By the end of this year IPower LLC join the enterprises-residents of free economic zone "Brest", whose products not only in high demand in the domestic market, but also actively exported abroad. At this time, the planned commissioning of the first starting complex of the plant full production cycle lead-acid batteries for cars and trucks, buses and automotive vehicles with a capacity of one million batteries per year. Correspondents "of the morning" visited the construction site and inquired about the progress of work and learned about the current concerns of the specialists of the enterprise.
Source: Information portal of the Brest region Zarya
At the finish line
From afar the elegant facades of the plant give the impression of a solid and very modern enterprises only production area which occupies more than 10 thousand square meters. Builders contractor — Brest UE "Alvor-Bel" — finished the flooring in the industrial building, installation of internal partitions, at the final stage of finishing work. And the outside is in full swing landscaping: somewhere green lawns, the remaining area is laid with paving tiles, using 3D fence see everything that is happening on site. There are a part of technological equipment, installation of which is scheduled to begin this week.
Chief engineer of LLC "IPower", Sergey Dubnovitsky holds for us a tour:
On the first floor of the administration building located changing rooms for staff, showers, Laundry. Workers will leave the clothes in the locker room, through a shower, dress in overalls and only after that go into the production area. After working a shift, the same way, through showers will follow back. Overalls will be washed daily. That is, home production the people will not carry even a speck of dust.
Heat ABK is a compact gas boiler, industrial building — heated ventilation with gas burners.
In the shop of forming a battery on the floor is coated with polymer coating, completes the installation of ventilation systems. Stock has already taken its place the loaders, to work they like: leveler ramp equipped platforms. Began the equipment of the laboratories — chemical, production, whichXia testing of batteries for compliance with regulatory documentation, and industrial sanitation. In a separate room connecting to the mains the ten chargers of the Italian company SOVEMA. The property has a carport for household wastes, to lead a special area, where they will accumulate up to a transport unit and send for recycling.
Suppliers chose sensitive
However, to catch Sergei Dubrovinskogo in Brest today is almost impossible: foreign travel smoothly flow into one another — the factory supplied technological equipment, which the representatives of IPower LLC go take them personally, to test with the production of trial product samples. By mid-September, the facility will be delivered 90 percent of the machines.
— Installation of equipment is planned to finish in October, to be tested both individually and in combination — and in early November to begin pre-commissioning activities, which will be assembled pilot batch of batteries. Acceptance will provide the Commission composed of representatives of public authorities and all relevant services, — says Sergey. — The choice of equipment manufacturers we approached a very sensitive — based on our own experience of such partnerships, as well as on the experience of similar plants that had attended themselves before starting the design of your company in Poland, Italy, Germany, Spain, Portugal, Turkey, Russia. Interested in the opinion of producers, techies. This allowed us to narrow the range of potential suppliers and to focus exclusively on high-quality machines. We stillosdem the first enterprise in the country, and I want to make it the most modern and safe not only in Belarus but also in Europe, to equip with what is called the latest technology. I think this will be possible because the equipment 2018 release, with all the innovations that are constantly making manufacturers.
On arms take low-waste technologies and high-performance automated and robotized technological equipment made by European and Korean firms. All of our technical requirements expanded metal production line gratings of the French company Roche, a recognized leader among suppliers to the EU countries and Russia. Danish firm Accurate Product she produces high quality equipment, and is the official dealer in Europe and Russia South Korean company Moojin, producing very high quality equipment for battery production, which for several decades has been successfully used at enterprises all over the world. It will put us a line pastanesi. From these same manufacturers will arrive composite Assembly line, which will add Italian high-end appliances LaPneumatica. Italian production companies, OMI and SOVEMA — set fill and correction of the electrolyte level in the battery, water baths and equipment for charging.
Very effective washing installation, made in accordance with our technical jobs Russian company ekofil'tr capable of filtering the air almost absolutely pure at 99.9 percent. Fully automated equipment complex for cleaning of sewage Ukrainian producer Ecosoft allows almost the same degree of cleaning and the water. But, I want to note that the water which comes into contact with lead, for thoserritory our company does not fall — it will be reused in the production process.
Not only in terms of production, but also from the point of view of ecology we want to be leaders and to show how there must be established and the level of organization of labor protection and environmental aspects. At the company where these issues are different, I wouldn't have come.
Installation and commissioning of equipment will produce suppliers. They together with our experts, who have rich experience in battery production, train new employees. It is planned that at the first stage the state will consist of 138 people. Today a lot of applications from people who Express just has a huge desire to work in our company, come personally for an interview and send their resume via e-mail.
Attracted the current level
Deputy chief technologist of factory "IPower" Alexander Romensky to Brest arrived from Dnepropetrovsk. Over 25 years ago as a young specialist after graduation he was on the construction of the first Ukrainian factory producing batteries Ista, then worked in a more substantial battery company Westa, which produces annually more than seven million batteries.
— Kind of activity I was looking through the news in this industry and in September 2015 in one of the Russian Internet portals came across information about the intention of the government to establish near Brest full production cycle batteries, — Alexander remembers. The second the news came in may next year, and it became clear that this is not some long-term plans, and the immediate prospect, — referred to in the report was about the selection of the plot in the free economic zone "Brest". The future of the company was interested in modern equipment, new technologies.
The establishment of branches in Ukraine as a specialist, I have observed since 1993. But to see something totally new in this field then go to work on a brand new venture. In short, the desire for professional growth, desire to touch own hands today's achievements and led me to the plant", IPower".
The need for rechargeable batteries has every country. And not only for vehicles in private use, and also of ambulances, emergency, police, armed forces. Do not forget about the domestic manufacturers of trucks and tractors. Having their own battery manufacturer, you can, at least, guaranteed to meet the needs of emergency services, services related to the security of the country. That is, have in this respect, shall we say, strong rear.
In our enterprise technology will be organized on world level. Over the past 25 years, she has leaped forward with the point of view of intensity of work has increased productivity, the precision of parts production, and in terms of environmental safety. If in the 90-ies of the electrodes of the batteries made from alloy, which includes the well-known poison arsenic, selenium, today this applies to a lead-calcium alloy. Besides eliminated a casting process collector. Before the operator stood at the machine with a separate little form that was filled alloy, checked the quality of the grid, one after the other they moved along the transportYeru, and chopped off the runner part is returned to the boiler, were the constant evaporation. Now one line replace 16 machines, and the operator is only involved in its set up.
Prepared alloy ingots we will supply plant Belinvesttorg-Splav. In the boilers are expected to maintain the temperature of the melt at the minimum level only necessary to move the pig in a liquid state. Alloy pump will be supplied through a closed heated tube where its temperature will reach about 450 degrees and immediately go into the wheel mold to cool. The temperature is selected in such a way as to eliminate the evaporation of lead and the formation of aerosols in the air basin workshop. And the extra energy we do not need.
Then on the rolling mill from the alloy ribbon is formed, it is wound into coils and supplied to the production of electrodes — lattices, which spread the paste. Equipment company Roche is fully automated, the task of the operator to bring up a new pallet with the tape. He didn't even have to fill the tape in the car — there is a special device.
The base paste for the plates is lead powder which we get in the mills. The paste composition includes demineralized water, sulfuric acid and additives that determine the characteristics of the paste. All equipment for preparation of this compound is sealed, all components come on closed thoroughfares: liquid — pipelines, powder — screw systems. They are also closed and work under pressure slightly below atmospheric so that in the event of any leakage of air will flow from the premises of the shop inside the system, and ;not Vice versa. Thus the penetration of lead in the atmosphere of the shop is eliminated entirely.
The most automated and line pastanesi. The old enterprises of Russia and Ukraine at the stage of discharge of the plates people are involved, we have the same pallets they will supply robotics, etc. The person with lead does not actually contact here.
On the Assembly line manual labor is also minimal — there is an operator only sets the plate of opposite sign in the cassettes and rolls of separator tapes. Further automation is valid for a given program. The output from the Assembly line assembled and tested the battery as well automatically, the conveyor on the machine, where the pouring sulfuric acid solution. This solution is also closed highways comes from the warehouse storage of the electrolyte. Then flooded batteries are loaded into tubs where will be the formation of the charge. Bath filled with water, which in the process will drain from the battery heat that ensures safety in the event of short circuits inside the battery (in the old days, charging of batteries was performed on the air).
Here also almost all makes smart tech — manual workers only connect the batteries to each other jumpers in the charging circuit, and installed in the fill hole special plugs, which prevent aerosols of the acid to evaporate into the closed cavity of the tub. This reduces the cost of the enterprise as on the materials used in the manufacture of batteries, and the neutralization of industrial effluents coming from the scrubber is designed to clean the air and installed directly in the production areas. The ventilation system is equipped with sensors of the hydrogen concentration, and if it reaches crucialOh value, the charge process stops automatically and increases the capacity of the ventilation system.
Preference — techies
The same prospect — professional development for modern trade — led in the city over bug countryman and colleague Alexander Romensky Peter Dmitruk. Belarusian battery factory he is the chief of the production of electrode plates.
— People have the stereotype that battery manufacturing is extremely dangerous and dirty and the people working there, who has nothing to lose. Lead do not be afraid — the lead should be respected. In principle, gasoline is too dangerous: if you put a lighted match will explode, but at the same time without it will not go to the car. Electricity can kill, but disable someone's house light or switch on the production — the life will stop. Remove the battery from the car, mobile phone, laptop...
I started in the battery industry for more than 20 years ago a machinist mill one of the plants at home. He graduated from the University of chemical technology on speciality "Technical electrochemistry", defending the thesis "foundry electrodes and shop pastanesi capacity of one million batteries per year". Science plus practice is a great motivator. When you understand the processes that occur in the battery, how it works, what can cause inaccuracy or error, the matter is treated with due respect.
In my former plant in Dnipropetrovsk to Brest identical machines were employed four people, the line served only two. The task of the operator is reduced to the control settings and their adjustments on different hardware acupress-analysis by an operator with the interval from 15 minutes to two hours, every four hours — laboratory analysis. The rest is done by technology. The snap-in only new, high-tech. Sure, the products that will descend from the conveyor of the plant will be a cause for pride not only collective enterprises, but also the country.
People who come to trade will be to master a brand new industry, unique for Belarus specialty — nemanjica battery plates, machinist mill, furnace operator, prigotovila active masses. They will be trained directly by foreign specialists who will arrive for installation of equipment, well, we're here for that too delivered. In the recruitment of staff workshops preference will be given to ambitious and able to learn techies, those who are familiar with the computer, one working the head and hands. In Brest, I think there are enough people, and the shortage of staff, I am sure, will not occur.
Monitoring of internal and independent
To work in the factory, which has no analogues in the country, burned with desire and the Brest Marina Kravchuk, now a leading engineer on environmental protection. Behind — two degrees: chemist, biologist and environmental engineer with specialization "Industrial ecology and rational use of natural resources" and 12 years of experience in this field. The fact that environmentalist took to the workforce in the forefront, confirms the commitment to establish manufacturing as safe as possible — both for people and for the environment.
— Today, our plant meets all the requirements of the Belarusian legislation in the sphere of sanitary-and-epidemiologic wellbeing of the population and environment. My main task — compliance: control of production processes, the implementation of standards in the field of waste production, wastewater discharge, air emissions, and the provision of industrial ecological control at the enterprise.
The degree of impact on atmospheric air "IPower" refers to the fifth category of danger — the least dangerous. Three-stage gas purification system, which will be installed here, will clean the air almost completely — 99.9 percent. Wet cleaning of the air in kruberg will also reach a high degree — up to 96-97 percent.
Waste water that had contact with lead, having a local sewage treatment plant will be directed to municipal treatment facilities, where they will be cleaned to standards, the brestvodokanal had brought, and only after that will fall into natural water bodies. But most of the production waste water after passing through the local sewage treatment plant will be re-directed to production outside the enterprise it will not fall.
With regard to waste management prior to commissioning of the plant will be developed and agreed in the Committee of natural resources appropriate instruction. It will define the procedure for applying with all the waste that will have to be formed. Waste from cleaning of the administrative offices and production shops will go to the grave, all the rest — on the use and further processing.
In accordance with the project, the plant will be organized the monitoring of environment and security jobs. Once a quarter plan to control sources of air pollution, degree of purification of wastewater annually — the status of lands in the territory of the enterprise, regularly — polluted air and soil in the sanitary protection zone. Measurements will be engaged by accredited third party laboratory. In addition, will operate the laboratory and factory. For the internal control samples of wastewater are planning to take daily.
With start-up businesses will be held certification of workplaces and then monitored their safety in accordance with the current sanitary norms and rules. The responsible person will monitor the technical condition of both production and pollution control equipment, the treatment of waste in each production. In short, monitoring of environmental and sanitary-epidemiological pays a lot of attention.
The penalty area for innovation (portrait)
Talked correspondent of "Zarya" and with representatives of the FEZ "Brest". As noted by the head of the administration of Theodore Colony, the most important task of a free economic zone is the creation and development of industries based on advanced technologies; new businesses must ensure the production of competitive products that are in demand both in the domestic and foreign markets.
More than 20 years of FEZ "Brest" is an attractive place for doing business, the implementation of investment projects with participation of foreign capital. Today the property includes 77 companies that provide 22 thousand jobs, about 30 percent of the export potential of the region and half of the industrial production of Brest.
For the effective functioning of the enterprises-residents the necessary infrastructure — emphasizes Fedor, Colony. Is electricity, gas, water, sewer, communication lines, driveways, and otherie elements. All these requirements are fully consistent with industrial site in the district of Brest airport. Today it is the most prospective and attractive for new industries.
In the existing industrial zone already operate 12 businesses that were created with participation of investors from UK, Germany, Italy, Israel, Poland, Russia. The enterprises-residents produce a variety of products, including led strip, lighting, thermal insulation coating for refrigeration and polyurethane foam cleaner, special formulations for the thermal, hydro and sound insulation, paints, varnishes, enamels, dry mixes, products from polyvinyl chloride. More than 110 hectares of vacant space with the engineering infrastructure are waiting for their investors.
Highly attractive investment platform, "Airport" is provided by and at the expense of high standards in the sphere of ecology and protection of the environment. Monitoring the environmental situation is carried out by ecological services and sanitary control of the Brest region in accordance with established regulations.
To organize independent monitoring and analysis of the impact on the environment of the enterprises-residents of FEZ administration this year signed an agreement with Polesski agrarian-ecological Institute of the National Academy of Sciences of Belarus that will perform scientific-research work "the Formation of a system of monitoring the content of heavy metals in environmental objects in the area site "the Airport" FEZ "Brest" and adjacent territories and the assessment of the level of their accumulation in soil, vegetation and snow cover".
Scientific institution will create on the ground monitoring network, includingconsisting of approximately 60 points for sampling soil, vegetation, snow cover. With 15 control points located in the area "Airport" and 45 in the surrounding areas, including settlements of Thelma, Stimulo, Sebrin, Bulkowo. A study of the quality of the samples and the determination of the content in selected samples of lead, zinc, cadmium, copper will be carried out in accredited laboratories.
Already tested the samples, which will be the starting point for subsequent monitoring and evaluation of the environmental situation around industrial areas. Such studies will be scheduled on a regular basis. The monitoring results will be reported to the public through the media.
Author
Irina ORLOVA