Projects

The project is implemented in order to increase the process efficiency and improve product quality. The first phase of polyamide production was commissioned in 2003. The project implementation period is 2017–2019.

The project involves the treatment of storm water of the Northern Industrial Hub and a part of the Central District of Togliatti. The construction works are currently in progress. Investments amount 1.18 billion rubles.

The start-up is scheduled for 2020-2021. The project is a part of the national project "Clean Volga".

As part of the joint venture with Maire Tecnimont Group, the implementation of one of the most ambitious projects of the Company continues - the construction of a urea unit with a capacity of 1,500 tons / day. The project envisages the use of advanced technologies that ensure environmentally friendly and safe production, as well as the resource consumption  at the level of the best world analogues. The total investment is estimated at 11 billion rubles. Project completion is scheduled for 2021-2022.

The project is aimed to increase the production capacity of caprolactam and its downstream products. In 2018, the following works were carried out as part of the project: revamping with an increase in the capacity for crystalline ammonium sulfate to 650 ktpa, overhaul and conversion of the hydrogenation unit from phenol to benzene, bringing the hydrogenation capacity to the equivalent of 256 ktpa for caprolactam.

The project implementation period is 2017-2023.

Investments - 14 billion rubles. The project implementation period is 2017 - 2024

The first stage is the construction of a new granulation and evaporation unit (prilling tower) to replace the 2 existing ones.

Investments - 3 billion rubles. The first stage completion date is 2021.

The project will allow significantly reducing the emissions.

In line with the strategic task of increasing value-added product output, a high-level caprolactam processing program is successfully implemented. In 2003-2004, following implementation of the first stage of the project, the Company started production of polyamide-6, industrial yarns, and tyre cord fabric. In 2006-2010, three more polyamide lines were put into operation. The capacities for the industrial yarn spinning and twisting were increased. In 2014, a plant for the production of dipped thermoset cord fabric was commissioned.

The acquisition of KurskKhimVolokno LLC, the largest domestic manufacturer of chemical fibres, in late 2007 provided leading positions for KuibyshevAzot PJSC on the Russian textile and industrial yarns markets.

In line with a long-term strategic program to increase caprolactam processing, a share of the Balashovsky Textile complex was acquired in 2010. On the basis of this complex, Baltex LLC was established and production of polyamide and blended fabric was restored. In 2011, another acquisition was made: STFG Filamente GmbH, a German company that produces textile polyamide yarns for technical purposes. In 2013, the Company acquired formerly-rented facilities in the city of Shchekino for the production of industrial and textile yarns.

The total amount of capital investments amounted 20 billion rubles.

An energy-efficient cyclohexanone production plant

In August 2016, new energy-efficient cyclohexanone production was put into operation, based on the technology patented by DSM (one of the world leaders in the development and manufacture of high-tech materials and chemicals – Royal DSM N.V., the Netherlands). This is one of the main projects in the Company’s strategic programme.

As a result of this project, KuibyshevAzot PJSC increased its caprolactam production capacities from 190,000 to 210,000 tons, and over the longer term – up to 260,000 tons per year. Furthermore, the Company got the opportunity to increase its output of derivatives: polyamide-6, industrial and textile yarns, and tyre cord fabric. The production scale, energy consumption level, and environmental performance of this complex all comply with the highest international standards. After its full development, a significant reduction in the consumption of main raw materials, such as benzene, electric power, steam, and caustic soda, is expected. The Company allocated 10.6 billion rubles for the project’s implementation, including reconstruction of the rectification unit.

The 5th PA-6 production plant

In 2018 construction of the 5th polyamide-6 production plant was completed, the first batch of finished product was produced, and the equipment is fine-tuned and adjusted for operation. The line capacity is 160 tons/day, or 58.4 thousand tons per year. The new equipment produces polymer materials for films, yarns, fibers, and also engineering plastics. Investments into the project amounted to 2.2 billion rubles (with VAT). After the start-up, the total Company’s polyamide-6 production capacity increased to 212 thousand tons per year.

 The Company continued construction of the ammonium sulphate-nitrate plant (nitro-sulphate) with a capacity of 1,100 tons per day (385,000 tons per year). This fertilizer, having an ideal ratio of nitrogen and sulfur, is able to efficiently replace consumption of ammonium nitrate. The product is characterized by its improved physicochemical properties, enhanced granulate strength, 100% friability, good shelf-life (without dust or caking), and it fully meets the requirements of modern agricultural technologies, ensuring an exceedingly high level of application uniformity. Planned investments above 4 billion rubles. 

In November 2016 a joint venture was started with Praxair Inc. for the production of oxygen, nitrogen, and compressed air for consumption by KuibyshevAzot PJSC and other independent factories in Togliatti, as well as liquid oxygen, nitrogen, and argon for sale to other customers. With a 70% increase in plant capacity it is planned to cut energy consumption by 10%. Total investment amounted to 4 billion rubles.

Construction of a new of non-concentrated nitric acid plant with an increase in the production of nitric acid by the enterprise from 1,350 to 2,050 tons per day with an investment of 2.0 billion rubles. Start-up took place in 2017, the production has reached the design capacity. An increase in the production of nitric acid is necessary to ensure the production of nitrogen fertilizers.

The project has been executed as part of a joint venture with one of the world's largest companies in the field of industrial gas production and engineering – Linde Group (Germany). The shares of participating companies in the authorized capital of JV Linde Azot Togliatti LLC are 50% on each side. The company has been operating since 2017. The official launch took place in July 2018.

The production capacity is 480 ktpa (1340 tons/day) of ammonia and 8,000 m3/h of hydrogen. This project takes advantage of a high-tech technology for the direct ammonia synthesis, which provides environmentally friendly and safe production, with the level of resource consumption below the industry average. The plant is one-of-a-kind in Russia. The investments amounted to 20 billion rubles.

The granulated ammonium sulphate plant with a capacity of 140 kt p.a. Grinifest, LLC reached its design capacity as a JV. KuibyshevAzot began production of granulated ammonium sulphate in 2012 and was the first Russian company to offer this fertilizer to the market in a form that fully complies with the requirements of modern agricultural technologies. The main advantages of the product are both its improved physical and mechanical properties (high strength of granulate and its friability) as well as its agrochemical properties (uniformity of application, possibility of using as a component in fertilizer mixtures).

Investments - 1.5 billion rubles. The project is executed to increase the output of nitric acid for fertilizer production and to allow the shutting down of the existing equipment for modernization in order to reduce environmental impact. The project implementation period is 2017-2020.

In 2018, the project “Construction of a production facility for grade K sulfuric acid and improved oleum with a total capacity of 500 thousand tons per year” entered its active investment phase. The project of sulfuric acid and improved oleum plant is aimed at raw materials supply, existing capacities build-up, improvement of competitiveness and export potential of the only process chain in Russia from caprolactam and polyamide to threads and fabrics created by KuibyshevAzot PJSC. The project uses advanced resource-saving technologies that provide a high level of industrial and environmental safety. At the St. Petersburg International Economic Forum (SPIEF-2018), KuibyshevAzot PJSC and the VEB.RF State Development Corporation signed a Memorandum of Intent on the implementation of this project using the Project Financing Facility. The volume of investments will amount to 8.6 billion rubles, the total amount of financing from VEB.RF - 3.8 billion rubles. The commissioning is planned in 2020.