29 April 2025

The Kastamonu Plant, located in the special economic zone of Alabuga (Republic of Tatarstan), is Europe's largest enterprise for the production of laminate flooring and wood panels MDF / HDF.

Since April 2015, own electric power for production needs is produced by a gas turbine unit (GTU), created on the basis of the GE turbine of LM2500+G4 DLE type. The installed capacity of GTU is 25 MW (rated capacity is 30 MW).



The factory GTU-TPP also includes a waste heat boiler, the heat capacity of which is used to provide process procedures. At the site of power supply complex, there is operates boiler house for output additional amounts of heat.

The fuel for turbine GE and boiler house for own needs is natural gas. Its treatment is provided by special gas feeding module supplied and commissioned by ENERGAS Group.

The main element of this module is ENERGAS block-type gas treatment unit of GS-FME-1200/12 brand. BGTU performs flow measurement and filtration of gas; it is equipped with a commercial gas-metering subassembly and a highly efficient separation system. The degree of gas purification from mechanical impurities and droplet moisture (over 10 μm in size) is 99.98%.



BGTU is a sound- and heat-insulated block-box with maximum integration of equipment on a single frame; operates in automatic mode; equipped with life support systems (heating, ventilation, and lighting) and safety systems (fire detection, gas detection, alarm, and firefighting).

The BGTU's capacity is 15,000 m3 / h. After preliminary treatment, the gas is divided into two streams. The first flow is sent into the ENERGAS reducing unit (RU) of GS-P-250/12 brand. This equipment is placed in its own shelter and designed to reduce the gas pressure from 1.2 MPa to 0.4 MPa before it is fed to the factory boiler house. The RU's throughput is 3,000 m3 / h.

The second flow enters to the compressor unit (CU) of fuel gas. The Enerproject CU, made based on screw oil-filled compressor, compresses the gas to 3.8 MPa and feeds it to the power plant turbine. The unit is housed in a separate all-weather enclosure; it is equipped with a two-level capacity control system and an automated control system with data transfer function to the top level of APCS. The gas flow rate of CU is 12,000 m3 / h.



In 2017, due to the growing energy needs of the enterprise, the thermal power plant was expanded. The GTU No. 2 – Kawasaki cogeneration gas turbine unit of GPB 180D type with an electric capacity of 17 MW and a thermal capacity of 27 MW was put into operation. GTU-1 and GTU-2 were synchronized with each other, as well as with the power grid. Autonomous power supply complex also comprises power generating units that use wood waste from the main production.

Like at GTU No. 1, compression and direct supply of fuel gas to the Kawasaki turbine are provided by a compressor unit manufactured by the Swiss company Enerproject SA, which implements projects in Russia together with its partner, the Russian company ENERGAS. The inlet pressure is 0.9...1 MPa, the delivery pressure is 2.5...3 MPa. The capacity of CU is 9,000 m3 / h.

REFERENCE:

SEZ Alabuga is Russia's largest special economic zone of industrial type. It was opened on December 21, 2005 on the territory of Tatarstan (Elabuga district), 210 km from Kazan. In global ratings for 2015, 2016 and 2017, Alabuga was named the best in Europe special economic zone for large businesses.

Kastamonu Entegre (part of HAYAT Holding) is a leader in the forest products sector in Turkey and one of the top 5 largest companies in the woodworking industry in Europe. The plant in the SEZ Alabuga is one of the most large-scale projects of the Kastamonu.

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