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Eka Engineering

World class engineering and project management

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Our latest project; building an Integrated Manufacturing Model in Ribas do Rio Pardo in 2024

Eka Engineering specialize in the design and supply of chlorine dioxide plants and equipment to the pulp and chemical industries

Eka Engineering is the engineering and contracting division that is part of our bleaching chemicals business. We specialize in the design, build and supply of chlorine dioxide plants and equipment to the pulp and chemical industries.
 
We offer completely new turnkey plants, the upgrade and repair of existing plants and comprehensive services for large-scale production and application of chlorine dioxide; for both vacuum and atmospheric technology plants. Our experienced personnel, world class technology and project management capabilities provide customers with a significant advantage for their operations. We operate globally and provide customers with quick and personal service.
 
 

Our offering - Expert Services for Optimal Plant Performance

• New ClO2 generators and rebuilds
• Process optimization and troubleshooting
• Inspections and maintenance
• Trainings and startup support
• Spare parts service
• R&D support

>200 installations

Having completed over 200 installations globally, we bring a wealth of experience and knowledge to every tailored project.

Safe & Stable Operations

We deliver high-standard safe and stable installations based on well-established industry practices and cutting-edge innovations.

Optimized Consumption

Our advanced integration with pulp mills ensures that we minimize losses and optimize resource use.

 

Costsaving Efficient

Integrating our processes with the mill's operations reduces waste and maximizes efficiency, helping our customers become more cost efficient.

Best Available Technique (BAT)

Ensuring a cleaner, more sustainable solution by lowering environmental impact.

 

 

Eka Engineering specialize in the design, build, and supply of chlorine dioxide plants and equipment

We offer turnkey plants, upgrades, repairs, and comprehensive services globally with experienced personnel, world-class technology, and project management capabilities.

SVP generator and tank area

We offer Best Available Techniques (BAT) for safe, effective and sustainable chlorine dioxide production

We design systems to meet your mill's specific needs and requirements. We recommend technologies using methanol (CH₃OH) or hydrogen peroxide (H₂O₂) as reducing agents, based on their high yield, low cost and good fit with the mill's chemical systems.

We offer processes that produce chlorine dioxide (ClO₂) without formation of elemental chlorine (Cl₂). Our processes are optimized regarding high safety and high efficiency. It operates primarily within a closed-loop system, minimizing waste, promoting sustainability, and reducing overall environmental impact. While vacuum processes are more complex compared to atmospheric processes, they are preferable for larger ClO₂ demands. However, the HP-A process is frequently used, especially when retrofitting older installations.

 

Processes

On-Site ClO2 Production

The formula to produce (ClO2) is to reduce sodium chlorate (NaClO3) in an acidic solution. The different processes are distinguished from each other by use of different reducing agents and acids for reducing sodium chlorate (NaClO3), to chlorine dioxide (ClO2) and respective biproducts.

NaClO3, to ClO2 and respective biproducts.

The SVP (Single Vessel Process) chlorine dioxide process family consists of several similar processes based on the same equipment configuration. It is relatively easy to switch from one to the other. The most common chemicals for SVP processes is sulphuric acid for acidification and methanol as reducing agent to produce ClO2.

For more details see below or download our broschures.

SVP-LITE® Process

The SVP chlorine dioxide process consists of numerous variations where LITE is the simplest one. Reaction, crystallization, and gas-liquid separation all take place inside the SVP generator, hence the name single vessel process (SVP). The process operates in vacuum to ensure a high concentration and yet safe level of chlorine dioxide. The by-product stream consists of an aqueous solution of acidic sodium sesquisulphate which is generally used for acidification in the pulp mill.

SVP-SCW Process

The SVP-SCW is a modified version of the LITE which adds another washing step for the by-product stream. The advantages of washing sodium sesquisulphate is to recover an acidic filtrate stream of sulphuric acid, reducing the overall H2SO4 consumption by approximately 17%. Moreover, the salt after the second wash is neutral sodium sulphate which is desired in the mill’s evaporation plant for caustic make-up, reducing the waste generation to almost zero.

HP-A® Process

HP-A is one of the newest processes by Nouryon. The proprietary technology has several advantages over earlier atmospheric chlorine dioxide processes and is commonly rebuilt from older Mathieson processes. The processs utilizes sulphuric acid for acidification and hydrogen peroxide as reducing agent to produce ClO2.

Integrated Manufacturing Model

The Integrated Manufacturing Model concept lowers the carbon footprint and enhances chemical production efficiency while reducing transportation needs. Nouryon recently completed the construction of sodium chlorate and hydrogen peroxide facilities in Ribas do Rio Pardo, Brazil, supporting the pulp mill that began production in late 2024.

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Integrated Manufacturing Model - A state-of the-art facility located next to a customer's pulp mill, often inside the perimeter fence.

With a full-scale Integrated Manufacturing Model in place, our customers benefit from a tried, tested and successful concept managed and operated – on site, 24/7 – by our experts who ensure consistent production and delivery of chemicals needed to operate the mill.

Learn more


Advancing Environmental Sustainability through Innovative Technologies

Our technology contributes to the lowest levels of AOX in the industry, demonstrating our commitment to reducing harmful emissions. Our process operates with an efficient and well optimized closed loop system, minimizing waste, promoting sustainability, and reducing overall environmental impact.

Why does ECF bleaching by Eka Engineering technology make good environmental sense?

Following the abandonment of chlorine as a bleaching agent due to environmental considerations, two technologies were developed. The first is Elemental Chlorine Free (ECF) and the second is Total Chlorine Free (TCF). The distinguishing factor between the two processes is the use of chlorine dioxide, which is used in ECF but not TCF. To compensate for the lack of chlorine dioxide, TCF will either add higher dosages of hydrogen peroxide, or supplement the process with ozone.

In 2024, ECF pulp constituted 93% of the world share of bleached chemical pulp market. TCF, although decreasing slightly in market share, has remained at approximately 5% of the bleached chemical pulp market.

Learn more in the research paper Environmental systems analysis of alternative bleaching sequences with focus on
carbon footprint by Pia Jour, Karin Halldén and Eva Wackerberg.

Related content

Deepen your knowledge in AOX by reading the article

"The effect of the transition from elemental chlorine bleaching to chlorine dioxide bleaching in the pulp industry on the formation of PCDD/Fs* by Peter Axegård, Published by Science Direct.

Environmental systems analysis of alternative bleaching sequences with focus on
carbon footprint

Research paper by Pia Jour, Karin Halldén and Eva Wackerberg.

Read more about Eka Engineering in our brochure

Eka Engineering is a world-leading supplier of chlorine dioxide (ClO2) plants.

World-class service and spare parts ensure your plant availability is maximized

Enhance your pulp bleaching processes with our expert services. We offer flexible programs to optimize chlorine dioxide production and maintenance, improving plant efficiency and output through optimization, inspection, and troubleshooting. Equip your staff with customized training sessions and ensure maximum plant availability with our rapid, reliable spare parts delivery supported by a global logistics network.

Service and spare parts

  • Our spare parts service will help ensure your plant availability is maximized and any downtime is minimized.
  • We deliver all parts rapidly and reliably using our extensive supply chain and global logistics network.

For quality assurance, we deliver spare parts from the original supplier whenever possible. Some typical spare parts we provide include pump parts, instruments, valves, and filter inserts.

Optimization

  • Assessment of chemical yield on sodium chlorate, reducing agent and acid
  • Chlorine dioxide production capacity tests
  • Saltcake removal & utilization
  • Vent system emissions recovery
  • Investigations of emissions to both air and sewers
  • Advanced process control implementation

Operational Support

Our experts are invaluable in troubleshooting and solving mill problems. With knowledge of kraft, mechanical and sulfite pulp bleaching and associated processes our engineers have helped solve pulp brightness problems, scaling issues and environmental concerns

  • Remote or on-site troubleshooting
  • Applied Kepner-Tregoe methods
  • Inspection on material conditions
  • Root cause analysis
  • Maintenance planning assistance
  • Inspection and advice on sodium chlorate, sulfuric acid, methanol, hydrogen peroxide and chlorine dioxide storage
  • Investigations of process and production limitations in the chlorine dioxide plant

Process safety

  • Participation in safety audits and risk analysis at the chlorine dioxide plant
  • Interlock checkouts for Process Safety Management (PSM) program
  • Process Hazard Analysis (PHA) re-validation for methanol, chlorine dioxide, turpentine, ammonia and non-condensable gas (NCG) systems
  • Supporting documentation / process safety information / Management of Change (MOC) process verification
  • PHA Facilitation & OEM Process Expert

Training

Our experts are often asked to deliver customer-specific bleach plant operations training. In these sessions, we train mill personnel how to evaluate, troubleshoot and optimize their own process and often present case studies of real situations encountered. Training is onsite and is beneficial to all personnel – operators, engineers and foremen.

  • Operator training
  • Safety training
  • Laboratory analysis

Downloads

Eka chlorine dioxide generation systems

Details of vacuum and atmospheric processes

Type: Brochure
Language: English
Format: pdf | 2.7 MB
-
Download

Services for chlorine dioxide generators

Eka Engineering

Type: Other
Language: English
Format: pdf | 354 KB
-
Download

Eka chlorine dioxide technologies

Best available techniques (BAT) for ClO2 production

Type: Brochure
Language: English
Format: pdf | 752.3 KB
-
Download

Eka Engineering: The SVP process

Eka Engineering’s most commonly built processes to generate chlorine dioxide in large quantities.

Type: Other
Language: English
Format: pdf | 830.9 KB
-
Download

Eka Engineering: The HP-A® ClO2 process

A proprietary technology which has several advantages over earlier atmospheric chlorine dioxide (CIO...

Type: Brochure
Language: English
Format: pdf | 839.8 KB
-
Download

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Eka® ClO2 - chlorine dioxide

Eka® chlorine dioxide is a preferable bleaching agent used in the production of elemental chlorine-free (ECF) bleached chemical wood pulp all over the world.
Operator at a chemical plant. Experts can help optimize your process by improving bleaching and chemical efficiency.

Eka® bleaching services

We provide pulp bleaching services and chlorine dioxide generator expertise to help keep our customers operations running smoothly.

Contact us - We are happy to help!

We value your feedback and inquiries. Whether you have a question about our products, need assistance with an order, or simply want to share your thoughts, we're here to help.

Eka® is a registered trademark of Nouryon in a number of territories worldwide.

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