AFRY leads the recovery boiler modernization
Driving efficiency, reliability, and sustainability for the global pulp & paper industry
The global pulp and paper industry is at a critical crossroads. Aging assets, volatile energy markets, and stricter environmental regulations are forcing mills to modernize to stay reliable, efficient, and profitable. At the center of this transformation is the recovery boiler—a key component for technical performance, economic viability, and long-term savings.
Recovery boilers make the kraft process largely energy self-sufficient by turning spent pulping liquor into steam and subsequently power, and reusable chemicals. Their performance shapes the mill’s efficiency, sustainability, and cost competitiveness. When a recovery boiler nears or exceeds its design life, reliability drops, safety risks rise, fossil fuel dependence grows—and operating costs escalate.
The key to reducing GHG emissions
"Installation of a new efficient recovery boiler and power generation capacity leads to a significant reduction in the mill’s natural gas consumption in power boilers,“ says Magnus Ivarsbacke, Senior Technology Specialist at AFRY’s Pulp and Paper segment.
"In some cases, the power boiler can even be decommissioned and natural gas consumption for steam generation is fully eliminated. The mill’s power balance is significantly improved through modernization, aiming to minimize purchased fossil-based power or maximize green power sold to the national grid. The resulting substantial reduction in GHG emissions is a key contribution to the project’s overall goal,“ he concludes.
Aging assets: a global view
When we look at the age profile of recovery boilers worldwide—based on data from AFRY’s Smart Business Intelligence database—the picture is clear: some markets are operating with equipment far beyond its intended lifespan, while others have already made significant strides in modernization. This contrast highlights where the need for upgrades is most urgent.
In North America, the average recovery boiler is 35 years old. Roughly 60 percent of the fleet was built before 1978, meaning many units are running well past their expected 40-year lifespan. Europe faces similar challenges—though to a lesser degree—with many boilers dating back to the 1980s and an average age of around 24 years.
Latin America stands in clear contrast. Significant investments in new mills and upgrades since the early 2000s have resulted in a younger fleet with an average age of 17 years. Asia’s fleet, averaging around 22.5 years, is not the youngest, but the region has been steadily investing in new capacity and modernization. Several major facilities built in the past decade are gradually lowering the overall age and improving performance.
Modernizing recovery boilers with AFRY
AFRY has been driving recovery boiler modernization for decades, building on 130 years of expertise in the industry. Its expertise in boilers dates back to 1895, when Ångpanneföreningen (AF) was founded to improve steam boiler safety in Sweden. What began as a mission to prevent industrial accidents evolved into world-class engineering and consulting services. Today, this heritage underpins AFRY’s role in helping pulp and paper producers modernize recovery boilers, upgrade mill infrastructure, and optimize energy systems globally.
AFRY delivers advanced solutions for recovery boiler upgrades and replacements, enabling pulp and paper operations to achieve higher efficiency, reliability, and sustainability. Combining deep industry expertise with innovative engineering, AFRY ensures compliance with evolving environmental standards while creating long-term operational value.
AFRY’s track record speaks for itself – over decades in this field, the company has been involved in hundreds of modernization projects worldwide and has contributed to improvements at 90% of the world’s largest pulp and paper mills.
Examples of concluded or ongoing assignments include Green Bay Packaging’s modernization of its Arkansas Kraft paper mill in Morrilton, USA. This project aims to improve the mill’s operational efficiency and infrastructure. The investment encompasses vital replacements of key process components, including the recovery boiler and biomass boiler infrastructure. AFRY’s assignment includes detail engineering, procurement support, site engineering and commissioning support for the Balance of Plant.
In Sweden, AFRY supported Stora Enso’s Skutskär mill with the modernization of the process control system for Recovery Boiler No. 7, ensuring smooth commissioning and improved operational reliability. In Brazil, AFRY is currently involved in a major EPCM for the implementation of a new recovery boiler at a confidential client, contributing to increased efficiency and long-term operational performance.
AFRY can support clients worldwide with recovery boiler upgrades or replacements, from early studies through implementation, including full EPCM delivery capabilities.
