Heat Recovery Solutions for the Paper Industry

Unlock Maximum Energy Efficiency With BUCO Pillow Plate Heat Exchangers

In the pulp and paper industry, energy efficiency isn’t optional – it is a strategic advantage. With rising energy costs, tightening sustainability requirements, and increasing competitive pressure, effective heat recovery in the paper industry has become one of the fastest, most profitable levers for improving operational performance.

BUCO pillow plate heat exchangers deliver a proven, high-efficiency pathway to reclaiming valuable thermal energy from exhaust air, reducing fuel demand, stabilizing production, and generating rapid, measurable returns. Engineered specifically for fiber-laden and moisture-rich environments, BUCO heat exchange systems solve the fouling, downtime, and performance issues that undermine conventional solutions.

Why Heat Recovery Is a Game-Changer for Modern Paper Mills

Capture High-Value Waste Heat and Convert It Into Immediate Savings

Paper machines generate exhaust air containing extremely high moisture loads – typically 150 g H₂O per kg of dry air at around 80°C, with dew points near 60°C. This makes latent heat one of the largest untapped energy sources inside your mill.

By extracting this energy, you unlock:

• Significant reductions in steam and fuel consumption
• Reliable heating for process water, dryer bonnets, machine halls, and district heating loops
• Lower CO₂ emissions and improved sustainability metrics
• More stable production with reduced thermal fluctuations

BUCO systems are engineered to recover heat efficiently even from particle-heavy, fibrous exhaust streams, overcoming the persistent fouling problems that plague shell-and-tube technologies.

BUCOair: High-Efficiency Pillow Plate Heat Exchangers Built for the Paper Industry

Engineered for Maximum Heat Transfer, Minimum Downtime

What Are Pillow Plate Heat Exchangers?

BUCOair utilizes fully welded stainless steel thermoplates housed in a compact rectangular casing that flanges directly into existing air ducts. A water or water-glycol mixture flows through a multi-stage cross-counterflow configuration, ensuring optimal heat transfer – even under demanding operating conditions.

As humid air contacts the external plate surfaces, condensation boosts heat recovery rates, significantly increasing system efficiency.

Key Advantages of BUCO Pillow Plate Heat Exchangers in Pulp & Paper Applications

Designed to Eliminate Fouling, Reduce Costs, and Deliver Long-Term Reliability

BUCO’s pillow plate design ensures:

• Low pressure drop and minimal fouling, even with fibrous exhaust air
• Flexible customization of plate spacing, dimensions, and pass configurations
• Easy, fast cleaning with options such as spray nozzles, condensate tanks, and maintenance access panels
• High heat transfer coefficients at low pressure losses
• Corrosion-resistant stainless steel for long operating life
• Lower production costs and reduced heating medium volume requirements
• Consistent, homogeneous temperature control for water, refrigerants, or steam
• Compliance with the European Pressure Equipment Directive (PED)

These advantages translate directly into lower OPEX, reduced maintenance cycles, higher uptime, and more predictable mill performance.

Fast Payback Time for Waste Heat Recovery

Immediate ROI, Sustainable Cost Reductions, and Operational Stability

Because BUCO systems capture large amounts of latent heat while maintaining reliable operation in high-fouling environments, paper mills typically see:

• Extremely short payback times
• Major reductions in energy expenditure
• Less reliance on external heating sources
• Improved climate control in machine halls and dryer sections
• Enhanced overall process stability

For many facilities, waste heat recovery becomes one of the most profitable energy upgrades available, with long-term savings continuing for decades.

Ready to Unlock Immediate Savings and Long-Term Efficiency?

Request Your Custom BUCO Heat Recovery System Today

Every paper mill has a unique operating environment – and every BUCO system is engineered to match it. Whether you're aiming to reduce energy costs, boost sustainability, or enhance production stability, BUCO delivers proven performance backed by industry-leading expertise.

Take the next step toward lower energy bills and higher profitability.

Contact BUCO now for a custom proposal tailored to your plant’s exact requirements and start capturing the energy savings your facility is currently losing.

Unlock your mill’s full efficiency potential today.

FAQ

How much energy can a paper mill realistically save with a heat recovery system?

Paper mills can typically save between 10% and 25% of thermal energy demand by installing efficient waste heat recovery systems – sometimes even more on machines with high exhaust moisture content.

Why savings are so high:

• Paper machines emit exhaust air with extremely high latent heat (dew points near 60°C).
• Recovering this energy reduces steam consumption in:
  • Process water heating
  • Dryer section support heating
  • Machine hall air systems
  • District heating integration

BUCO pillow plate heat exchangers maximize this recovery by efficiently condensing water vapor in fibrous, particle-laden air without the performance losses common in shell-and-tube units.

Most mills see a payback time of 1–3 years, depending on machine size, operating hours, and energy prices.

Why do BUCO pillow plate heat exchangers outperform traditional shell-and-tube systems in paper mills?

The biggest reason: minimal fouling + higher heat transfer efficiency.

Traditional shell-and-tube units struggle with:

• Fouling from fibers, dust, and stickies
• Frequent cleaning intervals
• High pressure drops
• Lower condensation efficiency

BUCO pillow plate heat exchangers solve these pain points through:

• Large, smooth external surfaces that reduce fouling adhesion
• Fully welded stainless steel thermoplates with customizable spacing
• Cross-counterflow configuration for optimized heat transfer
• Easy access for cleaning (optional spray systems, plates, and condensate management)

This results in:

• Higher uptime
• Lower maintenance costs
• Consistently high recovery rates

Can pillow plate heat exchangers handle fibrous, contaminated air streams?

Yes – this is exactly what they are designed for.

Paper mill exhaust air contains:

• Fibers
• Paper dust
• Coating particles
• Moisture and stickies

BUCO’s pillow plate technology maintains high performance in these environments due to:

• Wide plate spacing
• Low-pressure-drop air channels
• Smooth stainless steel surfaces
• Optional automated cleaning systems
• High structural integrity under wet, corrosive, or variable operating conditions

This makes pillow plate exchangers one of the only long-term reliable solutions for exhaust air heat recovery in paper production.

What is the typical payback time for waste heat recovery in paper mills?

Typical payback is between 12 and 36 months, depending on:

• Machine size and speed
• Air humidity levels and temperature
• Local energy prices (gas, steam, district heat)
• Operating hours (continuous operations yield shorter payback)
• Integration scope (e.g., process water heating vs. district heating feed-in)

Where moisture levels are high – as they are in dryer sections – latent heat recovery offers exceptionally fast ROI because condensing water vapor releases large amounts of energy.

BUCO systems are designed for long service life and decades of stable output, further strengthening long-term returns.

Can BUCO heat exchange systems be integrated into existing paper machines or retrofits?

Yes – BUCO pillow plate systems are highly customizable and often used in retrofit projects.

Typical retrofit advantages:

• Direct flanging into existing air ducts
• Modular plate spacing adapted to available space
• Custom unit dimensions for machine hall constraints
• Scalable number of passes for performance targeting
• Minimal disruption to machine uptime during installation
• Easy integration with district heating, HVAC, or process water loops

Because BUCO systems have compact rectangular housings and flexible design options, they can fit into tight or complex plant layouts.

This makes them ideal for:

• Energy efficiency upgrades
• Replacing outdated shell-and-tube units
• Increasing heat recovery as part of decarbonization strategies