Mondi Syktyvkar operates new lime kiln number four

Mondi Syktyvkar (Russian Republic of Komi) has started up its new number four lime kiln which is a part of Mondi’s Syktyvkar Step mill development project. This completion and start up took place beginning of December 2009.

Mondi Syktyvkar started reconstruction of the white liquor plant in spring 2008, before the Step project construction work was initiated. Erection of the lime kiln with a daily production capacity over 700 tonnes of lime (CaO) started in autumn 2008.

The scope of the executed work was extensive: a 105-meter long kiln was delivered to the Mondi site in 12 shell rings, each of them weighing approximately 60 tonnes. It was then erected into a single structure which was aligned, welded and installed on the foundation supports. Finally it was lined up inside with refractory bricks. Buildings for the feed-end and the discharge-end, as well as a building for white liquor filtrate were constructed around the kiln. This was followed by the process- and electrical-equipment and the installation of the cyclone. All the equipment was piped, wired and provided with communication systems. In spite of the world economic downturn in 2009 and the complexity of the project, construction work was completed on time.

Quick lime is required for the production of strong white liquor used for pulp cooking at Mondi Syktyvkar. In the near future the kiln will run at a lower capacity and will operate at its design output after the start-up of the other elements of the Step project during 2010. The new white liquor plant will start operating fully in spring, when the thick liquor filter is put into operation.

Currently the Step project, valued at EUR 525 million, is 67 % completed. Its completion is scheduled for the second half of this year and entails the reconstruction of all the main production process capacity, replacement of outdated equipment, introduction of new high-technology facilities and improvement of the mill’s environmental performance.

The main goals of the Step project are cost reduction through an increase in production process efficiency. Increased energy output will partially be sold to the electrical grid. Total paper and board production will amount to nearly 1 million t – a 20 % increase. In addition improvements to the mill’s safety performance are also expected.

Step project:

• Investment programme of EUR 525 million
• Construction of a new wood yard capable of handling 4 million m³ of wood per year
• Rebuild of softwood and hardwood pulp production lines
• Rebuild of White Liquor plant, construction of a new lime kiln with the capacity of 700 t of CaO per day
• Construction of a new soda recovery boiler with the capacity of 3,560 t of dry substances per day
• Installation of a new turbo-generator with the capacity of 100 MW
• Commissioning of a new evaporation plant with the capacity of 550 t of water/hour and two new cooling towers
• Rebuild of PM-14 (office paper production) and BM-21 (board production)