On the benefits of multidisciplinary development and current trends of the polyester products market tells the deputy CEO produced by Pyotr Solovyov.
Petr Alexandrovich, today the Mogilev complex for the production of polyester fibers and threads remains the largest in Europe? Or is it already better known as a producer of, for example, biodiesel, the output of which is growing almost every year?
JSC "Mogilevkhimvolokno" was and remains the largest producer of polyester fibers and threads both in the republic and in Europe. The enterprise has not deviated from the standard assortments, today it produces more than 6,000 tons of fiber and about 1,500 tons of industrial yarns monthly.
Some of the original fiber-thread assortments, due to various economic circumstances, the enterprise really refused. For example, the production of textile threads has been discontinued since 2006. This is a forced measure dictated by the situation in the domestic market for textile products. The fact is that the production of synthetic complex yarns, which specialized in the production of textile yarns, was a competitor to RUE Svetlogorsk PO Khimvolokno, one of the enterprises of the concern. The decision to close the division was made in favor of this enterprise for economic reasons - Svetlogorsk Production Association Today it is equipped with more modern, with a one-stage production process, equipment.
New projects - a school of trial and error. Over the past 5 years, Mogilevkhimvolokno OJSC has put into operation about 10 new units. Is the production service of the enterprise satisfied with the results, how is the five-year development program being implemented?
The success of each new project, in my opinion, largely depends on the quality of the development of the terms of reference. Our own experience of commissioning new installations speaks just about this.
Most of the installations commissioned at the site of the enterprise are successfully operating and have already reached their design capacity. Their products have found their customers. This applies to the production line for roofing materials, food grade polymer, preform, fatty acid methyl ester and biodiesel plants. JSC "Mogilevkhimvolokno" today remains the only one in the city industrial enterprise producing its own electricity.
Were on initial stage work problems with the installation of continuous polycondensation with a capacity of 80 thousand tons per year. Currently, they have been eliminated - the plant is operating at full capacity.
There are questions about the operation of the line for the production of composite materials in terms of obtaining a stable profit. Practice shows that one installation with a small capacity cannot respond mobilely to demand, moreover, we produce composite materials- this is a semi-finished product, and for maximum profit, injection molding machines are needed, which make it possible to independently produce and sell the final product. Despite the existing difficulties, today the line operates mainly fulfilling the orders of our own enterprise.
It does not have a 100% load and installation for the production of strapping tape. Its production from high quality polymer increases its cost; the production of strapping tape from recycled materials does not allow full loading due to its unstable quality. We hope to solve this problem in the near future: firstly, the Mogilev processor plastic bottles promises to improve the quality of flakes, and secondly, after the installation of a modern crushing machine at the ZSV (synthetic fiber plant), which is envisaged as part of the polymer waste processing project, we will be able to produce tape from used tape.
At present, a new type of product for the enterprise - fire hoses - is undergoing the process of market development. It is not going very intensively yet, but with a progressive growth trend: for the second month the portfolio of orders for this type of product has been filled.
In general, out of 8 facilities of our enterprise, which are under the control of the Belneftekhim concern, 6 are loaded by more than 80% - this is a normal practice.
What is most in demand on the sales market today, and what type of manufactured products does the company's management rely on when planning the near future?
Today, a food-grade polymer comes almost off the wheels, which makes us especially happy. There are minimum stocks of fiber in stock. At the same time, there is an increase in the number of orders for special fibers. In recent months, the situation with the sale of technical thread has changed dramatically - the polyester yarn plant is now operating at full capacity. production capacity. With the production of 500 tons per month of roofing materials, there is practically no shipment to the warehouse. Both geotextiles and roofing materials are in high demand.
This situation of demand dictates the prospect of development. An analysis of the food polymer market suggests that today its consumption exceeds supply. That is why a decision was made to build a new plant for the production of food-grade polymer on the territory of OAO Mogilevkhimvolokno.
The issue of expanding the production of roofing materials, but already reinforced, is being seriously studied. Preparatory stage this project is already underway.
Due to the increased demand for technical thread, the Company's Technical Development Program plans to modernize ZPN (polyester yarn plant), aimed at a gradual increase in capacity. The possibility of returning to the previous volumes of this type of product - up to 2,000 tons per month is being discussed.
We have huge plans to expand the range of special fibers and nonwovens. Already at the beginning of this year, two related projects for the production of polymer and fiber with reduced flammability were implemented. By the end of the year, we plan to launch an installation for the production of needle-punched nonwovens with the prospect of producing thermally bonded fabrics. The nearest plans include mastering the cutting of short fiber, which will be used in the production of paper.
The production of a bioadditive to diesel fuel brings a stable profit to the enterprise. According to state program for the production of methyl esters of fatty acids and the decision of the concern "Belneftekhim" next year OJSC "Mogilevkhimvolokno" should produce 50,000 tons of FAME. Based on the increase in the production of methyl esters of fatty acids, JSC "Mogilevkhimvolokno" is faced with the task of increasing the production of biodiesel.
Traditional for our company is the production of DMT (dimethyl terephthalate). Despite the fact that in recent years TPA (terephthalic acid) has been actively replacing DMT, we retain this market segment, remaining one of the three world producers of it over the past 5 years, the volume of DMT production, having dropped to 200,000 tons per year, remains stable . In order to keep these positions, it is necessary to reduce the cost of manufactured dimethyl terephthalate as much as possible. This can be achieved through the modernization of the DMT-4 shop, which provides for an increase in capacity to 150,000 tons per year and a reduction in energy consumption.
We plan to keep the DMT-3 workshop. So far, two options for its further loading are being worked out: production of DMT under a tolling scheme or reorientation to the production of, for example, isophthalic acid. The Institute of Oil and Chemistry of the Belneftekhim concern also offers its own options for converting the DMT-3 workshop into the production of products related to the processing of petrochemical products.
Within the framework of the program of advanced processing of the polymer, which we obtain on the basis of the TPA monomer, the production of preforms has been mastered at the enterprise. Currently, two injection molding machines are operating on the premises of OAO Mogilevkhimvolokno, producing preforms for bottles with a capacity of 2.1.5 and 1 liter. Of the 6.5 thousand tons of food polymer produced per month, we process only about 400 tons into preforms. The task is to increase the volume of processing. To do this, it is necessary to purchase another injection molding machine and replace the old one, which produces preforms for two-liter containers, with a modern model. We plan to implement this project next year.
The polyester market has never been stable. In the last few years, he simply surprises with dramatic changes. In addition, the demand for products in the face of fierce competition directly depends on its quality and cost. The launch of a power plant on the territory of the enterprise is one of the ways to reduce the cost of manufactured products. But the cost of electricity is not the only cost component. Practice shows that a systematic approach to reducing internal costs, provided for by a specially developed program, can solve the problem. Is there such a thing in Mogilevkhimvolokno OJSC?
Every year, each division of the organization develops measures to reduce costs per unit of output. Heads of subdivisions on the balance commission report on their implementation.
Currently, we are working on reducing the amount of regenerated ethylene glycol, the production process of which is characterized by increased energy consumption. The task is to direct all flows of ethylene glycol to the shop for the regeneration of volatile and organic solvents of the AIA (organic synthesis plant), and to re-profil the similar shop of the WWTP. This event will significantly reduce energy consumption.
We are also actively working to reduce the consumption of process air, for example, at the ZOS. We continue to work on reducing the specific norms of raw materials. Today, however, the reserve is almost exhausted, which gives results without capital investments. Now we are moving to a new level of action in this area of activity - through modernization.
Issues are being worked out on organizing the production of fiber from bottled PET flakes (flexes).
All of the above activities contribute to the reduction of internal costs, which positively affects the cost of products manufactured at the enterprise.
The work was added to the site site: 2014-12-21Order writing a unique work
BELARUSIAN STATE UNIVERSITY
Department of Economics
ESSAY
On the topic:
Practical analysis of oil enterprise management chemical industry on the example of JSC "Mogilevkhimvolokno"
Mogilev Production Association "Khimvolokno" (abbreviated name MPO "Khimvolokno") was established in accordance with the order of the Ministry of Chemical Industry of the USSR dated July 21, 1975 No. 453 and operated on the principles of full cost accounting.
open joint-stock company"Mogilevkhimvolokno" (hereinafter referred to as the Company) was established on the basis of the order of the Ministry of Economy of the Republic of Belarus dated December 31, 2002 No. #186 by transforming the Republican unitary enterprise"Mogilev Production Association "Khimvolokno" and the Republican Unitary Subsidiary "Hockey Club "Khimvolokno Mogilev" in accordance with the legislation on the privatization of state property and the legislation on joint-stock companies.
JSC "Mogilevkhimvolokno" carries out the following activities: production chemical fibers and threads using in the production of units and parts made of precious metals, chemical reagents (components); production equipment and spare parts for it; consumer goods; performance of work and provision of services.
Open Joint Stock Company "Mogilevkhimvolokno" is a major producer of dimethyl terephthalate, PET polyester granulate, incl. for food purposes, polyester fibers and threads and the main supplier of raw materials for the light industry of the Republic of Belarus.
The company has modern infrastructure ensuring the functioning of a major production complex in the presence of qualified personnel and a system for their training.
JSC "Mogilevkhimvolokno" is the city-forming enterprise of Mogilev.
The enterprise is a part of the Belarusian State Concern for Oil and Chemistry (Concern "Belneftekhim").
A feature of the enterprise is the unification on one site in
a single complex of industries connected by the technological cycle - from
obtaining monomers before the release of finished products in the form of fibers, threads,
nonwoven materials of various assortment and purpose.
The decision to start construction of the enterprise was made in 1965.
In 1970-1971 the first stage of the enterprise was put into operation as part of a workshop for the production of dimethyl terephthalate with a capacity of 54 thousand tons per year and the production of polyester fibers, technical and textile threads using the technology of the English company ICC AI with a total output of 50 thousand tons per year.
In 1977, it was put into operation, and in 1980, the production of fiber with a capacity of 88.4 thousand tons per year was modernized. In 1982, under the license of the Japanese company Mitsui Torey, the production of textured yarns with a capacity of 5 thousand tons per year was mastered. Together with the German companies Ude GmbH. and HechstAG designed and in 1988 put into operation the production of high-strength yarns with an output of 24.6 thousand tons per year.
In 1991, as part of the association, the foreign trade export-import company "VSV" began its activities. She established and expanded trade relations in Europe, Asia, America, Africa. Today the association cooperates with more than 80 foreign companies.
At present, the enterprise is a complex of four factories and two production facilities:
- organic synthesis plant produces dimethyl terephthalate ( effective power 180 thousand tons per year) and polyethylene terephthalate (capacity 86 thousand tons per year);
the synthetic fiber plant produces polyester fibers (operating capacity is 93.5 thousand tons per year); PET granulate (96.33 thousand tons per year); composite materials (1.8 thousand tons per year);
a polyester yarn plant (operating capacity 20.1 thousand tons per year) produces threads for technical purposes;
The production of synthetic complex yarns ensures the production of textile smooth and textured yarns, gray and dyed (capacity 10.3 thousand tons per year), polyester base for roofing materials (capacity up to 40 million m2 per year), non-woven fabrics made of polyester fiber of various destination, strapping tape (capacity 600 tons per year;
mechanical repair plant specializes in the production of equipment for chemical industries and spare parts for it.
From September 1, 2007, as a result of the acquisition of 100% of the shares of JV Belpak CJSC joint venture included in the structure of the company as a structural unit - the post-polycondensation shop of the organic synthesis plant.
The main objectives of the enterprise are: making a profit to meet the social and economic interests of members of the workforce and property owners, as well as meeting the public need for products, works and services on the basis of effective methods management.
At present, the main block of shares remains in the ownership of the state, and as privatization proceeds, the Government of the Republic of Belarus provides for the possibility for investors to participate in the corporatization of the enterprise with the acquisition of a block of shares.
1. The high dependence of OJSC “Mogilevkhimvolokno” on foreign suppliers of raw materials makes the enterprise vulnerable to the impact of fluctuations in world prices for the main raw materials.
2. Many product ranges of the enterprise are inferior to imported counterparts in terms of energy and raw materials costs. The technical development of the enterprise, starting from the 90s, has sharply slowed down, the technologies used are outdated.
3. As of 09/01/2008, the degree of wear of the main production assets is 76.2%, depreciation of the active part of fixed assets is 87.93%. The use of both morally and physically worn out equipment is the main reason for the high cost of production. In addition, in recent years, there has been a need in the market for a number of new types of polyester products.
The founder of the enterprise is the Ministry of Economy of the Republic of Belarus. The enterprise is the successor of the rights and obligations of the named enterprises in accordance with the deed of transfer, except for the rights and obligations that cannot belong to the enterprise.
"Mogilevkhimvolokno" is commercial organization – legal entity, has a self-balance, printing.
Authorized fund divided into 149,375,170 (one hundred and forty-nine million three hundred seventy-five thousand one hundred and seventy) ordinary registered shares with a par value of 3,740 (three thousand seven hundred and forty) rubles each.
The Company's shares are owned by its shareholders. A shareholder of the Company does not have property rights to the property of the Company, except in the event of its liquidation.
Shares are issued in the form of entries in accounts.
The governing bodies at the enterprise are:
General Meeting of Shareholders;
supervisory board.
The directorate and the general director are the executive bodies of the enterprise, whose competence includes the solution of all issues that are not within the competence of the enterprise's management bodies.
Control over the financial and economic activities of the enterprise is carried out by the audit commission.
To check and confirm the correctness of the annual financial reporting the enterprise annually attracts an auditor who is not connected by property interests with the enterprise or its participants. The company is exempt from the mandatory annual audit if in the reporting period the departmental control and audit service conducted an audit of its financial and economic activities.
Within three working days from the date of receipt by the enterprise of the auditor's report, the act (certificate) of the audit conducted by the supervisory authority, the general director is obliged to send copies of them to each member of the supervisory board, chairman of the audit commission.
General meeting shareholders is the highest management body of the enterprise. The Supervisory Board is a management body that carries out general management of the enterprise's activities in the period between meetings of shareholders.
The Supervisory Board elects the Chairman of the Supervisory Board from among its members.
The management of the current activities of the enterprise is carried out by the directorate (collegiate executive agency) and CEO (sole executive body).
The Directorate and the General Director carry out their activities within the competence established by the legislation, this Charter, decisions of the meeting of shareholders and the Supervisory Board.
The meeting of shareholders or the supervisory board of the enterprise has the right to establish the procedure (to approve the Regulations), on the basis of which the management and the general director carry out their activities. The management, the general director are accountable for all issues of their activities supervisory board and shareholders' meeting. The General Director heads the Directorate, organizes its work and chairs its meetings.
The reorganization of an enterprise (merger, accession, division, separation, transformation) can be carried out by decision of the meeting of shareholders. Other grounds and procedure for the reorganization of an enterprise are determined by legislative acts.
The number of personnel as of December 31, 2007 is 11348 people. In the first half of 2007, 169 people were hired, 524 people were dismissed. Number as of 30.06.2007 10988 people The decrease in the number was 360 people.
Consider economic indicators enterprise development.
Manufacturing program for the release of products is completed. Over the plan, 338 tons of fiber, 479 tons of commercial PET were produced.
The indicators for the growth rates of industrial output and consumer goods have been exceeded. Costs per 1000 rubles. marketable products are reduced, compared with the planned ones, from 1026 rubles. up to 1010.1 rubles.
The planned losses from production (980 million rubles) were reduced by 581 million rubles. and amounted to 399 million rubles, the profitability of marketable products was "minus" 1% with the plan "minus" 2.6%. The growth of material consumption has been reduced compared to the plan.
The plan for the sale of finished products, including for export, was overfulfilled, as a result, stocks of finished products were reduced against the plan by 230 million rubles.
The planned losses from the sale of finished products were reduced by 803 million rubles. and amounted to 980 million rubles.
Net profit according to the results of work for 2007, 55 million rubles were received. and is secured by receiving non-operating income, from which:
for the parent company 29 million rubles. (including covering the losses of DKiT 73.4 million rubles), the sanatorium "Sosny" profit 26.2 million rubles.
The main indicators are presented in Table 1.
Table 1
Enterprise development indicators
| Indicators | 2007 |
||
| Plan | Fact | Off |
|
| Commodity products in action. prices, million rubles | 37421 | 39507 | +2086 |
| The rate of production of goods. products in sop. prices, % | 97,2 | 103,1 | +5,9 |
| The rate of production required. goods, % | 99,9 | 100,1 | +0,3 |
| Costs per 1000 rubles. marketable products, rub. | 1026 | 1010,1 | -16,1 |
| Profit from production, million rubles | -980 | -399 | +581 |
| Profitability of marketable products, % | -2,6 | -1,0 | -1,6 |
| Reducing the level of material consumption | Height 14 | Height 11.7 | |
| Stocks goth. products (without taxes), million rubles | 27327 | 27097 | -230 |
| Export volume, thousand dollars | 17321 | 17816,7 | +496 |
| Export rate, % | 144,2 | 148,4 | +4,1 |
| Proceeds from the sale of products, mln. | 51636 | 54945 | +3309 |
| Profitability of sold products, % | -3,6 | -1,9 | +1,7 |
| Profit from the sale of products, million rubles | -1783 | -980 | +803 |
| Net profit for the head enterprise, mln. rub. | -1621 | 29 | +1650 |
| Net profit, total mln. rub. | -1621
| 55
| +1676 |
At the end of 12 months cost reduction as a result of implementation of measures to reduce costs structural divisions amounted to 3.5 billion rubles. with the planned volume of 2.21 billion rubles. Based on the results of work for 2007, the target indicators for industrial products, consumer goods, energy saving indicators, investments in fixed assets, and exports were met. Positive balance secured foreign trade. Below the standard stocks of finished products in warehouses.
Indicators not achieved:
to reduce material consumption, an increase of 0.3%,
by specific gravity new products,
in terms of the share of certified products, it should be noted the positive dynamics of increasing this indicator, the indicator of profitability of sold products, works, services in June has a negative value, since the beginning of the year 3.3%. The achievement of targets is presented in Table 2.
table 2
Achievement of targets
| № | Indicators | exercise for 2007 | fact |
|
| 2006 | 2007 |
|||
| 1 | Industrial products in Sop. prices, % | 107,3 | 103,1 | 109,3 |
| 2 | Production of consumer goods, % | 100,0 | 100,1 | 104,2 |
| 3 | Export of goods, % | 131,7 | 148,4 | 136,2 |
| 4 | Import of goods, % | 140,4 | 104,5 | 116,5 |
| 5 | Foreign trade balance, thousand $ | -2605 | 5705,3 | 16874,6 |
| 6 | Reducing the level of material consumption, % | - 1 | height 11.7 | Height 0.3 |
| 7 | Energy saving indicator, % | -11,5 | -4,8 | -18 |
| 8 | Profitability of realized products, works, services, % | 8 | -0,8
| 3,3
|
| 9 | Oud. weight of stocks in production volume (net), % | 60 | 57,1 | *
|
| 10 | The volume of investments in fixed capital, million rubles | 33979 | 5222 | 38089 |
| 11 | Growth rate of investments in fixed assets, % | 66 | * | 73,9 |
| 12 | Share of new products in total volume industrial production, % | for a year 20 | 10,2
| 11,1
|
| 13 | Share of certified products | 23,5 | 25,5
| 12,6
|
Table 3
Saved in terms of feedstock, tons
| Raw material | 2007 |
| Paraxylene | 180 |
methanol | 447 |
| ethylene glycol | 336 |
The cost of saved energy resources (- savings, + overspending) is shown in Table 4
Table 4
The cost of saved energy resources (- saving, + overspending
| Unit. | 2007 |
||
| in kind. | million rubles |
||
| electricity | Thousand kWh | -4246 | -528,6 |
| heat energy | Gcal | -3483/8 | -1209,3 |
| fuel | Here. | -570 | -131,6 |
| Total | Here. | -7856
| -1869,6
|
In monetary terms, energy savings in 2007 amounted to 1,869.6 million rubles.
The fulfillment of the supply plan for the main raw materials is shown in Table 5
Table 5
Supply structure of the main raw materials:
| PARAXILOL | 2007 |
|
| tn | specific weight in the total supply, % |
|
| Total delivered | 67183
| 100,0
|
| including: | 0,0 |
|
| from the Republic of Belarus (JSC Naftan) | 26874
| 40,0
|
| Imported to the Republic of Belarus: | 40309
| 60,0
|
| including: | 0,0 |
|
| from Russia, including: | 37692
| 56,1
|
| 1) Omsk refinery, from it: | 23374 | 34,8 |
| 2) OAO Ufaneftekhim | 0 | 0,0 |
| 3) OOO PO Kirishinefteorgintez | 14318 | 21,3 |
| from Far Abroad (Belorusneft, BNTD) | 2617
| 3,9
|
In the period January-April, when supplying paraxylene under direct contracts, OJSC Naftan provided a discount from the price of 39%. In accordance with the order of the concern dated April 26, 2007 No. 345, when supplying paraxylene under direct contracts, OJSC Naftan provides a discount from the price of 22% for the period from May 1 to May 31, 2007 and in accordance with the order of the concern dated May 29, 2007 No. 449 a 22% discount will be provided until the end of 2007.
Table 6
Dynamics of average actual prices for paraxylene on import, $/tn (excluding VAT)
Average contract prices (excluding VAT) for paraxylene imports above than the prices for paraxylene, produced by OAO Naftan, by $705 per ton (3.3 times).
In conclusion of the analysis, it can be concluded that the Mogilevkhimvolokno enterprise is the largest complex in Europe for the production of polyester fibers and threads. A feature of OAO Mogilevkhimvolokno is the integration into a single industrial complex of a number of industries connected by a single technological cycle - from the receipt of raw materials to the production of finished products. An enterprise should rightfully owe its success to both local management and the system government controlled the entire petrochemical complex of the Republic of Belarus.
To improve performance foreign economic activity
in the period up to 2012 JSC "Mogilevkhimvolokno" considers the following
strategic steps:
- to work in a certain market through a limited
number of dealers, which will avoid unhealthy competition and price
lack of control;
- intensify work through representative offices of the concern
Belneftekhim in Russia, Ukraine, the Baltic States, Germany with the involvement of
Ministry of Foreign Affairs, Embassies of the Republic of Belarus in the countries - the main markets
enterprise products;
- respond quickly and flexibly to change pricing policy on the
specific markets;
- promptly receive information from the objects of the commodity distribution
networks about market demand, price levels, financial position processors,
competitor strategies;
- constantly participate in the company's specialists,
engaged in foreign economic activity, in seminars, internships, advanced training
employees in relevant courses;
- actively participate in exhibitions and fairs at all representing
commercial interest markets;
- in order to develop new assortments, improve quality
products, packaging, stable supplies and other issues
to hold scheduled meetings of technologists of the enterprise with technologists of plants -
processors;
- continue work on the abolition of anti-dumping sanctions on imports
polyester fibers to Turkey, together with the Ministry of Foreign Affairs of the Republic of Belarus and lawyers
offices representing the interest of Mogilevkhimvolokno OJSC in this
region;
- to purchase raw materials on a competitive basis from
direct manufacturers.
During the implementation of the Development Program, it is planned to increase
direct sales of products to direct consumers.
JSC "Mogilevkhimvolokno" has the image of a stable enterprise with
products High Quality and further organization of close work with
consumers, based on deep marketing study of markets
sales will allow the company to compete in the polyester market.
Thus, the main goal of JSC "Mogilevkhimvolokno" in
sales of products at this stage of work - the preservation and strengthening
positions in the sales markets based on deep marketing
research, development of its own commodity distribution network, complete and
rational use representative offices of Belneftekhim Concern for
abroad, direct work with direct processors of products
enterprises for the most complete satisfaction their needs.
LITERATURE
1. Statistical report of JSC "Mogilevkhimvolokno" for 2007.
2. Economics of the enterprise. Workshop: Proc. allowance / A.N. Senko, E.V. Krum. – Mn.: Vysh. school, 2002.
3. Economics of the enterprise: Proc. manual / L.N.Nekhorosheva, N.B.Antonova, M.A.Zaitseva and others; Under total ed. L.N.Nekhoroshevoy. – Mn.: Vysh. school, 2003. - 383 p.
On the last Sunday of May, a professional holiday - Chemist's Day - will be celebrated by workers in the chemical industry. Given that Belarus is a country with a powerful petrochemical complex, which makes the largest contribution to the country's budget of all industries, this day of the calendar is really red. Chemist's Day is a significant holiday for Mogilev as well. JSC Mogilevkhimvolokno is located in the heart of the resulting chemical cluster. business card cities. It is visible from afar. Every day, buses, trolleybuses, cars carry thousands of citizens to its production.
In chemistry, each compound has its own formula. Mogilevkhimvolokno has a formula for SUCCESS. We tried to get her out by visiting the organization on the eve of the holiday.
At management decisions and competent management
Over the past five years, OAO Mogilevkhimvolokno has used investments in fixed capital in the amount of 478.4 billion rubles. And every ruble went to the modernization of production, which, despite the difficult economic situation, is working at a profit. The growth driver was modernization, investment in modern equipment and technologies.
New PET bottle preform production facilities were commissioned, resulting in the production of preforms for 2 liter bottles for carbonated and non-carbonated drinks and 1 liter wide-mouth bottles for still drinks and dairy products.
We launched a PET waste recycling line, which made it possible to reduce the costs of processing wastes obtained at different stages of the production of PET, fibers and threads.
The equipment of the warping and twisting shop for the production of polyester yarns has been updated through the introduction of modern equipment for warping and twisting of technical threads. Thanks to the modernization, it was possible to decommission worn-out equipment and ensure the production of a wide range of folding and torsion.
The production of fatty acid methyl esters with a capacity of 50 thousand tons per year, which is a component for the production of biodiesel fuel, an alternative type of motor fuel from a renewable source of raw materials, was organized.
The range of produced polyester threads has been expanded.
At the production of synthetic films of OAO Mogilevkhimvolokno, the production of multilayer films was organized using the Double-Buble technology with a capacity of 2 thousand tons per year for packaging bakery and confectionery products.
FROM life and development of new markets
OJSC Mogilevkhimvolokno, like most large enterprises have to adapt to complex economic conditions. Due to the limited domestic market, the task of increasing and diversifying exports for the organization remains very relevant. According to Dmitry Sergomassov, head of the department and sales of finished products, last year the commercial service managed to achieve some success in terms of export diversification. The total shipments of the organization's products to new markets during this period reached 15.192 million dollars.
Since the quality of manufactured products is not inferior to foreign analogues, it ensures its competitiveness in foreign markets. In total, the organization ships products to almost 30 countries around the world. Armenia, Kyrgyzstan, Turkmenistan, Uzbekistan have appeared among the new partner countries only in the last year. In connection with the expansion of the geography of deliveries, new areas of application of the products have been mastered.
By the way, each country is interested in a certain type of product. Fatty acid methyl esters go to Slovakia, Poland and the Czech Republic, bottled PET is in demand in Armenia, Hungary, Kyrgyzstan, Lithuania, Poland, Serbia, Turkmenistan, Uzbekistan and Croatia, film PET is purchased by the Russian Federation, non-woven fabrics are in demand in Italy and Georgia.
In total, in 2010-2015, Mogilevkhimvolokno OJSC put into production 31 types of products.
In 2016 commercial service not going to slow down. Even more attention will be paid to the sales policy and marketing strategy, which will focus on improving sales efficiency, export diversification, expanding the trading portfolio and increasing activity in the areas of advertising and exhibition and fair activities.
P polyester products
“In 2015, OJSC Mogilevkhimvolokno launched the implementation of the project “Complex for the production of polyester products”, which provides for the reconstruction of the existing and construction of new production facilities for polyethylene terephthalate, polyester fiber and technical threads,” said the deputy chief engineer for technical development Oleg Burakov. — The cost of the project is 202 million euros. It will be implemented in two stages."
The first stage of construction provides for the reconstruction of the chemical workshop No. 2 for the production of organic synthesis with the organization of the production of polyester fiber by direct molding with a capacity of 50 thousand tons per year, of which 25 thousand tons of conjugate fibers per year.
On September 30, 2015, a contract was signed with a German company for the supply of necessary equipment. In general, the planned completion date for the first stage is 2017.
The second stage includes the construction of technologically interconnected new production facilities for textile polyethylene terephthalate, polyester fiber and technical yarns. The large-scale project is scheduled to be completed in 2019.
The implementation of the project will allow OAO Mogilevkhimvolokno not only to decommission high-cost obsolete production facilities and increase the competitiveness of polyester fiber and threads through the use of new modern technologies, but also to start production of a new type of polyester fiber "conjugate", the price of which is higher, and to expand the range of polyester fibers threads.
E unity of management and employees
Perfected to the smallest detail, the professionalism of the employees, their responsibility, the coordination of the actions of the entire team. In the chemical industry, this is perhaps more important than in any other industry. According to specialists of the department for ideological work and personnel, the average age of employees does not exceed 44 years. There is a gradual rejuvenation of the team - this also benefits the common cause. For young specialists, it is important to work at an enterprise with long-term traditions and experienced colleagues. This is a good start to a career and an opportunity to get into the reserve of the organization's management personnel - Mogilevkhimvolokno relies on young people.
Senior employees who have accumulated a huge professional baggage are a unique resource of the enterprise. They are able to teach young people who come to the company a lot, and, as a rule, they have a need to transfer their experience and best practices. Young employees can become the driving force behind the development of the organization - they are energetic, want to develop and have a “clear” look, and they make up for the lack of experience creativity. "Naive" questions asked by beginners help to reconsider the usual and "for granted" procedures, to see the reserves for development. Thus, with the cooperation of the older and younger generations, the most promising and interesting innovations can be born, new ones can be formed. competitive advantages enterprises.
Loyalty to a common cause is worthy and paid. The average monthly salary in 2015 amounted to 6 million 341 thousand rubles.
X good prospects
The organization began the new year with major victories. Based on the results of socio-economic development in 2015, Mogilevkhimvolokno OJSC was recognized as the best enterprise of the Oktyabrsky district of Mogilev among industrial enterprises and entered on the Board of Honor of the Oktyabrsky district.
The organization also confirmed the title of laureate of the Prize of the Government of the Republic of Belarus for achievements in the field of quality in 2015. Republican professional competition polyester fabric for roofing materials produced by Mogilevkhimvolokno OJSC was awarded the title of "Best Goods of the Republic of Belarus-2015" in the nomination "Industrial and technical products". And how, after such successes, to rest on our laurels and not move forward?
In his speeches, President of Belarus Alexander Lukashenko has repeatedly said that 2016 will not be an easy year for the country. And those enterprises that can survive will pass this test of strength and will operate successfully in 2017 and subsequent years. Mogilevkhimvolokno OJSC is convinced that the organization will adequately pass this test. Of course, we need a regime of austerity, a reduction in production costs.
In April of this year JSC "Mogilevkhimvolokno" and Ivanovo University of Chemical Technology signed a cooperation agreement. Within the framework of cooperation between Mogilev and the Ivanovo region on the joint development of the fiber industry of Belarus and the textile industry Russian Federation The parties signed a cooperation agreement.
The subject of the agreement is Team work JSC "Mogilevkhimvolokno" and Ivanovo State University of Chemical Technology in several directions: career guidance, training of specialists, advanced training, internships and professional retraining of personnel, research activities, and other areas of mutual interest.
The legendary brand of JSC "Mogilevkhimvolokno" from year to year confirms its reputation. Here they understand that without constant renewal, improvement of technologies, progress in energy saving, re-equipment, one can instantly lose competitive advantages. It is gratifying that the organization knows how to competently realize the huge potential of the enterprise. So, higher achievements are yet to come!
Ekaterina Ldova, photo from the Trudovaya Slava newspaper archive
I.G. Sabaev,
First Deputy Director of JSC Ivanovo Polyester Complex
Information about the investment project "Creation and development of industrial production of polyethylene terephthalate (PET) for textile purposes in the city of Vichuga, Ivanovo Region"
FROM THE EDITOR. The construction project for the production of polyethylene terephthalate for textile purposes in the city of Vichuga, Ivanovo Region, causes diverse, sometimes sharply critical assessments of specialists and representatives of the business community (see, for example, p. 8 of this issue of the Bulletin). At the same time, we believe that comprehensive information about the progress and problems of this large-scale project will help to better understand its prospects and make the right decisions for its participants and potential partners.
In this regard, we are publishing a detailed message from the First Deputy General Director of Ivanovo Polyester Complex JSC I.G. Sabaev about and invite all interested parties to the discussion.
Project management and financing
Joint Stock Company "Ivanovo Polyester Complex" (JSC "IPK") is a private specialized design company established in 2014 with the aim of building a PET plant for textile purposes in the Ivanovo region.
The project is exclusively commercial without attracting budget money. JSC "IPK" did not spend a penny of public funds. Moreover, the funds spent at the design stage for the development of project documentation and the passage of state expertise were returned to the budget of the Ivanovo region.
Funding sources are private investments and a loan from Vnesheconombank. At the same time, the participation of SC Vnesheconombank, as an institution of project financing, does not provide for the use of public money, but only funds raised in foreign banks. In June 2017, Ivanovo Polyester Complex entered into a loan agreement with VEB. total cost project - 25 billion rubles, including the amount of participation of Vnesheconombank will be 19 billion rubles. The funds will be provided for up to 13 years.
Prerequisites for the creation of a synthetic fiber plant in the Russian Federation
World production of polyester fiber is about 16 million tons, together with polyester threads, it is about 60% of all fibers and threads produced in the world, including natural ones. The share of Russia in production is 0.45% of world production, and the consumption of polyester fibers and threads is not more than 2 kg per capita, while in developed countries consumption is much higher (for example, in Germany - 7 kg, in China - 23 kg) . The room for growth is obvious.
The production of polyester fiber is the first redistribution of the technological chain for the creation of synthetic textile materials with a wide market segmentation by areas of their application. The enterprises of the Russian petrochemical industry operate in large volumes, and their interest ends in the production of bottled granules, at best. Working with small and medium-sized enterprises, with numerous shipments of products in batches that are multiples of one Gazelle, is not very convenient for petrochemists. The textile industry is hundreds of transactions and a deep dive into the intricacies of the final textile product consumption market right up to the counter, it is a diverse range of final products using many types of raw materials in various blend combinations to give the products the required properties and characteristics.
The creation of a modern plant for the production of polyester staple fiber and textile-quality granulate in the Ivanovo region is a breakthrough project for the development of Russian light industry in order to replace imported raw materials for textiles by producing a wide range of domestic polyester staple fibers. This is in line with the Russian Chemical Industry Development Strategy for the period up to 2030, which provides for full import substitution of polyester products, as well as the Light Industry Development Strategy until 2025, which aims to create a complete value chain for technical textiles.
Currently, in the structure of value added in the light industry of the Russian Federation, 15% (~0.5% of GDP) is accounted for by the production of synthetic fibers and threads. At the same time, 60% of the country's need for them (especially for the sub-sectors of technical textiles and nonwovens) is provided by imports (see diagram).
Site selection for the plant
Ivanovo region has a long tradition of textile production and quite a lot of experience and professional competencies in this industry and, of course, the potential for further local processing of the produced staple fibers. Therefore, the creation of a domestic raw material base for the production of textile materials on Ivanovo land is more correct than in places close to oil and gas processing enterprises.
Production is well located in terms of logistics (in close proximity to railway lines and roads). Taking into account the planned cargo traffic, there are already agreements with the Northern railway on the use of currently underloaded railway terminals and stations in the cities. Ivanovo, Vichuga and Kineshma. In terms of external infrastructure (electricity, natural gas, water), there are free volumes and capacities in the region to provide the plant with the necessary resources.
There will be no problems in the region with the provision of engineering and technical personnel for the enterprise. Chemical technologists and textile engineers are already being trained by Ivanovo universities, which will minimize the number of invited specialists. In addition, the terms of the contract with the supplier of the main technological equipment it also provides for the education and training of the required specialists at foreign companies both in polycondensation and in the production of staple fiber.
Applied technologies and technical solutions
Ivanovo polyester complex is a high-performance enterprise of the first redistribution of the technological chain for the creation of technical textiles, using the most modern technology for the production of polyester staple fibers by their direct spinning from a polymer melt directly from its synthesis plant. In this case, the cost of the fiber is almost 15% lower than with a two-stage scheme: first, by obtaining polymer granules and then molding them using extruders. Both investment (since extruder molding requires a much larger number of single lines) and energy and operating costs are significantly reduced (the stages of granulation, cooling of granules, their intermediate transportation and storage, crystallization, drying and melting of PET granules are excluded).
Polymer synthesis is carried out using the most highly efficient two-pot technology from the world leader - Uhde Inventa-Fischer GmbH (Germany). From the synthesis unit, the PET melt goes directly to the fiber spinning lines. In this way, manufacturing process(from PET melt to fiber packed in bales) is carried out on a continuous production line with a capacity of up to 600 tons / day. In production, the largest molding lines and staple units of the company are used. Oerlikon Neumag (Germany). There are three such lines, and they have the maximum productivity achieved by the world leaders today (up to 225 tons / day) for each type of fiber.
Finished product range
It is planned to produce fibers with a linear density from microfiber (0.7-0.9 den) to high titers (15 den), including the latest world innovations (3D crimped, self-crimped, hollow siliconized fiber, etc.). The lines have a very high technological flexibility and interchangeability in units and assemblies. A single management system ensures the conduct and control technological process at all stages from the supply of raw materials to the packaging of finished products. The end products are packaged staple fiber bales weighing up to 350 kg and PET granules packed in containers (soft "big bags") weighing up to 1 ton.
Provision of the enterprise with raw materials
Pure terephthalic acid (TPA) and monoethylene glycol (MEG) are used as the main raw materials.
TFA in the next two or three years after the start of production will be purchased by import. There is an excess of this product on world markets (the volume of world production is about 60 million tons). The customs duty for its import into the Russian Federation has been zeroed. When capacities are not loaded more than 80%, there will be no issues with import deliveries. At the same time, the Ivanovo polyester complex is very much looking forward to expanding the TPA capacity at Polyef OJSC (part of SIBUR Holding OJSC) by 100 thousand tons per year, which can cover up to 50% of the project's demand for domestic TPA. It is also possible to launch the production of TPA in Kazakhstan, which would reduce the delivery time of this raw material and completely abandon its import from far abroad in the future.
MEG in Russia is produced in sufficient volumes and will be supplied from the Russian enterprises of OAO SIBUR-Neftekhim and OAO « Nizhnekamskneftekhim”, agreements have already been signed with them. At the same time, the Ivanovo plant is only 208 km away from Dzerzhinsk (SIBUR-Neftekhim). Auxiliary raw materials and additives used in production in small volumes (fractions of a percent of the main raw materials), initially, to ensure warranty tests, imported, will later be mastered by chemical production in the Russian Federation (including partially in Ivanovo, where their analogues are already produced) .
Benchmarking of applied design solutions
At the stage of a comprehensive examination of the project, a deep analysis was carried out of similar enterprises, similar in capacity to the Ivanovo Combine, and built over the past 10 years in the world (China, Korea, India, Iran), both in terms of capital costs and operating costs in relation to investment in these projects. The project of the synthetic fiber plant is in no way inferior to its counterparts, but individual parameters more attractive, which, in particular, made it possible to obtain a positive assessment from Vnesheconombank based on the results of an examination (financial, economic, technological, marketing, environmental) conducted with the participation of independent international consultants, and to attract project investors.
The production cost of 1 ton of PET in South Korea, China, India is approximately the same, fluctuations are in the range of +/- 2.5% of the average value. The indicators of the Ivanovo project are also in this range. This is due to the fact that 92% of production costs are accounted for by raw materials, which are exchange goods on the world market and are sold at one quotation. Fluctuations are possible only within the framework of other costs, which make up 8% of the production cost of fiber (mainly energy costs and labor costs). Taking into account the fact that the cost of labor costs in the above countries and Russia is approaching, the fluctuations in this indicator are insignificant.
The plant's products will be competitive not only in comparison with imported fiber, but also with domestic producers of fiber from secondary raw materials, not to mention the high export potential products of the future plant - they are also expected in Europe.
Thanks to the most modern technologies and equipment from world leaders, production will have the best of the currently achieved indicators in the world in terms of raw material consumption and energy consumption. This will ensure the release of products with a lower cost compared to competitors.
The only enterprise in the post-Soviet space for the production of primary fiber - OAO Mogilevkhimvolokno, the Republic of Belarus - was very late with the modernization of its production, which was built back in 1976 using the fiber production technology through DMT (the raw material is paraxylene OAO « Naftan», Novopolotsk). Due to the less efficient technology, they cannot boast of stable fiber quality, which is confirmed by all consumers on the market (Mogilevkhimvolokna on Russian market today - about 13%).
The maintenance of the existing infrastructure greatly influences the price of Mogilevkhimvolokno's products, which are sometimes more expensive than imported fiber. The modernization of production conceived by them will affect only the plant for the production of bottled PET. However, in essence, this is the creation of a new production, but with the need to maintain the old, worn out, costly infrastructure. Let's not forget at the same time that the main raw materials (TFK and MEG) are completely imported by Mogilev.
In the Russian Federation, two more projects for the production of PET are being implemented - SafPet in Nizhnekamsk and the Plant of Pure Polymers « Etana» in Kabardino-Balkaria, but their end products do not overlap with the plant planned for production in Vichuga, as they focus on PET granules for packaging.
Environmental aspect of the created production
During the development of the synthetic fiber plant project, increased attention was paid to environmental issues.
During the design, all the necessary procedures in terms of ecology and safety, provided for by the Town Planning Code of the Russian Federation, the Law of the Russian Federation "On the Sanitary and Epidemiological Welfare of the Population", the Law of the Russian Federation "On Environmental Expertise" and the Regulations "On the Assessment of the Impact of Planned and Other Activities on the Environment" Wednesday in the Russian Federation".
Important justifications were prepared: the Environmental Justification (EIA) and the Draft Justification of the Size and Boundaries of the Sanitary Protection Zone. A positive conclusion on the compliance of the placement of the PET complex with the requirements of sanitary and epidemiological rules and regulations was received by the Office of Rospotrebnadzor for the Ivanovo region, and the EIA materials, respectively. were finalized taking into account the opinions and comments received, based on the results of public discussions of EIA materials held in 2015.
According to the design documentation and the results of engineering surveys for the facility "Complex for the production of polyethylene terephthalate (PET) for textile purposes", containing, among other things, the environmental section and sections of industrial, fire and other safety, a positive conclusion was issued by the Federal Autonomous Institution "Glavgosexpertiza of Russia", confirming the compliance of the presented documents to the requirements of technical regulations, including environmental requirements.
In addition, due to the fact that international financial institutions, environmental and social risks of the project were assessed international company Mott Macdonald (Great Britain) for compliance with the requirements of the Organization for Economic Cooperation and Development, the European Union and the Russian Federation. Mott Macdonald's Environmental and Social Impact Assessment (ESIA) materials conclude that the identified environmental impacts are low or negligible.
Note that, according to the explanation Federal Service for Supervision in the Sphere of Natural Resources Management (Rosprirodnadzor), the design documentation for the PET Complex is not subject to federal state environmental expertise, in accordance with 174-FZ.
In the course of checking the compliance of Ivanovo Polyester Complex JSC with the requirements of the legislation on the protection environment and environmental management, on environmental expertise, urban planning legislation conducted in 2017 by the Ivanovo interdistrict environmental prosecutor's office, no violations of laws related to the subject of the audit were identified.
Demand for the plant's products
The appearance on the Russian market of such demanded products will give a serious impetus to the growth of the production of various synthetic materials and fabrics containing polyester fibers and threads, as products of high processing of hydrocarbon raw materials used in various industries. For reference, today about 1.3 billion square meters. m of polyester-containing fabrics and materials are imported to the Russian Federation, and this, with the support of the Ministry of Industry and Trade of the Russian Federation, can be gradually replaced domestic production, but if the necessary raw materials are available within the country.
The project is extremely relevant due to the growing volume of consumption (in 2016, consumption of about 180 thousand tons, of which more than 60% is imported) in the Russian Federation of polyester staple fibers and, above all, in the production of various nonwoven materials. The greatest demand is observed in such segments as the automotive industry, industrial and civil construction, medicine and hygiene, protective textiles, where the added value is not lower than woven processing.
The range of the plant is very wide - from microfibers to fibers for special purposes, as well as textile PET granules for the production of filament yarns. The flexibility of production allows you to quickly respond to changes in market conditions and switch from one type of fiber to another in a short time.
All domestic consumers of textile raw materials and semi-finished products will be provided with high-quality and affordable raw materials at competitive prices. Already at the stage of designing and making an investment decision, the Ivanovo polyester complex held negotiations with Russian and foreign buyers and consumers, as a result of which letters of interest in cooperation were received and preliminary agreements were signed in the amount of 158 thousand tons of polyester fiber and textile PET granulate per year ( which is about 80% design capacity plant). The potential of the CIS market is about 100 thousand tons more. IPK JSC is continuously working with potential processors of textile PET in order to meet their demand for the future. The first batches of polyester fiber and textile PET granulate will enter the Russian market in 2020.
Labor resources of an enterprise (organization) and organization of remuneration
Currently, the average number of employees of Mogilevkhimvolokno OJSC is 7638 people, including the average number of industrial and production personnel - 6918 people. The staff of the administrative apparatus is 663 units or 7.7% of the total headcount personnel.
It is planned to accept 53 graduates of educational institutions, including: young professionals with higher education-12 people, young professionals and young workers with secondary specialized education -16 people, young workers with vocational education -25 people, to ensure proper training of young professionals and a rational combination of experienced highly qualified workers and young professionals in the organization.
4004 people have been trained. Among them, 127 managers and specialists improved their qualifications in educational institutions, 865 managers and specialists studied in organizations in various areas of activity. 696 workers of various professions underwent retraining, 504 workers improved their skills, 1021 workers studied at special-purpose courses. 482 people will continue their education in educational institutions.
Mogilevkhimvolokno OJSC pays attention to the selection, placement and retention of personnel, improving the quality of managers and specialists, as a result of which a stable labor collective, which faces a difficult task - ensuring the release of competitive products.
Fund planning wages carried out taking into account the predicted macroeconomic parameters of the development of the Republic of Belarus and its amount will be 125,026 million rubles, including the wage fund of industrial and production personnel 116,254 million rubles. Payroll fund for non-industrial personnel (section for sewing and repairing garments, repair and construction workshop for repairing social and cultural facilities, non-industrial personnel of the economic workshop, information and editorial bureau, housing and communal services, hotel service, center for sports and recreational work, workshop Catering, agricultural workshop, sanatorium "Sosny" of the 1st category) will amount to 8772 million rubles. The planned size of the average monthly salary of the employees of the organization is 1362.0 thousand rubles. The growth rate of real wages is calculated based on the average annual consumer price growth index of 108.0% and will amount to 103.4%. Labor productivity will increase by 5.6% compared to the level achieved in 2010. Thus, the growth of labor productivity outstrips the growth of real wages by 2.2 percentage points.
