Technological production

POLYAMIDE-6 PRODUCTION — PA-6 chips      — industrial yarns — tire cord fabrics

NITROGEN FERTILIZERS PRODUCTION — urea — ammonium nitrate — UAN

CAPROLACTAM PRODUCTION — caprolactam — cyclohexane — cyclohexanone — hydroxylamine sulphate — ammonium sulphate

TECHOLOGICAL GASES PRODUCTION — argon — nitrogen — oxygen — hydrogen

AMMONIA PRODUCTION — ammonia liquid — ammonia aqueous

In 2007 within the complex program of the enterprise development a number of major projects was implemented. They were aimed at capacity expansion, lower consumption figures, improvement of the ecological and industrial safety. As a result of the technical re-equipment and renewal of the fixed assets the production nearly of all products went up. The historical record high was noted for caprolactam output at 167,000 t, 13,6% up on 2006. Such figures are attributable to higher efficiency of the utilization of the existing facilities and technical measures taken. Commissioning of HAS storage facilities at the hydroxylamine sulphate unit and two standby cooling towers supplying circulating water to the cyclohexanone unit ensured the stable operation of the caprolactam plant with higher loads. The modernization of cyclohexanone unit B resulted in lower consumption of benzene, the main feedstock.

The higher value-added product output has grown by 2,2 times for polyamide 6 to 72,200 t; by 18,7% to 4,900 t for technical yarns; by 47,1% to 3,700 t (7,2 m. L.M.) for cord fabric. The growth of caprolactam processed volumes has brought to its captive use up to 41% of its output.

The major project realized in 2007 was start-up of the 3rd 23,000 t/a line of the polyamide 6 plant. Uhde Inventa-Fischer, Germany supplied the technology and the equipment. The new line produces high viscosity polyamide 6 (relative viscosity 3.4 to 4.0). It is used to manufacture high tenacity technical yarns, food and pharmaceutical grade films.

The fourth spinning line was put into operation at the technical yarn and cord fabric plant. Rieter, Switzerland procured the equipment.

Last year the decision on construction of the 4th line of polyamide 6 plant was taken. It will produce polymer for textile yarns and fibers. Thus, in 2009 after start-up of this polymerization plant KuibyshevAzot would be able to offer its consumers the entire mix of PA6 and the total design capacity of the company will be 150,000 t of PA6 per year.

Compared to 2006 the ammonia output increased by 12,7% to 570,000 tons. With installation of the new equipment at the ammonia plant its daily capacity rose up to 1,740 tons. Now this capacity is one of the highest in Russia among this type of plants. However, planned figures were not achieved due to unscheduled maintenance shutdowns.

In the reporting year the output of nitrogen fertilizers amounted to 417,000 tons in terms of 100% N, 13% up from the previous year. It includes 301,000 tons of urea (record quantity) by physical weight (+17,6% from 2006), 495,600 tons of ammonium nitrate (+10,7 %), 430,100 tons of ammonium sulphate (+11%). At the caprolactam plant the postevaporation of ammonium sulphate solution was installed. As a result the ammonium sulphate output rose up to 1,500 tons/day.

The most part of construction and erection works was carried out in the new air separation unit of the feed gas preparation plant. When this equipment is put into operation this plant will meet the growing requirements of the main production facilities in process gases (oxygen, hydrogen and nitrogen ).

We are completing capacity expansion of the water-treatment stages as well as expansion of the existing unit for mechanical treatment of clarified water and erection of the equipment of demi water preparation using the advanced technology. Implementation of this innovation will result in decrease of water wastes and establish a reserve for introduction of new production facilities.

A new plant for food grade carbon dioxide production was started up at the site of KuibyshevAzot as a JV. It uses waste gases of the ammonia plant and as a result greenhouse gas emissions fell by 2,098,5 t.

Auxiliary and service departaments

Mechanical-repair shops

Civil construction and repair

Quality control

Transport

Utilities

The specialists of auxiliary and service departaments are in charge of maintenance and repair of different machines and installations, utilities units, instruments and buildings.