Application and Measurement of Steam in the Pulp & Paper Industry

In the pulp and paper industry, steam plays an essential role in nearly every stage of the production process—from pulping and chemical treatment to drying and finishing. As a major energy source, accurately measuring steam flow is critical for ensuring operational stability, energy efficiency, and cost control.

In this article, we explore how steam is used in paper production, the challenges in monitoring steam usage, and how Comate’s VFM60MV vortex flow meter provides an ideal solution.

Steam Applications in Pulp & Paper Plants

Steam is utilized in a variety of key processes throughout a typical paper mill:

  • Chemical preparation and dissolving: Heating chemicals used in pulping and bleaching

  • Pulp cooking: High-temperature saturated steam softens wood chips and breaks down lignin

  • Black liquor concentration: Evaporating moisture from waste liquor before recovery

  • Drying section of paper machines: Steam heats drying cylinders to remove water from paper

  • Process heating & sterilization: Supporting auxiliary processes, including heating and CIP/SIP systems

These operations rely on stable, controlled steam delivery, making accurate flow measurement essential.

Importance of Steam in the Pulp & Paper Industry

Steam drives critical processes such as chemical pulping, where it cooks wood chips to break down lignin, and mechanical pulping, where it aids fiber separation. In paper production, steam heats dryer cylinders to remove moisture from wet sheets, ensuring the desired texture and strength. It also supports energy generation via steam turbines, enabling cogeneration to meet electricity and heat demands. Efficient steam use reduces energy costs—accounting for up to 43% of total energy demand in mills—and supports sustainability by minimizing waste.

Steam Flow Monitoring Challenges

Monitoring steam usage in a paper mill is far from straightforward. Some of the major challenges include:

  • Wet steam conditions: Moisture content in the steam flow can affect measurement accuracy

  • Highly fluctuating flow rates: Different production loads lead to variable steam demand

  • Demand for real-time data: Central control systems require accurate and timely input for process regulation

  • Need for cost transparency: Energy usage must be monitored precisely to optimize cost per ton of paper produced

Traditional flow meters often struggle under these conditions. That’s where Comate’s VFM60MV comes in.

Comate’s Steam Flow Solution: VFM60MV Vortex Flow Meter

The VFM60MV vortex flow meter from Comate is designed specifically to handle saturated steam measurement in industrial environments like paper mills.

✔ Key Features:

  • Integrated temperature and pressure compensation
    → Delivers direct mass flow output, reducing system complexity

  • Low starting velocity (down to 2 m/s)
    → Accurate even under low-load or fluctuating conditions

  • Compatible with wet steam
    → Ensures stable readings even with moisture in the flow

  • Rugged, all-welded stainless steel sensor
    → Withstands high-temperature, high-pressure applications

  • Communication-ready (Modbus/RS485)
    → Seamless integration into energy management or DCS systems

📈 Benefits for Paper Manufacturers

By adopting Comate’s vortex flow meter solution, pulp and paper plants can:

  • ✅ Improve energy efficiency

  • ✅ Monitor and manage steam consumption across different units

  • ✅ Enable real-time feedback for production adjustment

  • ✅ Optimize operational costs and sustainability goals

  • ✅ Increase data transparency for performance benchmarking

📌 Real-World Use Case

A large paper mill recently installed a saturated steam pressure-reduction system, converting high-pressure wet steam into low-pressure dry steam. The plant required precise monitoring of steam flow rate, pressure, and temperature to support real-time control.

Comate’s VFM60MV vortex flow meter was selected to measure steam flow to various production lines—ensuring reliable supply for cooking, concentration, and drying processes. The result: better process stability, improved energy allocation, and measurable cost savings.