The main targets for the Syktyvkar mill were to replace obsolete technologies, enhance mill safety, employ additional environmental measures and increase the quality and competitiveness of Mondi's products.
Metso's automation delivery included new control systems for both the hardwood and softwood digesters, and the new white liquor production area for causticizing and the lime kiln. Systems for both fiber lines and the existing causticizing plant previously delivered by Metso were also upgraded and expanded, as were the control systems for PM14 and PM21.
Metso's delivery scope in valves included more than 1400 control and automated on/off valves and almost 5500 manual valves. Their role is critical in ensuring good controllability and thus contributing to savings in water and chemicals usage. Part of the delivery included Metso's device and asset management solution DNAFieldAssessor, which allows continuous monitoring of valve performance with remote access to valve diagnostics and configuration. The mill had already been a user of Metso FieldCare, a standalone version to monitor the valves.
The installation and start-up of the various systems and upgrades by Metso were completed in various phases during the two-year project. In addition to the metsoDNA control systems, the delivery included project management and engineering services, both factory and site testing, installation supervision and start-up assistance. The metsoDNA systems represent the latest in control technology with Profibus DP motor controls and DNAfieldAssessor field device management for intelligent field device configuration. Integrated HIMA safety related systems were also included for the three digesters as well as the oxygen and bleaching stages in the hardwood line.
Mondi Syktyvkar is one of the largest producers in the Russian pulp and paper industry with one board machine and three paper machines. The mill also comprises a wood yard, two fiber lines, a power plant and a complete complex of effluent treatment facilities. The STEP project, started in 2008, involved new wood-handling facilities, a recovery boiler, turbine and white liquor process, as well as upgrades to the two chemical pulp lines and rebuilds of the PM14 uncoated wood-free paper machine and the PM21 container board machine.