Construction of chemical complex “Ammonia-carbamide-melamine”. Phase I

In February 2018, RTL Company in cooperation with its Italian partner won a tender for delivery of equipment for the largest investment project of JSC “METAFRAX”. According to this project, the chemical complex “ Ammonia-carbamide-melamine” (AKM) in Gubakha, Perm region should be built and put into operation by 2021. The estimated cost of the complex construction – 950 million euros.

In March 2018, at the site of the AKM complex, the first cube was laid in the foundation of the highest structure of the future production - the urea prilling tower. Construction has been officially launched.

At the same time, RTL specialists started a preparation for transportation of large and heavy cargo for construction. In June 2-18, the delivery of the first, most complicated, batch of equipment began. This batch included delivery of the ammonia reactor, decompressor, high-pressure separator, the separator lean gas and valving modules. In total, the first batch of 13 items, with the weight of 488 tons and a volume 0f 2,066 m3. After delivery of the cargo from Italian vendors to the port of Chioggia and port of Marghera, Italy, cargo was loaded on a river-sea vessel. The delivery was arranged among the Adriatic, Aegean, Marmara, Black and Azov seas to the port of Rostov-on-Don. After completing the required procedures for the further transportation of cargo through the internal waters of the Russian Federation, customs transit was opened.

The cargo loaded on vessel passed through the Volga-Don canal system and the Kama River to the mooring complex “Transkama” in Nizhnekamsk, where it was unloaded to the berth for further shipment. Cargo handling operations were performed by a special gantry crane with lifting capacity of 320 tons. The whole process of unloading took about 6 hours. According to the preliminary logistics scheme developed by RTL Company, transportation of cargo from Nizhnekamsk was to be performed by the tug and tow to the temporary berth on the Chusovaya River and then delivered by road transport to the site of the consignee. However, it was required to adjust the scheme of delivery. During the planned process of repair of bridges on the route, the displacement of span beams was revealed, which made the transportation of cargo with the weight of 230 tons through these bridges impossible. The employees of RTL Company made an immediate decision to change a logistic scheme of delivery.

According to the new developed plan, the transportation of ammonia reactor from the city of Nizhnekamsk to the site of the consignee was performed by 16-axle rail transporter of an articulated type with capacity of 240t. The scheme of loading and lashing of cargo on rail transport was developed and agreed with the Central division of special transportation RZD and with the special Department of Kuibyshev railway. Another important challenge that had to be solved immediately was the lack of export status of departure station, which did not allow to release cargo following under the customs transit. As a result of intensive documentary work with the Ministry of transport, the Russian Railways control department, the Russian Railways corporate service department, as well as a number of other institutions; the departure station was included in the export list and there was assigned an export code. After the arrival of the rail platforms at the destination station, the cargo was transshipped to specialized road transports. For transshipment was used a hydraulic gantry system with a capacity of 500 t. The distance of the final transportation of the ammonia reactor from the Ugleuralskaya station to the site of the complex of AKM took 15 km, including 6 km among the narrow streets of Ugleuralsk. Previously for the successful transportation were extended a few road curves. Additionally engineers of RTL Company developed scheme of multi-axis transportation with the minimum radius of curves. All road transportation took 8 hours, after this, the cargo was successfully unloaded at the site of AKM.

Same time with the delivery of the ammonia reactor from the city of Nizhnekamsk on the barge-towing arrangement, the other oversized cargo was delivered to temporary jetty on the river Chusovaya. Due to the 2018 World Cup, a significant discharge of water was made at the Kama river, its level rose in the Kama river and this did not allow the tug and tow to pass under the railway bridge near the Palniki, Perm Krai. To solve this problem, there was urgently decided to replace the tug with a similar driving characteristics one, but with a lower deck structure. After arriving at the temporary berth, the cargo was unloaded from the barge by RO-RO method. Unloading was performed in a prepared customs control zone.

At the final stage of delivery from the temporary berth to the site of consignee, the road transport with cargo overcame 130 km of mountain roads with challenging terrain, steep climbs, long down-grade and serpentines.