Industry
Tissue, Pulp & Paper
Location
Canada
Solution
FLU-ACE™ & GEM Steam Traps™
The Thunder Bay mill sought to cut its heavy natural gas consumption and greenhouse gas emissions without compromising continuous 24-hour operations. Rising fuel costs, tightening sustainability targets, and the inherent energy intensity of pulp and paper production created a clear need for a step change in efficiency.
To address this, the company partnered with Thermal Energy International (TEI) on an $11 million turnkey efficiency programme, supported by $5 million from the Ontario Centres of Excellence Target GHG initiative. The project combined advanced heat recovery with a site-wide steam trap conversion, delivering deep reductions in fuel use and emissions while improving system reliability and lowering operating costs.
Nearly a decade on, and following the mill’s acquisition in 2023, the installed systems remain fully operational, demonstrating both durability and long-term value.
Challenge
With the Thunder Bay mill running continuously and only narrow maintenance windows available, precision design and execution were essential. Every stage of the installation had to be carefully sequenced to avoid production disruption.
Bringing large equipment into an ageing site added further complexity, with restricted access routes, crowded pipe racks, and limited entry points to contend with. The distance between the heat source and heat sink required long pipe runs through congested infrastructure, with new lines installed alongside redundant legacy piping. Outdoor sections had to be insulated and heat-traced to guarantee reliable operation in sub-zero winters.
Exhaust streams containing particulates and corrosive compounds required systems designed for long-term durability and minimal maintenance, while the high cost of downtime meant full redundancy was built into the solution to protect continuous 24-hour production.
In addition, securing external funding introduced further requirements, with the project subject to independent technical review, and third-party validation of projected environmental benefits.
35% Energy Savings
Thermal Energy International engineered a comprehensive efficiency programme that addressed the mill’s major sources of energy loss in a single, integrated solution.
Around 500 mechanical steam traps were replaced with high-efficiency GEM steam traps, a complex installation undertaken in a live mill, with critical phases aligned to rare cold shutdowns to minimise disruption.
Two FLU-ACE direct contact condensing heat recovery units were also installed on the pulp dryer and smelt dissolving tank exhausts. These systems captured low-grade waste heat and redirected it into useful energy, supplying hot air to 13 air make-up units and providing the full heat demand of the site’s demineralised boiler feed-water system.
Together, these measures delivered permanent reductions in steam losses, improved thermal efficiency across the mill, and provided a stable, low-carbon source of recovered energy.
Delivered as a turnkey package, the project covered feasibility assessment, detailed design, installation, and commissioning. TEI also assumed responsibility for compliance, including pressure vessel certification and emissions permitting, and prepared the technical documentation required for independent review. This ensured all operational and environmental benefits were validated and formally approved.
This integrated programme provided substantial verified savings and a compelling return on investment, establishing a blueprint for other large energy users seeking practical, proven decarbonisation.
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Leading pulp and paper producers are achieving substantial reductions in fuel use and emissions through proven heat recovery and steam efficiency solutions deployed in live, 24-hour operations. Speak with our team to explore how validated savings could be delivered at your mill.