The new saw line was put into operation in June 2004 as the final step of the first stage of sawing production modernization.
Unique for Russia, the sawmill complex united the latest technologies of the best global timber processing equipment manufacturers.
The logs are sorted at the log sorting line by AS «Hekotek» (Estonia) with 42 bins.
Profiling line by «Linck Holzverarbeitungstechnik GmbH» (Germany) is the basis of the complex.
Equipment by «AS Hekotek» (Estonia), «Valon Kone Oy» (Finland), «Lekopa Oy» (Finland), «Vollmer» (Germany) is applied as well.
The plant’s building is made of the constructions by «Alajarven Steely Oy» (Finland) and wall panels by JSC «Petropanel» (Russia).
The saw line consists of:
- •Log sorting line with 42 bins
- Green sorting line by AS «Hekotek» (Estonia) with 15 vertical bins
- Fire extinguishing pump station with tanks
- Fire-fighting water supply, heat supply and storm drainage utility networks
- Electrical substation
The designed capacity of the new saw line is over 500 000 m3 of logs per year.
The building of kiln drying and processing sites became the next stage in the sawmilling technical upgrade programme. This project stipulated a complex change of outdated technologies and kiln equipment, enabling automating of the operations, reducing production costs and increasing the quality of the produced timber.
There are two types of drying capacit in the battery of kilns:
- 10 compartment kilns (for midsection and heavy section timber drying)
- 5 tunnels (for midsection and sideboard section timber drying).
WSAB OY (Finland) producing safe and high quality timber drying equipment (kilns and automatic drying control systems), was chosen as a drying equipment supplier.
The drying and sorting equipment complex includes:
- battery of kilns by WSAB OY (Finland);
- dry sorting line;
- area for a buffer stock of;
- sheds for ready packs storage.
Thus, the new efficient drying systems with law energy consumption for timber drying were introduced in the production process.
The kilns are located in close proximity to the saw line, which enables to reduce transportation costs and heat networks length, and hence energy losses amount.
Excellent production quality gives the factory an additional competitive advantage and enables strengthening the Western European market position.
The building of a new central heat and power plant (CHPP) at the Sawmill 25 Maimaksa unit was subject to the necessity of:
- utilization of sawmilling wood waste;
- own production of electricity and heat;
- Harmful emissions reduction into the atmosphere caused by heavy fuel and coal burning.
The CHPP boiler systems were launched on January 2008 and the turbine generator was set on February 2008. The heat energy transmitted through turbine generator, covers the requirements of drying capacities and the heat supply systems in the plant’s departments.
Damp bark supplied directly from the saw line is the main fuel for CHPP.
The new air cooler, delivered by “POLYTECHNIK” (Austria) was launched in December 2008 to provide the maximum electricity output (2300 kW) irrespectively of the production heat consumption. The CHPP main components include:
- damp bark burner with hydraulic grate;
- air-delivery system, effluent gases removing and recycling system;
- steam boilers with economizers, air-heaters;
- water preparation and consumer heat supply system equipment;
- automation system providing functioning of all the CHPP processes: fuel supply, combustion modes, evaporation capacity regulation, ash removal system, safety system etc.;
- steam turbine generator with automation and safety systems;
- 6 kW main switch device with own transformer substation;
- air cooler with auxiliary equipment.
The introduction of the project allowed:
- to include bark in the company’s fuel balance, to stop its dumping;
- to improve the drying technological process quality;
- to reduce heat energy costs;
- to minimize electric power purchase costs;
- to eliminate coal boiler in the company’s transport department;
- to substitute purchased electric energy generated by burning heavy fuel with electric energy generated by burning ecologically neutral fuel – wood waste.
Fuel pellets are widely used nowadays as an environmentally friendly biofuel, generated by wood waste processing. Pressed pellets with calorific value comparable with coal and are valuable as fuel for industrial or residential boilers. Moreover, 100% environmentally friendly fuel wood pellets have more advantages than traditional fuel.
The following advantages can be pointed out:
Pellets have two-three times higher calorific value compared to ordinary wood, bark or chips. The thing is that pellets have lower moisture content which is just 7-10%, while ordinary wood has 30 to 50% humidity. Besides, pellets’ density is 1.5 times higher.
The pellets calorific value is similar to coal. However, fuel pellets emit 20-40 times less carbon dioxide and produce 20 times less ash than coal, while heat generation remains equal.
Unlike hydrocarbon fuel (diesel, heavy fuel, gas) that inflames easily, has unpleasant smell and pollutes everything around if used improperly, this biofuel being dense and dust- and spore-free, is less subjected to self-inflammation thus making the object equipped with pellet heating safe. Besides that, pellets burn without odour, do not spark, give almost no smoke, soot or other harmful substances.
Rationality of waste use, comparatively low prices for fuel pellets applied for heating, storage convenience, entire safety for allergic people, high calorific value, biological cleanliness and other things – everything speaks in favour of this kind of biofuel as the most efficient, qualitative and economic.
The building of wood pellet plant was necessary for sawdust processing as the CHPP running on bark waste was put into operation in 2007.
This allowed stopping using sawdust for heat production and use them for the wood pellets production.
A trial run of the pellet plant was made in 2008, the plant was put into operation in April 2009. The plant’s equipment was delivered by “Hekotek” (Estonia). Project capacity is 75 000 tons of wood pellets per year.
Automatic system covers all options and status of the main and auxiliary equipment, provides main technological processes’ automatic management. The production works in the non-stop mode.
The launch of a new pellet plant in Tsiglomen will enable to produce totally 120 000 tons of pellets per year.
The quality of the produced pellets corresponds to the international standards, enabling to export production to the European countries.
SOME PELLETS ANALYSES DATA
|Value||unit of measurement||Data|
|Calorific value||Kkal/kg||4536 – 4860|
The introduction of the project allowed:
- to process all the wood waste delivered from the sawmilling,
- to get high quality environmentally friendly fuel from the production waste,
- to improve the environmental situation in the Maimaksa district,
- to organize entirely waste-free production alongside with CHPP launch.
The pellet plant functioning enabled to install some new boiler houses, operating on wood pellets in the region. Boiler houses are installed in the Laisky dock, Katunino village, Brevinnik island, Bobrovo, Lugovoi and Malye Karely.