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

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Mill Story Naberezhnye Chelny Board & Paper Mill K-28, Russia Mill story Naberezhnye Chelny Board & Paper Mill K-28, Russia www.andritz.com We accept the challenge! 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 electricity. @ Хафизов Ахат The Republic of Tatarstan lies in the heart- settlement there in the middle of the third and started profitable manufacture of trucks, Paper industry Naberezhnye Chelny — key facts: land of Russia, 800 km east of Moscow. millenium B.C.. Until the nineteenth century, diesel engines, and tanks. This led to a KBK is the only producer of paper and cor- Inhabitants: approx. 513,193 On the banks of the Kama River is the Naberezhnye Chelny was a small town, rapid population growth and other indust- rugated board in Tatarstan. The company Size: 146 km2 small, yet thriving city of Naberezhnye shaped by fishing and trade. In 1976, the ries like metallurgy, construction, food, and awarded ANDRITZ the order for a major re- Main industries: automotive, Chelny, home to Naberezhnye Chelny Russian company KAMAZ opened its doors paper. build of the mill's K-28, as described in the paper, mechanical engineering Board & Paper Mill (KBK). following pages. 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 km2 and a vo- historical past. Archeological excavations lume of 45 billion m3, the water reservoir num- have shown that tribes established the first KAMAZ brought industry to Naberezhnye Chelny and bers among the largest in the world. At the today numbers among the world's most renowned truck manufacturers. The company even won the famous hydropower station, 16 Kaplan turbines Dakar rally for 13 times. @ KAMAZ each with an output of 80.5 MW produce View of the Naberezhyne Chelny city center 1,288 MW in total. 02 03 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 fami- lies near the mill. Today, KBK has its own two kinder- gartens and a school. The mill site of KBK at Naberezhnye Chelny New press section after the rebuild Selecting the right partner Vladimir Bestolkov KBK has two machines – one for the pro- “ Since this was going to be the largest single It is with sadness that we report that duction of tissue and one for the produc- investment in this mill’s 33-year history, we took Vladimir Bestolkov, General Director, tion of packaging grades. In 2012, KBK the decision regarding the has died since this story was first pub- decided to make an investment to rebuild equipment supplier very seriously.” lished. Director Bestolkov made sig- and upgrade the wet end and press section Vladimir Bestolkov nificant contributions to the Russian of its K-28 board machine. former General Director pulp and paper industry and had a KBK passion for papermaking. “We wanted to increase our quality, ma- During the tender period, the KBK manage- chine efficiency, and production through- ment team assessed the various industry put,” says KBK’s former General Director, players, locally and abroad, to determine Vladimir Bestolkov. “Since this was going who could embrace this challenge and to be the largest investment in this mill’s deliver the best payback. “We opted for ◄ Georg-Michael Sautter, ANDRITZ Senior Director Sales Paper and Board Machines, and Vladimir 33-year history, we took the decision ANDRITZ based on the company’s ex- Bestolkov, KBK former General Director, with the signed regarding the equipment supplier very perience, reputation, and knowledge,” Final Acceptance Certificate. seriously.” Bestolkov says. 04 05 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 Shoe press technology to increase production and reduce was a quick 45 days – truly a for efficient dewatering energy consumption per ton of prod- game-changer in the Russian A decisive highlight of the rebuild is uct produced. Nip widths from 120 to paper industry.” the PrimePress X shoe press. It can be 350 mm are engineered for each appli- Andrei Fomichev installed in any multi-nip press configur- cation to maximize press dryness and General Director ation, or as a stand-alone single-nip sheet properties. KBK press. 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 PrimePress X is the right shoe press ations where space is limited. K-28 paper machine ▼ The benefits and results have been noth- ing short of remarkable. “I am proud of the work our employees did, working in very close cooperation with ANDRITZ,” says In terms of raw materials, KBK is moving er. “Everything had to be in place so that according to Unger, “We also supplied Bestolkov proudly. “We had saleable paper in the green direction. Furnish is OCC re- the erection team could carry out its as- the PrimeFeeder threading system from from the second reel on.” cycled fiber for hygiene, fluting and liner signments without delay.” the press section to the drying section, products; delivered from various regions of PrimeRun web stabilizers for the machine’s The rebuilt machine was started up on Russia, with 10% coming from Tatarstan. Scope of supply single-tier dryer section, the machine August 28, 2014. Post upgrade, the aver- “After signing the contract in late 2012, the The ANDRITZ delivery included the ma- drives, the quality control system, the age machine speed increased 27% (470 pressure was on all of us to meet the pro- chine approach system, pumps, two-ply distributed control system, the machine to 600 m/min) and capacity was boosted jected deadlines and keep within budget,” wire section with new headboxes and drives, and the motor control center for 21% to 190,000 t/a on this two-ply ma- notes Fomichev. dilution control, and a press section with our scope of supply.” chine with a working width of 4.25 m. The shoe press in the second nip. In addition, “usual” pressures: time and money. Mak- Strategic and detailed planning 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 site in order to succeed. Since ANDRITZ growing demand for packaging and tissue, was supplying the main technical compo- “Seven months from the start-up the company is in the right niches (it produc- nents as well as supervision of the erec- to the final acceptance. This is a es packaging and hygiene products). “Our tion, commissioning, and start-up, detailed record in itself!” Georg-Michael Sautter products are sold throughout Russia and handoffs had to be planned. “For our part, Senior Director Sales Paper and Board Machines demand continues to grow, with a current we planned everything in detail to ensure 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- 06 07 From a seven-ply suction former to a two-ply machine with new press section 08 09 The entire forming section was pre- initiated. Metal cutting, rolling, bending, assembled at the ANDRITZ workshop in and welding are all core technologies for Graz, Austria. Founded in 1852, the Graz the workshop. workshop today has an area of about 95,000 m2. This is 9.5 times the area of a Like KBK (see picture on the left), cus- soccer field. Approximately 3,000 tonnes tomers come to the workshop to wit- of steel plates (stainless and carbon steel) ness the tests and have a final look at are processed each year. When the engi- their equipment prior to disassembly for neering for a product is completed, the shipping. production planning begins. Schedule and sourcing are fixed and fabrication is 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.
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