz, M., “EXPLORE software: Improving process operation using the power of advanced data analysis,” Report, Natural Resources Canada, Ottawa, ON, Canada, 22 October 2015. Available [Online] https://natural-resources.canada.ca/maps-tools-publications/publications/explore-software-improving-process-operation-power-advanced-data-analysis <23April2026>.