1. Modernization of the Ground Wood Mill with a New GW Reject Refining Line
Year of Rebuild: 2006
- increase the mechanical strength of pulp;
- enable reduced consumption of market chemical pulp by 3% in the furnish;
- improve the quality of GW and TMP; and
- enhance the newsprint strength and printability: i.e. higher breaking length, CD strength and density, reduced dusting and shive content.
The project includes new equipment for GW screening and reject refining, as well as for chemical pulp (kraft) refining. Three FS-503E Optiscreens are installed to ensure fine screening of groundwood. Accept pulp goes to the process, while screen rejects are sent to a reject refining line.
The screen rejects go first to the CleanPac-700 cleaner plant (centricleaner system) to remove mineral impurities (sand, abrasive materials, etc) and then to TS-3 bow screens and SP70SL screw press for thickening. The pulp is then transported by screw conveyors to RGP-268 reject refiner. The refining chamber is sprayed with water and the resulted air-steam mixture is blown into the cyclone to separate the pulp from steam. In the end, after diluting and mixing, the refined pulp goes through FS-503 fine screen.
In addition, three FR-4 Optifiners are included to improve kraft refining.
Volga's Design & Development Department took an active part in designing the project. The equipment is supplied by Metso (Finland).
2. Wood-Fired Boiler Plant
Year of Commissioning: 2008
The boiler plant includes:
- bark handling line;
- dispose of all wood residuals and sludge from the waste water treatment facilities;
- improve cost-effective use of resources and energy efficiency in the industrial process; and
- reduce greenhouse gas emissions in the waste incineration process.
The project presents a unique combination of recycling technologies and equipment from the three companies: Wellons Incorporated (USA) for the boiler plant, MCE Stahl-und Maschinenbau GmbH & Co (Austria) for the sludge dewatering/handling area, and Saalasti Oy (Finland) for the wood rejects dewatering/handling area.
A distinguishing feature is that the wood-fired boiler does not need any additional fuel sources. The plant includes an advanced flue gas treatment system, with a total treatment effect of 98.5%.
The Mill's wood residuals and sludge from the waste water treatment facilities, which receives sewage water from the whole Balakhna community, are disposed of in the most ecologically and cost- effective way. The heat recovery boiler generates more than 50 tonnes steam per hour for the Mill's processes, enhances the energy efficiency and creates new jobs.
3. PM6 Rebuild
Year of Rebuild: 2011
- improve the quality of PM6 newsprint; and
- enhance PM6 performance.
The main features of the project are the replacement of the headbox and the reel and the installation of a new quality control system.
The PM6 rebuild project has resulted in less deviation in basis weight, caliper and moisture profiles in the paper sheet, increased paper machine productivity and better (tighter) winding of finished paper rolls.
PM6 newsprint has been successfully tested to comply with stringent demands for paper quality from the printing market.
4. Water-Filled Ash Conveyor
Year of Commissioning: 2014
- minimize dust hazards during ash removal, transportation and storage;
- cool down the temperature and reduce the amount of disposed ash; and
- improve the energy efficiency of the process.
A new ash conveyor collects both bottom ash (from cells) and fly ash (from ESP) to discharge it in one concrete platform instead of two cart-loading points previously employed.
Ash disposal has become easy and safe: The new water-filled conveyor quenches the ash, so it does not present a hazard during transportation or storage. In addition, wet ash volume is about 30-35% less.
Ash handling system is fully automated.
In addition, the energy consumption and efficiency after the retrofit were improved by eliminating three ash valves, power 0.75 kW each, and two augers, power 5.5 kW each, while the new conveyor drive consumes only 1.1 kW.
5. Energy complex (Nizhny Novgorod Regional Power Station)
Project implementation: 2014-2015.
- To provide a reliable, high-quality and affordable energy supply to JSC Volga and other consumers in the long-term by organizing the most efficient network infrastructure that corresponds to global standards;
- To increase the electricity-producing capacities required by JSC Volga;
- To increase energy-efficiency.
The acquisition of the A.V. Vinter Nizhny Novgorod Regional Power Station that has been a part of JSC Volga as its structural unit since 1st January, 2015 allowed the company to increase its energy-efficiency, to ensure an uninterrupted supply of heat and hot water to Balakhna and Balakhna enterprises.
Currently, the power plant provides the Mill’s electricity needs in full.
6. Investment project “The construction of a new prefabricated chemo-thermomechanical pulp plant with an increase in the newsprint volume production”.
Project implementation: 2019-2020
Project objective is to increase the production of the newsprint paper from 100% TMP, a new innovative product that possesses improved characteristics, as well as to create new employment opportunities.
In 2020 JSC Volga completed the works to implement the investment project “The construction of a new prefabricated chemo-thermomechanical pulp (CTMP) plant with an increase in the newsprint volume production”.
The new thermomechanical pulp production line with the productivity of 180 tons per day (63 000 tons per year) was designed to enable further performance improvements up to 400 tons per day (140 000 tons per year).
Included in the priority list by the Order of the Ministry of Industry and Trade of the Russian Federation, the project was implemented with the support of the Industrial Development Fund. The attraction of state support measures allowed JSC Volga to receive a concessional loan in the amount of 394 million rubles. These funds were used to purchase innovative equipment for the production of thermomechanical pulp. The amount of investment in the project was about 1.5 billion rubles.
The general equipment supplier was the company Andritz Group (Austria). Unique technology, as well as the level of automation of management and control systems of the new thermomechanical pulp production line meet the standards of the world's leading timber industry enterprises and have no equivalents in Russia.