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Mill storyNaberezhnye Chelny Board & Paper MillK-28, Russia

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Located in the Republic of Tatarstan, Naberezhnye Chelny mill draws "green energy" from one of the world's largest reservoirs.

Gathering impressionsNaberezhnye Chelny

The Republic of Tatarstan lies in the heart-

land 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).

Due to its oil, natural gas, and gypsum re-

sources, Tatarstan is one of Russia's ri-

chest regions.

From fishing to industry

The city of Naberezhnye Chelny has a rich

historical past. Archeological excavations

have shown that tribes established the first

and started profitable manufacture of trucks,

diesel engines, and tanks. This led to a

rapid population growth and other indust-

ries like metallurgy, construction, food, and

paper.

Green energy

In 1987, construction work was completed on

the hydropower plant at the Nizhnekamsk

reservoir. It supplies the city of Naberezhnye

Chelny with "green energy". Four rivers —

Kama, Belaja, Ik, and Isch — feed the re-

servoir. With an area of 2,580 km2 and a vo-

lume of 45 billion m3, the water reservoir num-

bers among the largest in the world. At the

hydropower station, 16 Kaplan turbines

each with an output of 80.5 MW produce

1,288 MW in total.

contents

Gathering impressions 02

Naberezhnye Chelny 04Board & Paper Mill

Looking for a technology partner

A Russian game-changer 06Fast rebuild and fast acceptance

The Nizhnekamsk Reservoir, one of the largest in the world, provides the city of Naberezhnye Chelny with electricity. @ Хафизов Ахат

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 times. @ KAMAZ

naberezhnye chelny — key facts:

Inhabitants: approx. 513,193

Size: 146 km2

Main industries: automotive,

paper, mechanical engineering

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

View of the Naberezhyne Chelny city center

Paper industry

KBK is the only producer of paper and cor-

rugated board in Tatarstan. The company

awarded ANDRITZ the order for a major re-

build of the mill's K-28, as described in the

following pages.

0504

naberezhnye chelny Board & Paper MillLooking for a technology partner

The mill site of KBK at Naberezhnye Chelny New press section after the rebuild

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.

selecting the right partner

KBK has two machines – one for the pro-

duction of tissue and one for the produc-

tion 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, ma-

chine efficiency, and production through-

put,” 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.”

05

“ 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

During the tender period, the KBK manage-

ment 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 ex-

perience, reputation, and knowledge,”

Bestolkov says.

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.

Vladimir Bestolkov

It is with sadness that we report that

Vladimir Bestolkov, General Director,

has died since this story was first pub-

lished. Director Bestolkov made sig-

nificant 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.

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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-

ation, or as a stand-alone single-nip

press.

With speeds of up to 2,000 m/min

and nip loads up to 1,800 kN/m, the

PrimePress X is the right shoe press

to increase production and reduce

energy consumption per ton of prod-

uct produced. Nip widths from 120 to

350 mm are engineered for each appli-

cation to maximize press dryness and

sheet properties.

A compact version is available as well.

Featuring a 700 mm belt diameter, the

compact version is ideal for rebuild situ-

ations where space is limited.

A Russian game-changerFast rebuild and fast acceptance The rebuild of the K-28 paper machine for Naberezhnye Chelny in Russia was executedand accepted in record time. From the second reel on, the paper quality was of consistently high quality and very saleable.

In terms of raw materials, KBK is moving

in the green direction. Furnish is OCC re-

cycled 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 pro-

jected deadlines and keep within budget,”

notes Fomichev.

strategic and detailed planning

A machine rebuild of any magnitude re-

quires detailed planning to reduce the

shutdown time and close cooperation on-

site in order to succeed. Since ANDRITZ

was supplying the main technical compo-

nents as well as supervision of the erec-

tion, commissioning, and start-up, detailed

handoffs had to be planned. “For our part,

we planned everything in detail to ensure

that all the components and specialized

tooling would be on-site for the shutdown

beginning at the end of June 2014,” says

Klemens Unger, ANDRITZ Project Manag-

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

Bestolkov proudly. “We had saleable paper

from the second reel on.”

The rebuilt machine was started up on

August 28, 2014. Post upgrade, the aver-

age machine speed increased 27% (470

to 600 m/min) and capacity was boosted

21% to 190,000 t/a on this two-ply ma-

chine with a working width of 4.25 m. The

“usual” pressures: time and money. Mak-

ing the right investment choices is not an

easy task. KBK’s rebuild project had to suc-

ceed in order for the company to be well

positioned for future market growth. With a

growing demand for packaging and tissue,

the company is in the right niches (it produc-

es packaging and hygiene products). “Our

products are sold throughout Russia and

demand continues to grow, with a current

market share for board-based products of

7.5% and hygiene products of 17%,” says

Andrey Fomichev, General Director.

“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

General Director

KBK

Wet-end view of the rebuilt K-28 paper machine ▼

er. “Everything had to be in place so that

the erection team could carry out its as-

signments without delay.”

scope of supply

The ANDRITZ delivery included the ma-

chine approach system, pumps, two-ply

wire section with new headboxes and

dilution control, and a press section with

shoe press in the second nip. In addition,

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.”

“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

0908 0908

From a seven-ply suction former toa two-ply machine with new press section

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excellent formation

The old wire section of K-28 had seven

vacuum formers, but now has two wire

tables. “We opted for the PrimeFlow SW

headboxes with dilution control since they

are technologically state-of-the-art,” says

Mikhail Nokhrin, Chief Engineer. “The la-

mella design inside creates excellent forma-

tion, fiber distribution, and paper profiles.

The PrimePress X significantly improves

dewatering and saves us energy. Because

of this, we were able to increase production

without rebuilding our drying section.”

Unforeseen challenges

KBK, with its professional leadership, was

meticulous and focused on garnering the

best results from the project. “We certainly

faced challenges,” says Unger of ANDRITZ.

“In any rebuild, you need to be flexible to

adapt your technical solutions if required.

For example, a detailed study of the ex-

isting foundation concluded that it would

not be sufficient to carry the static loads

created by machine clothing replacement.

Together with specialists from a Russian

construction company, we developed a

solution to reinforce the existing founda-

tion and adapt the construction of the ma-

chinery beams to avoid the expense and

time delays for making a completely new

foundation.” Geographic distances, and

the complexity of preparing documents

for Russian customs clearance were also

challenging at times. “We all entered this

project with a team spirit and a common

goal,” says Unger. “The teams united

seamlessly on all levels to meet the dead-

lines and KBK’s expectations.”

A conclusion and a new beginning

K-28 was restarted in its new configura-

tion and saleable paper came quickly.

So did the final acceptance. “By includ-

ing ANDRITZ’s technologically advanced

solutions, we have increased speed, in-

creased production, increased quality,

and increased machine efficiency,” says

Fomichev. “Productivity has improved by

a large measure due to the sheet forma-

tion, web stabilization, and the closed

draws between wire and press, and within

the press section. Sheet breaks are a rare

event now.”

The entire forming section was pre-

assembled at the ANDRITZ workshop in

Graz, Austria. Founded in 1852, the Graz

workshop today has an area of about

95,000 m2. 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 engi-

neering 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), cus-

tomers come to the workshop to wit-

ness 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

March 17, 2015 became a noteworthy

day when KBK management signed the

Final Acceptance Certificate (FAC) with

ANDRITZ. “Seven months from the start-up

of the new and improved K-28 and we have

final acceptance,” says Georg-Michael

Sautter, Senior Sales Director for ANDRITZ.

“This is a record in itself, being the fastest

achieved for such a complex rebuild project

in Russia.”

Although the project has been concluded,

it is not intended to be the end. “I have

mixed emotions, Sautter says. “The busi-

ness 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 moderniza-

tion plans now concluded, a third stage is

anticipated during 2016 to 2020. “Our goal

is to optimize the machine to achieve 800 m/

min with stable quality parameters, which

will increase production to 250,000 t/a,”

says Fomichev. “ANDRITZ delivered what

they promised. Any time we faced a tech-

nical hurdle, we found a working solution.

This is a valuable asset that ANDRITZ

people possess. We will strongly consider

partnering with them in the future.”

collectively committed and

responsible

KBK is one of the few employee-owned

enterprises in Russia. “We are committed

to the 1,717 employees here,” Fomichev

explains. “Our founder, General Director

Titov, had a vision 20 years ago regarding

the ownership structure. He had housing

built for employees and their families near

the mill.” KBK has also built two kinder-

gartens 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 gov-

ernment ministers to witness the ANDRITZ-

upgraded K-28 in action producing

linerboard. President Minnikhanov was im-

pressed by what he saw at the enterprise.

“Today, we have seen the fruits of modern-

ization,” he said. “You are a good example

for other companies.”

“ By including ANDRITZ’stechnologically advancedsolutions, we have increasedspeed, increased production,increased quality, and increased machine efficiency.”

Andrei Fomichev

General Director

KBK

(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.

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