27 October 2021

HAYAT Russia, a subdivision of Hayat Kimya Sanayi A.S., Turkey, is increasing its production capacities – a large plant for the production of sanitary and hygienic paper products is being built at the Borovsk site of the Kaluga special economic zone. The volume of investments exceeds 16 billion rubles. The owner is Hayat Consumer Goods LLC.

Construction is carried out in 2 stages; each is designed to produce 70 thousand tons of products per year. Like the Hayat Kimya enterprise operating in the SEZ Alabuga (Tatarstan), the new plant in the Kaluga Region is designed as an innovative production complex, based on fully automated advanced resource-saving systems. The high-tech project will strengthen the position of HAYAT Russia as the country's largest manufacturer of toilet paper, paper towels and napkins, with a total volume of 280 thousand tons.

Here, an autonomous (decentralized) power supply complex is also being created to supply production with its own energy resources. Electricity will be generated by a Mars 100 gas turbine unit (Solar Turbines) with a nominal capacity of 11.35 MW.

SOLAR Mars 100 is a high efficiency, simple cycle gas turbine unit designed primarily for long-term operation in industrial systems. The first GTU was built in 1989. Mars 100 turbines are characterized by high reliability, durability, ease of maintenance due to their design, as well as low emissions due to the low-emission SoLoNOx combustion chamber.

The process steam production will be provided by the waste heat boiler, which uses the heat from exhausted hot gases (products of fuel combustion in the turbine). Therefore, the cogeneration cycle significantly improves the overall fuel effectiveness.

In addition to the cogeneration power unit, the structure of the power supply complex includes an auxiliary boiler house, which will also run on natural gas. The system of conversion of gas into electricity and heat resources required to produce paper products, being introduced at the new HAYAT plant, will provide an efficiency of 80%.

One of the most important factors contributing to the reliable and efficient operation of generating equipment is the quality of fuel gas. The supply of the turbine and boiler house with fuel with the pre-set design parameters in terms of purity, temperature, pressure and flow rate is guaranteed by the ENERGAS multifunctional system – a block-type gas treatment station (BGTS) and a booster compressor station (BCS).

The BGTS with a throughput of 9,317 m3 / h is intended for metering, filtration and pressure reduction of gas. Station is equipped with coalescing filters, the purification efficiency is 99.9% for solid particles larger than 3 microns and 100% for droplet moisture.

The purified gas is divided into two flows. The first one is directly headed to the BCS and then to the GTU turbine, the second one passes through a reduction system, which reduces the gas pressure and stabilizes it at the level required for feeding to the boilers (0.3 MPa).

At BGTS there is measured total volume of gas supplied to the power supply complex (commercial metering) and separately measured volume of fuel for the boiler house (process metering). Data are transmitted via communication channels to the upper level of the APCS. Metering units with a relative error of no more than 1.5% made based on flow meters of ultrasonic type.

The gas treatment station is additionally equipped with fuel quality control assemblies located on the outlet pipelines and equipped with various measuring and analytical equipment. The BGTS is placed in a separate all-weather block-box with the integration of elements on a single frame, equipped with systems of working and emergency lighting, heating and ventilation, safety systems.



The screw-type booster compressor station, which is part of the ENERGAS system, is intended to compress the fuel treated in the BGTS and feed it to the turbine at a pressure of 2.6 MPa. The maximum volume capacity of BCS is 6,336 m3 / h, gas flow rate depends on the load of the GTU and is controlled in the range from 0 to 100% by a special two-circuit regulation system.

The process flow scheme of the BCS guarantees stable maintenance of the design fuel temperature necessary for the normal operation of turbine. The delivery line of the station is equipped with a shell-and-tube heat exchanger that cools the working medium and ensures the optimum gas supply temperature (up to +70°C) set by the GTU manufacturer and terms of the project.

Taking into account the stringent requirements for the purity of fuel gas, the basic filtration system of the BCS, consisting of gas-oil separator and coalescing filter of the 1st and 2nd stages of purification, is enhanced due additional elements: 1) a protective strainer is installed on the suction line of the compressor station; 2) a safety filter for fine purification of gas is built into BCS module. Eventually, the content of impurities in the fuel at the inlet to the GTU shut-off valve block does not exceed 0.1 ppmw (mg / kg).

Gas-booster unit is housed in its own shelter equipped with life support systems. According to safety requirements, BCS is equipped with fire detection, gas detection, alarm, and fire-extinguishing systems.



Gas treatment station and compressor station are fully automated. Their control systems are made based on microprocessor technology, using modern software, switching equipment and communication channels and protocols. The local ACSs will be integrated into facility's APCS and will provide remote control of units, automatic protections and alarm, monitoring of process parameters and indoor gas hazard, handling parameters of the workflows and emergency events, information output to the operator panel.

BGTS and BCS are delivered in maximum factory readiness (98%) what reduces the duration of the pre-start stage. The equipment is characterized by the high maintenance ability and long service life. The technical use ratio is 0.92+, the confirmed rating of operational reliability exceeds 97%.

Commissioning of the gas treatment and fuel supply system (erection supervision, starting-up and adjustment, own and integrated tests) as well as training of operational personnel will be carried out by the specialists of ServicENERGAS (ENERGAS Group).



REFERENCE:

One of the key competencies of the ENERGAS Group is the production, comprehensive commissioning and maintenance of gas treatment and compression units for generating facilities in the electric power industry, oil and gas complex and industrial enterprises. Today, the ENERGAS process equipment provides high-quality fuel for more than 200 gas turbines and gas-reciprocating units with a total capacity of over 6.6 GW.

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