Mill story Naberezhnye Chelny Board & Paper Mill K-28, Russia

Transcription

1 Mill story Naberezhnye Chelny Board & Paper Mill K-28, Russia We accept the challenge!

2 Gathering impressions Naberezhnye Chelny Located in the Republic of Tatarstan, Naberezhnye Chelny mill draws "green energy" from one of the world's largest reservoirs. contents Gathering impressions 02 Naberezhnye Chelny 04 Board & Paper Mill Looking for a technology partner A Russian game-changer 06 Fast rebuild and fast acceptance The Nizhnekamsk Reservoir, one of the largest in the world, provides the city of Naberezhnye Chelny with Хафизов Ахат The Republic of Tatarstan lies in the heartland of Russia, 800 km east of Moscow. On the banks of the Kama River is the small, yet thriving city of Naberezhnye Chelny, home to Naberezhnye Chelny Board & Paper Mill (KBK). settlement there in the middle of the third millenium B.C.. Until the nineteenth century, Naberezhnye Chelny was a small town, shaped by fishing and trade. In 1976, the Russian company KAMAZ opened its doors and started profitable manufacture of trucks, diesel engines, and tanks. This led to a rapid population growth and other industries like metallurgy, construction, food, and paper. Paper industry KBK is the only producer of paper and corrugated board in Tatarstan. The company awarded ANDRITZ the order for a major rebuild of the mill's K-28, as described in the following pages. Naberezhnye Chelny key facts: Inhabitants: approx. 513,193 Size: 146 km 2 Main industries: automotive, paper, mechanical engineering Green energy Due to its oil, natural gas, and gypsum re- In 1987, construction work was completed on sources, Tatarstan is one of Russia's ri- the hydropower plant at the Nizhnekamsk chest regions. reservoir. It supplies the city of Naberezhnye Chelny with "green energy". Four rivers From fishing to industry Kama, Belaja, Ik, and Isch feed the re- The city of Naberezhnye Chelny has a rich servoir. With an area of 2,580 km 2 and a vo- historical past. Archeological excavations lume of 45 billion m 3, the water reservoir num- have shown that tribes established the first KAMAZ brought industry to Naberezhnye Chelny and today numbers among the world's most renowned truck manufacturers. The company even won the famous Dakar rally for 13 KAMAZ bers among the largest in the world. At the hydropower station, 16 Kaplan turbines each with an output of 80.5 MW produce View of the Naberezhyne Chelny city center 1,288 MW in total

3 Naberezhnye Chelny Board & Paper Mill Looking for a technology partner Naberezhnye Chelny Board & Paper Mill has more than 30 years' experience with tissue and packaging grades. For its largest investment so far, the rebuild of a board machine, ANDRITZ was selected as technology partner. Sergey Titov: Social engagement Twenty years ago, the former General Director of KBK, Sergey Titov, had a vision: social responsibility. He built houses for employees and their families near the mill. Today, KBK has its own two kindergartens and a school. The mill site of KBK at Naberezhnye Chelny New press section after the rebuild Selecting the right partner KBK has two machines one for the production of tissue and one for the production of packaging grades. In 2012, KBK decided to make an investment to rebuild and upgrade the wet end and press section of its K-28 board machine. We wanted to increase our quality, machine efficiency, and production throughput, says KBK s former General Director, Vladimir Bestolkov. Since this was going to be the largest investment in this mill s 33-year history, we took the decision regarding the equipment supplier very seriously. During the tender period, the KBK management team assessed the various industry players, locally and abroad, to determine who could embrace this challenge and deliver the best payback. We opted for ANDRITZ based on the company s experience, reputation, and knowledge, Bestolkov says. Since this was going to be the largest single investment in this mill s 33-year history, we took the decision regarding the equipment supplier very seriously. Vladimir Bestolkov former General Director KBK Vladimir Bestolkov It is with sadness that we report that Vladimir Bestolkov, General Director, has died since this story was first published. Director Bestolkov made significant contributions to the Russian pulp and paper industry and had a passion for papermaking. Georg-Michael Sautter, ANDRITZ Senior Director Sales Paper and Board Machines, and Vladimir Bestolkov, KBK former General Director, with the signed Final Acceptance Certificate

4 A Russian game-changer Fast rebuild and fast acceptance The rebuild of the K-28 paper machine for Naberezhnye Chelny in Russia was executed and accepted in record time. From the second reel on, the paper quality was of consistently high quality and very saleable. The time period from shutdown to start-up after the rebuild was a quick 45 days truly a game-changer in the Russian paper industry. Andrei Fomichev Shoe press technology for efficient dewatering A decisive highlight of the rebuild is the PrimePress X shoe press. It can be installed in any multi-nip press configur- to increase production and reduce energy consumption per ton of product produced. Nip widths from 120 to 350 mm are engineered for each application to maximize press dryness and General Director KBK ation, or as a stand-alone single-nip press. sheet properties. A compact version is available as well. With speeds of up to 2,000 m/min Featuring a 700 mm belt diameter, the and nip loads up to 1,800 kn/m, the compact version is ideal for rebuild situ- Wet-end view of the rebuilt K-28 paper machine PrimePress X is the right shoe press ations where space is limited. The benefits and results have been nothing short of remarkable. I am proud of the work our employees did, working in very close cooperation with ANDRITZ, says Bestolkov proudly. We had saleable paper from the second reel on. The rebuilt machine was started up on August 28, Post upgrade, the average machine speed increased 27% (470 to 600 m/min) and capacity was boosted 21% to 190,000 t/a on this two-ply ma- In terms of raw materials, KBK is moving in the green direction. Furnish is OCC recycled fiber for hygiene, fluting and liner products; delivered from various regions of Russia, with 10% coming from Tatarstan. After signing the contract in late 2012, the pressure was on all of us to meet the projected deadlines and keep within budget, notes Fomichev. er. Everything had to be in place so that the erection team could carry out its assignments without delay. Scope of supply The ANDRITZ delivery included the machine approach system, pumps, two-ply wire section with new headboxes and dilution control, and a press section with according to Unger, We also supplied the PrimeFeeder threading system from the press section to the drying section, PrimeRun web stabilizers for the machine s single-tier dryer section, the machine drives, the quality control system, the distributed control system, the machine drives, and the motor control center for our scope of supply. chine with a working width of 4.25 m. The usual pressures: time and money. Mak- Strategic and detailed planning shoe press in the second nip. In addition, ing the right investment choices is not an A machine rebuild of any magnitude re- easy task. KBK s rebuild project had to suc- quires detailed planning to reduce the ceed in order for the company to be well shutdown time and close cooperation on- positioned for future market growth. With a growing demand for packaging and tissue, the company is in the right niches (it produces packaging and hygiene products). Our products are sold throughout Russia and demand continues to grow, with a current site in order to succeed. Since ANDRITZ was supplying the main technical components as well as supervision of the erection, commissioning, and start-up, detailed handoffs had to be planned. For our part, we planned everything in detail to ensure Seven months from the start-up to the final acceptance. This is a record in itself! Georg-Michael Sautter Senior Director Sales Paper and Board Machines ANDRITZ market share for board-based products of that all the components and specialized 7.5% and hygiene products of 17%, says tooling would be on-site for the shutdown Andrey Fomichev, General Director. beginning at the end of June 2014, says Klemens Unger, ANDRITZ Project Manag

5 From a seven-ply suction former to a two-ply machine with new press section 08 09

6 The entire forming section was preassembled at the ANDRITZ workshop in Graz, Austria. Founded in 1852, the Graz workshop today has an area of about 95,000 m 2. This is 9.5 times the area of a soccer field. Approximately 3,000 tonnes of steel plates (stainless and carbon steel) are processed each year. When the engineering for a product is completed, the production planning begins. Schedule and sourcing are fixed and fabrication is initiated. Metal cutting, rolling, bending, and welding are all core technologies for the workshop. Like KBK (see picture on the left), customers come to the workshop to witness the tests and have a final look at their equipment prior to disassembly for shipping. ANDRITZ workshop in Graz Pre-assembly of the forming section Excellent formation Unforeseen challenges The old wire section of K-28 had seven KBK, with its professional leadership, was solution to reinforce the existing founda- March 17, 2015 became a noteworthy people possess. We will strongly consider vacuum formers, but now has two wire meticulous and focused on garnering the tion and adapt the construction of the ma- day when KBK management signed the partnering with them in the future. tables. We opted for the PrimeFlow SW best results from the project. We certainly chinery beams to avoid the expense and Final Acceptance Certificate (FAC) with headboxes with dilution control since they faced challenges, says Unger of ANDRITZ. time delays for making a completely new ANDRITZ. Seven months from the start-up Collectively committed and are technologically state-of-the-art, says In any rebuild, you need to be flexible to foundation. Geographic distances, and of the new and improved K-28 and we have responsible Mikhail Nokhrin, Chief Engineer. The la- adapt your technical solutions if required. the complexity of preparing documents final acceptance, says Georg-Michael KBK is one of the few employee-owned mella design inside creates excellent forma- For example, a detailed study of the ex- for Russian customs clearance were also Sautter, Senior Sales Director for ANDRITZ. enterprises in Russia. We are committed tion, fiber distribution, and paper profiles. isting foundation concluded that it would challenging at times. We all entered this This is a record in itself, being the fastest to the 1,717 employees here, Fomichev The PrimePress X significantly improves not be sufficient to carry the static loads project with a team spirit and a common achieved for such a complex rebuild project explains. Our founder, General Director dewatering and saves us energy. Because created by machine clothing replacement. goal, says Unger. The teams united in Russia. Titov, had a vision 20 years ago regarding of this, we were able to increase production Together with specialists from a Russian seamlessly on all levels to meet the dead- the ownership structure. He had housing without rebuilding our drying section. construction company, we developed a lines and KBK s expectations. Although the project has been concluded, built for employees and their families near A conclusion and a new beginning K-28 was restarted in its new configuration and saleable paper came quickly. So did the final acceptance. By including ANDRITZ s technologically advanced solutions, we have increased speed, increased production, increased quality, and increased machine efficiency, says Fomichev. Productivity has improved by By including ANDRITZ s technologically advanced solutions, we have increased speed, increased production, increased quality, and increased machine efficiency. Andrei Fomichev General Director KBK it is not intended to be the end. I have mixed emotions, Sautter says. The business negotiations were tough, but we have also established strong bonds and solid friendships. The cooperation has been truly remarkable. With the second stage of KBK s modernization plans now concluded, a third stage is anticipated during 2016 to Our goal the mill. KBK has also built two kindergartens and a school, and sponsors sports activities, charity and social events, and other activities. In September 2014, the mill was visited by the President of Tatarstan, Rustam Minnikhanov, together with various government ministers to witness the ANDRITZupgraded K-28 in action producing a large measure due to the sheet forma- is to optimize the machine to achieve 800 m/ linerboard. President Minnikhanov was im- tion, web stabilization, and the closed min with stable quality parameters, which pressed by what he saw at the enterprise. draws between wire and press, and within will increase production to 250,000 t/a, Today, we have seen the fruits of modern- the press section. Sheet breaks are a rare says Fomichev. ANDRITZ delivered what ization, he said. You are a good example event now. they promised. Any time we faced a tech- for other companies. (l-r) Sergey Gavrilov, Board Production Manager; Ivo Valtchev, ANDRITZ Sales Manager; Klemens Unger, ANDRITZ Project Manager; Andrei Fomichev, General Director; Sergey Poteryaev, Deputy General Director for Production; Mikhail Nokhrin, Chief Engineer; Vladimir Bestolkov, former General Director; and Georg-Michael Sautter, ANDRITZ Senior Sales Director. nical hurdle, we found a working solution. This is a valuable asset that ANDRITZ 10 11

7 Contact AUSTRIA ANDRITZ AG Stattegger Strasse Graz, Austria Phone: +43 (316) All data, information, statements, photographs, and graphic illustrations in this leaflet are without any obligation and raise no liabilities to or form part of any sales contracts of ANDRITZ AG or any affiliates for equipment and/or systems referred to herein. ANDRITZ AG All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ AG or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. ANDRITZ AG, Stattegger Strasse 18, 8045 Graz, Austria. KPP.xp.01.en.0116