Domtar's Clermont Mill, a nearly century-old institution in Quebec's Charlevoix region, has long been a pillar of the local community. The mill is home to a paper machine that produces 221,000 metric tons of newsprint a year from thermomechanical pulp. Faced with the high energy demands of paper production, the mill rose to the challenge with an innovative energy recovery project.
Fully aware of the opportunities to optimize steam consumption, the team at the Clermont Mill partnered with Hydro-Québec to develop an ambitious energy recovery project. Hydro-Québec provided CA$3 million of financial assistance to help the mill reduce its steam consumption by capturing and reusing waste heat. The project involved installing heat exchangers and two water-to-water heat pumps, directly integrated into the paper production process -- a first for Quebec's pulp and paper industry.
The initiative has yielded significant results, including an annual savings of CA$800,000 and a 15-million-kWh reduction in energy consumption. To better illustrate the impact, the energy saved could power 880 houses, a statistic that highlights the project's economic and environmental benefits.
Energy Recovery Project Breaks New Ground
Mario Girard, superintendent of energy, projects and engineering at the Clermont Mill, recounted his initial observations about the facility's excessive steam and heat losses. He saw the waste as an opportunity for optimization. The mill sought the expertise of FP Innovations, a nonprofit organization dedicated to the advancement of Canada's forest products sector. FP Innovations conducted an in-depth study to identify the sources of heat loss and presented a detailed report proposing areas for improvement.
But implementing the recommendations required funding and technical expertise. This is where Hydro-Québec made a crucial contribution. Initially, the utility proposed a heat pump from its R&D center in Shawinigan, but the equipment wasn't suited to Clermont's operations. Hydro-Québec was determined to complete the project and ultimately agreed to subsidize 75 percent of the cost of installing two specialized heat pumps.
As Stéphane Gadbois, then general manager of the Clermont Mill, pointed out, meeting the dual challenge of reducing energy consumption while planning for future production increases called for a bold approach. The project has been ground-breaking for the industry, proving that large-scale energy efficiency improvements are both feasible and cost-effective.
Hydro-Québec's involvement was not limited to financial assistance, however. It also provided technical expertise, advising Clermont Mill engineers on how to obtain industry certifications that enhanced the project's credibility and sustainability. From design to execution, the energy recovery project took two years, from implementation in January 2023 to full commissioning in July 2024.
The Clermont Mill's pioneering use of heat pumps in such a demanding environment has attracted attention from the entire industry. As Mario Girard pointed out, many have praised Domtar's boldness in carrying out the project, with some saying, "If Domtar has done it, there's no good reason not to."
The Clermont Mill's successful energy recovery project is a testament to the power of innovation and collaboration. In an industry where economic efficiency and environmental responsibility go hand in hand, this initiative is a model for advances in paper production. By leveraging strategic partnerships and cutting-edge technologies, the Clermont Mill has given Quebec's pulp and paper industry a new benchmark for energy efficiency.
