In a remarkable technological breakthrough, Valmet has implemented a robotic molten nozzle cleaning arm at Pixelle Specialty Solutions’ plant located in Spring Grove, Pennsylvania. This project marks the first installation of a molten nozzle cleaning robot in North America, revolutionising the way maintenance operations are carried out on recovery boilers in the paper industry.
The Need for Innovation
Cleaning molten nozzles in recovery boilers is an inherently hazardous and labour-intensive task. Traditionally, this process requires a high degree of personal protective equipment (PPE) and carries significant safety risks for operators. In addition, manual cleaning of these nozzles diverts valuable resources away from other critical boiler operations.
Valmet’s Robotic Solution
Valmet has addressed these challenges by implementing the FANUC M-900iB/360, an industrial robot known for its high load capacity and precision. This model excels in demanding industrial applications, providing a robust and efficient solution for cleaning molten nozzles.
Key Features of the FANUC M-900iB/360 Robot:
– High Accuracy: Ensures consistent and accurate cleaning of nozzles.
– Advanced Automation: Allows execution of pre-programmed cleaning routines, reducing human intervention and associated risks.
– High Load Capacity: Handles heavy, repetitive tasks with ease, increasing operational efficiency.
Implementation and Challenges
The implementation process was not without its challenges. Integrating the robot into the Pixelle plant required careful planning and minimal structural modifications to accommodate the rail system on which the robot travels. Valmet and Pixelle teams worked closely together to overcome obstacles such as overhead piping obstructions and insufficient support beams.
An innovative solution was to install the rail system on a separate support, thus avoiding significant modifications to the boiler. This strategy allowed the robot to access multiple nozzles without interruption, optimising the cleaning process and improving productivity.
Operational and Safety Benefits
The introduction of the molten nozzle cleaning robot has transformed the maintenance operation at Pixelle:
– Improved Safety: By reducing the need for manual intervention, the robot minimises the risks of health and safety incidents.
– Increased Productivity: Operators can focus on other critical tasks, such as inspecting air ports and changing nozzles, while the robot takes care of cleaning.
– Operational Efficiency: The robot’s ability to perform frequent and accurate cleaning improves the overall performance of the recovery boiler.
An Industry Milestone
The installation of the robot at Pixelle not only represents a significant breakthrough for the company, but also for the paper industry in North America. This pioneering project demonstrates the potential of advanced automation to improve safety, efficiency and operational effectiveness in challenging industrial environments.
Future of Automation in the Paper Industry
The success of this project underlines the importance of innovation and collaboration in the adoption of new technologies. Valmet continues to lead the way in the integration of robotic solutions in the paper industry, promoting a future where automation and digitalisation play a crucial role in optimising processes and improving industrial safety.
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