TEST
Is it easy to liquidate an old plant?
Development of the North began in the Soviet times when mining and processing operations were built. Since then, many facilities have grown irreversibly obsolete, and it is too complicated, expensive and time-consuming to upgrade them. And today, the dull factory ruins are no feast for the eye.
However, the reason for tearing down the legendary Nickel Plant, which gave rise to Norilsk, was different. Read the article to find out what followed this decision.
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The photo shows the last smelting operation performed at the Nickel Plant in Norilsk. When do you think the first smelting took place?
The first smelting product was obtained on 23 February 1942 in the factory building still under construction that had only been commenced at the outbreak of the Great Patriotic War. Russia was in critical need of nickel for armor steel, so the plant was completed in record time and under the most severe conditions.
As workers recall, the inaugural smelting took place at -47℃, both indoors and outdoors. To get the appropriate temperature in the furnace, they tossed coke and firewood into the furnace until late at night. It was only at 2 o’clock in the morning, that the molten ore from the first bucket started pouring into the molds.
Up until Victory Day, the Nickel Plant was the main supplier of the metal to support the military; after the war, it became the largest metal producer. Its smelter was shut down permanently on 27 June 2016.
As workers recall, the inaugural smelting took place at -47℃, both indoors and outdoors. To get the appropriate temperature in the furnace, they tossed coke and firewood into the furnace until late at night. It was only at 2 o’clock in the morning, that the molten ore from the first bucket started pouring into the molds.
Up until Victory Day, the Nickel Plant was the main supplier of the metal to support the military; after the war, it became the largest metal producer. Its smelter was shut down permanently on 27 June 2016.
The first smelting product was obtained on 23 February 1942 in the factory building still under construction that had only been commenced at the outbreak of the Great Patriotic War. Russia was in critical need of nickel for armor steel, so the plant was completed in record time and under the most severe conditions.
As workers recall, the inaugural smelting took place at -47℃, both indoors and outdoors. To get the appropriate temperature in the furnace, they tossed coke and firewood into the furnace until late at night. It was only at 2 o’clock in the morning, that the molten ore from the first bucket started pouring into the molds.
Up until Victory Day, the Nickel Plant was the main supplier of the metal to support the military; after the war, it became the largest metal producer. Its smelter was shut down permanently on 27 June 2016.
As workers recall, the inaugural smelting took place at -47℃, both indoors and outdoors. To get the appropriate temperature in the furnace, they tossed coke and firewood into the furnace until late at night. It was only at 2 o’clock in the morning, that the molten ore from the first bucket started pouring into the molds.
Up until Victory Day, the Nickel Plant was the main supplier of the metal to support the military; after the war, it became the largest metal producer. Its smelter was shut down permanently on 27 June 2016.
The first smelting product was obtained on 23 February 1942 in the factory building still under construction that had only been commenced at the outbreak of the Great Patriotic War. Russia was in critical need of nickel for armor steel, so the plant was completed in record time and under the most severe conditions.
As workers recall, the inaugural smelting took place at -47℃, both indoors and outdoors. To get the appropriate temperature in the furnace, they tossed coke and firewood into the furnace until late at night. It was only at 2 o’clock in the morning, that the molten ore from the first bucket started pouring into the molds.
Up until Victory Day, the Nickel Plant was the main supplier of the metal to support the military; after the war, it became the largest metal producer. Its smelter was shut down permanently on 27 June 2016.
As workers recall, the inaugural smelting took place at -47℃, both indoors and outdoors. To get the appropriate temperature in the furnace, they tossed coke and firewood into the furnace until late at night. It was only at 2 o’clock in the morning, that the molten ore from the first bucket started pouring into the molds.
Up until Victory Day, the Nickel Plant was the main supplier of the metal to support the military; after the war, it became the largest metal producer. Its smelter was shut down permanently on 27 June 2016.
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What was the main cause of plant shutdown?
The Nickel Plant was located in the center of Norilsk and annually emitted 400 thousand tons of sulfur dioxide. The people who worked in or near the plant’s offices remember never opening the windows. At the end of a working day, they waited for their commute on the first floor of the building and ran out only when the bus arrived. It was that difficult to breathe outside.
With the Nickel Plant shut down, atmospheric emissions of sulfur dioxide decreased by 380 thousand tons. Two wastewater outlets and 1.5 mtpa of waste have been eliminated.
Both air and soil quality has improved. Vegetation in the city has become more exuberant and intense. Today, spruce and larch trees are being planted in Norilsk, and scientists have seen nests of wild birds in the city. While the plant was running, trees did not take root and birds did not arrive.
With the Nickel Plant shut down, atmospheric emissions of sulfur dioxide decreased by 380 thousand tons. Two wastewater outlets and 1.5 mtpa of waste have been eliminated.
Both air and soil quality has improved. Vegetation in the city has become more exuberant and intense. Today, spruce and larch trees are being planted in Norilsk, and scientists have seen nests of wild birds in the city. While the plant was running, trees did not take root and birds did not arrive.
The Nickel Plant was located in the center of Norilsk and annually emitted 400 thousand tons of sulfur dioxide. The people who worked in or near the plant’s offices remember never opening the windows. At the end of a working day, they waited for their commute on the first floor of the building and ran out only when the bus arrived. It was that difficult to breathe outside.
With the Nickel Plant shut down, atmospheric emissions of sulfur dioxide decreased by 380 thousand tons. Two wastewater outlets and 1.5 mtpa of waste have been eliminated.
Both air and soil quality has improved. Vegetation in the city has become more exuberant and intense. Today, spruce and larch trees are being planted in Norilsk, and scientists have seen nests of wild birds in the city. While the plant was running, trees did not take root and birds did not arrive.
With the Nickel Plant shut down, atmospheric emissions of sulfur dioxide decreased by 380 thousand tons. Two wastewater outlets and 1.5 mtpa of waste have been eliminated.
Both air and soil quality has improved. Vegetation in the city has become more exuberant and intense. Today, spruce and larch trees are being planted in Norilsk, and scientists have seen nests of wild birds in the city. While the plant was running, trees did not take root and birds did not arrive.
The Nickel Plant was located in the center of Norilsk and annually emitted 400 thousand tons of sulfur dioxide. The people who worked in or near the plant’s offices remember never opening the windows. At the end of a working day, they waited for their commute on the first floor of the building and ran out only when the bus arrived. It was that difficult to breathe outside.
With the Nickel Plant shut down, atmospheric emissions of sulfur dioxide decreased by 380 thousand tons. Two wastewater outlets and 1.5 mtpa of waste have been eliminated.
Both air and soil quality has improved. Vegetation in the city has become more exuberant and intense. Today, spruce and larch trees are being planted in Norilsk, and scientists have seen nests of wild birds in the city. While the plant was running, trees did not take root and birds did not arrive.
With the Nickel Plant shut down, atmospheric emissions of sulfur dioxide decreased by 380 thousand tons. Two wastewater outlets and 1.5 mtpa of waste have been eliminated.
Both air and soil quality has improved. Vegetation in the city has become more exuberant and intense. Today, spruce and larch trees are being planted in Norilsk, and scientists have seen nests of wild birds in the city. While the plant was running, trees did not take root and birds did not arrive.
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Which plant was upgraded to ‘replace’ the liquidated operations?
The Nadezhda Smelter has been processing all of the nickel-containing feed mined by the company’s Polar Division since the Nickel Plant closure. The Nadezhda Smelter is located outside the city boundaries, and its stacks are 20 m higher than those operated by the Nickel Plant.
It took three years to upgrade the plant to enable processing of added volumes; during the same time, the Nickel Plant was being shut down. More equipment was supplied for the smelting shops; a new filtration and drying section for nickel concentrate was built in a year. As a result, smelting capacity increased from 1.85 to 2.4 million tons of concentrate per year.
To mitigate its environmental footprint, the Sulfur Program was launched in October 2023. Since then, emissions have decreased by 221 thousand tons.
The project to shut down the Nickel Plant (excluding demolition costs) and upgrade the Nadezhda Smelter was worth a total of RUB 11 bn.
It took three years to upgrade the plant to enable processing of added volumes; during the same time, the Nickel Plant was being shut down. More equipment was supplied for the smelting shops; a new filtration and drying section for nickel concentrate was built in a year. As a result, smelting capacity increased from 1.85 to 2.4 million tons of concentrate per year.
To mitigate its environmental footprint, the Sulfur Program was launched in October 2023. Since then, emissions have decreased by 221 thousand tons.
The project to shut down the Nickel Plant (excluding demolition costs) and upgrade the Nadezhda Smelter was worth a total of RUB 11 bn.
The Nadezhda Smelter has been processing all of the nickel-containing feed mined by the company’s Polar Division since the Nickel Plant closure. The Nadezhda Smelter is located outside the city boundaries, and its stacks are 20 m higher than those operated by the Nickel Plant.
It took three years to upgrade the plant to enable processing of added volumes; during the same time, the Nickel Plant was being shut down. More equipment was supplied for the smelting shops; a new filtration and drying section for nickel concentrate was built in a year. As a result, smelting capacity increased from 1.85 to 2.4 million tons of concentrate per year.
To mitigate its environmental footprint, the Sulfur Program was launched in October 2023. Since then, emissions have decreased by 221 thousand tons.
The project to shut down the Nickel Plant (excluding demolition costs) and upgrade the Nadezhda Smelter was worth a total of RUB 11 bn.
It took three years to upgrade the plant to enable processing of added volumes; during the same time, the Nickel Plant was being shut down. More equipment was supplied for the smelting shops; a new filtration and drying section for nickel concentrate was built in a year. As a result, smelting capacity increased from 1.85 to 2.4 million tons of concentrate per year.
To mitigate its environmental footprint, the Sulfur Program was launched in October 2023. Since then, emissions have decreased by 221 thousand tons.
The project to shut down the Nickel Plant (excluding demolition costs) and upgrade the Nadezhda Smelter was worth a total of RUB 11 bn.
The Nadezhda Smelter has been processing all of the nickel-containing feed mined by the company’s Polar Division since the Nickel Plant closure. The Nadezhda Smelter is located outside the city boundaries, and its stacks are 20 m higher than those operated by the Nickel Plant.
It took three years to upgrade the plant to enable processing of added volumes; during the same time, the Nickel Plant was being shut down. More equipment was supplied for the smelting shops; a new filtration and drying section for nickel concentrate was built in a year. As a result, smelting capacity increased from 1.85 to 2.4 million tons of concentrate per year.
To mitigate its environmental footprint, the Sulfur Program was launched in October 2023. Since then, emissions have decreased by 221 thousand tons.
The project to shut down the Nickel Plant (excluding demolition costs) and upgrade the Nadezhda Smelter was worth a total of RUB 11 bn.
It took three years to upgrade the plant to enable processing of added volumes; during the same time, the Nickel Plant was being shut down. More equipment was supplied for the smelting shops; a new filtration and drying section for nickel concentrate was built in a year. As a result, smelting capacity increased from 1.85 to 2.4 million tons of concentrate per year.
To mitigate its environmental footprint, the Sulfur Program was launched in October 2023. Since then, emissions have decreased by 221 thousand tons.
The project to shut down the Nickel Plant (excluding demolition costs) and upgrade the Nadezhda Smelter was worth a total of RUB 11 bn.
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The decision to completely dismantle the plant was unprecedented, as it is twice as large as the Vatican City. What machinery was used in complex activities?
Demolition excavators are used in complex and hazardous environments. Nobody in Russia has performed anything this big and complex. To compare: the area of the Nickel Plant is 80 hectares, and 44 hectares of Vatican City. The plant accommodated ca. 200 buildings and structures and five shops.
Some buildings were found to be in emergency condition. In particular, the sintering shop. It was unsafe to allow people to work in it. The solution was found in the 75-ton Liebherr demolition excavators with a 25.6-34 meter reach. These machines can work in a 360 degree radius. These excavators can operate in any direction at full reach without losing stability. It is an essential feature in the complex terrain of the Nickel Plant and strong Arctic winds. Electronics control the operator’s actions and ensure safety.
The Nickel Plant demolition began in 2020 and will be completed in 2025. The target cost of the work is RUB 5 bn.
Some buildings were found to be in emergency condition. In particular, the sintering shop. It was unsafe to allow people to work in it. The solution was found in the 75-ton Liebherr demolition excavators with a 25.6-34 meter reach. These machines can work in a 360 degree radius. These excavators can operate in any direction at full reach without losing stability. It is an essential feature in the complex terrain of the Nickel Plant and strong Arctic winds. Electronics control the operator’s actions and ensure safety.
The Nickel Plant demolition began in 2020 and will be completed in 2025. The target cost of the work is RUB 5 bn.
Demolition excavators are used in complex and hazardous environments. Nobody in Russia has performed anything this big and complex. To compare: the area of the Nickel Plant is 80 hectares, and 44 hectares of Vatican City. The plant accommodated ca. 200 buildings and structures and five shops.
Some buildings were found to be in emergency condition. In particular, the sintering shop. It was unsafe to allow people to work in it. The solution was found in the 75-ton Liebherr demolition excavators with a 25.6-34 meter reach. These machines can work in a 360 degree radius. These excavators can operate in any direction at full reach without losing stability. It is an essential feature in the complex terrain of the Nickel Plant and strong Arctic winds. Electronics control the operator’s actions and ensure safety.
The Nickel Plant demolition began in 2020 and will be completed in 2025. The target cost of the work is RUB 5 bn.
Some buildings were found to be in emergency condition. In particular, the sintering shop. It was unsafe to allow people to work in it. The solution was found in the 75-ton Liebherr demolition excavators with a 25.6-34 meter reach. These machines can work in a 360 degree radius. These excavators can operate in any direction at full reach without losing stability. It is an essential feature in the complex terrain of the Nickel Plant and strong Arctic winds. Electronics control the operator’s actions and ensure safety.
The Nickel Plant demolition began in 2020 and will be completed in 2025. The target cost of the work is RUB 5 bn.
Demolition excavators are used in complex and hazardous environments. Nobody in Russia has performed anything this big and complex. To compare: the area of the Nickel Plant is 80 hectares, and 44 hectares of Vatican City. The plant accommodated ca. 200 buildings and structures and five shops.
Some buildings were found to be in emergency condition. In particular, the sintering shop. It was unsafe to allow people to work in it. The solution was found in the 75-ton Liebherr demolition excavators with a 25.6-34 meter reach. These machines can work in a 360 degree radius. These excavators can operate in any direction at full reach without losing stability. It is an essential feature in the complex terrain of the Nickel Plant and strong Arctic winds. Electronics control the operator’s actions and ensure safety.
The Nickel Plant demolition began in 2020 and will be completed in 2025. The target cost of the work is RUB 5 bn.
Some buildings were found to be in emergency condition. In particular, the sintering shop. It was unsafe to allow people to work in it. The solution was found in the 75-ton Liebherr demolition excavators with a 25.6-34 meter reach. These machines can work in a 360 degree radius. These excavators can operate in any direction at full reach without losing stability. It is an essential feature in the complex terrain of the Nickel Plant and strong Arctic winds. Electronics control the operator’s actions and ensure safety.
The Nickel Plant demolition began in 2020 and will be completed in 2025. The target cost of the work is RUB 5 bn.
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The plant stacks were not torn down but blasted. How long did blasting preparations take?
It takes six months to calculate the project, prepare the documentation, and obtain a blasting permit. In addition, the cable lines, pipelines and other infrastructure facilities in place need to be moved away from the blasting site.
Each of the five Nickel Plant stacks is 150 - 180 meters high and weighs up to 13 thousand tons.
Demolition should be performed by directional blasting to ensure a directed fall of the stack. For this purpose, holes were drilled at the base of the stacks to precisely calculated depths at specific distance from each other to position the explosive. The weight of the explosive was also calculated to the highest precision possible. After all, the stack should fall, and not shatter into pieces in all directions.
Thorough preparations have ensured a smooth stack demolition process. And it looked spectacular!
Each of the five Nickel Plant stacks is 150 - 180 meters high and weighs up to 13 thousand tons.
Demolition should be performed by directional blasting to ensure a directed fall of the stack. For this purpose, holes were drilled at the base of the stacks to precisely calculated depths at specific distance from each other to position the explosive. The weight of the explosive was also calculated to the highest precision possible. After all, the stack should fall, and not shatter into pieces in all directions.
Thorough preparations have ensured a smooth stack demolition process. And it looked spectacular!
It takes six months to calculate the project, prepare the documentation, and obtain a blasting permit. In addition, the cable lines, pipelines and other infrastructure facilities in place need to be moved away from the blasting site.
Each of the five Nickel Plant stacks is 150 - 180 meters high and weighs up to 13 thousand tons.
Demolition should be performed by directional blasting to ensure a directed fall of the stack. For this purpose, holes were drilled at the base of the stacks to precisely calculated depths at specific distance from each other to position the explosive. The weight of the explosive was also calculated to the highest precision possible. After all, the stack should fall, and not shatter into pieces in all directions.
Thorough preparations have ensured a smooth stack demolition process. And it looked spectacular!
Each of the five Nickel Plant stacks is 150 - 180 meters high and weighs up to 13 thousand tons.
Demolition should be performed by directional blasting to ensure a directed fall of the stack. For this purpose, holes were drilled at the base of the stacks to precisely calculated depths at specific distance from each other to position the explosive. The weight of the explosive was also calculated to the highest precision possible. After all, the stack should fall, and not shatter into pieces in all directions.
Thorough preparations have ensured a smooth stack demolition process. And it looked spectacular!
It takes six months to calculate the project, prepare the documentation, and obtain a blasting permit. In addition, the cable lines, pipelines and other infrastructure facilities in place need to be moved away from the blasting site.
Each of the five Nickel Plant stacks is 150 - 180 meters high and weighs up to 13 thousand tons.
Demolition should be performed by directional blasting to ensure a directed fall of the stack. For this purpose, holes were drilled at the base of the stacks to precisely calculated depths at specific distance from each other to position the explosive. The weight of the explosive was also calculated to the highest precision possible. After all, the stack should fall, and not shatter into pieces in all directions.
Thorough preparations have ensured a smooth stack demolition process. And it looked spectacular!
Each of the five Nickel Plant stacks is 150 - 180 meters high and weighs up to 13 thousand tons.
Demolition should be performed by directional blasting to ensure a directed fall of the stack. For this purpose, holes were drilled at the base of the stacks to precisely calculated depths at specific distance from each other to position the explosive. The weight of the explosive was also calculated to the highest precision possible. After all, the stack should fall, and not shatter into pieces in all directions.
Thorough preparations have ensured a smooth stack demolition process. And it looked spectacular!
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Where did most of the employees find a job after the Nickel Plant closure?
The Nickel Plant employed 2,307 people. They were surveyed to find out how many would want to move to the mainland. At least 80% were expected to be willing to relocate. However, 85% of employees opted to stay in Norilsk.
To provide employment for them, a special program was developed. 1,682 people transferred to the production units of the Polar Division and subsidiaries, and approximately 1,000 workers got retrained for new roles and qualifications.
The Metallurgy Veteran program was developed for 560 people who chose to move to the mainland. Under this program, each worker, depending on the length of service, was paid 10 - 12 base salaries. The company also paid for cargo containers to the mainland in the amount that exceeded the contract-prescribed value.
For comparison: when the Baikalsk Pulp and Paper Mill closed down, only 494 out of 1.6 thousand people retained their jobs. The rest had to look for a job on their own.
To provide employment for them, a special program was developed. 1,682 people transferred to the production units of the Polar Division and subsidiaries, and approximately 1,000 workers got retrained for new roles and qualifications.
The Metallurgy Veteran program was developed for 560 people who chose to move to the mainland. Under this program, each worker, depending on the length of service, was paid 10 - 12 base salaries. The company also paid for cargo containers to the mainland in the amount that exceeded the contract-prescribed value.
For comparison: when the Baikalsk Pulp and Paper Mill closed down, only 494 out of 1.6 thousand people retained their jobs. The rest had to look for a job on their own.
The Nickel Plant employed 2,307 people. They were surveyed to find out how many would want to move to the mainland. At least 80% were expected to be willing to relocate. However, 85% of employees opted to stay in Norilsk.
To provide employment for them, a special program was developed. 1,682 people transferred to the production units of the Polar Division and subsidiaries, and approximately 1,000 workers got retrained for new roles and qualifications.
The Metallurgy Veteran program was developed for 560 people who chose to move to the mainland. Under this program, each worker, depending on the length of service, was paid 10 - 12 base salaries. The company also paid for cargo containers to the mainland in the amount that exceeded the contract-prescribed value.
For comparison: when the Baikalsk Pulp and Paper Mill closed down, only 494 out of 1.6 thousand people retained their jobs. The rest had to look for a job on their own.
To provide employment for them, a special program was developed. 1,682 people transferred to the production units of the Polar Division and subsidiaries, and approximately 1,000 workers got retrained for new roles and qualifications.
The Metallurgy Veteran program was developed for 560 people who chose to move to the mainland. Under this program, each worker, depending on the length of service, was paid 10 - 12 base salaries. The company also paid for cargo containers to the mainland in the amount that exceeded the contract-prescribed value.
For comparison: when the Baikalsk Pulp and Paper Mill closed down, only 494 out of 1.6 thousand people retained their jobs. The rest had to look for a job on their own.
The Nickel Plant employed 2,307 people. They were surveyed to find out how many would want to move to the mainland. At least 80% were expected to be willing to relocate. However, 85% of employees opted to stay in Norilsk.
To provide employment for them, a special program was developed. 1,682 people transferred to the production units of the Polar Division and subsidiaries, and approximately 1,000 workers got retrained for new roles and qualifications.
The Metallurgy Veteran program was developed for 560 people who chose to move to the mainland. Under this program, each worker, depending on the length of service, was paid 10 - 12 base salaries. The company also paid for cargo containers to the mainland in the amount that exceeded the contract-prescribed value.
For comparison: when the Baikalsk Pulp and Paper Mill closed down, only 494 out of 1.6 thousand people retained their jobs. The rest had to look for a job on their own.
To provide employment for them, a special program was developed. 1,682 people transferred to the production units of the Polar Division and subsidiaries, and approximately 1,000 workers got retrained for new roles and qualifications.
The Metallurgy Veteran program was developed for 560 people who chose to move to the mainland. Under this program, each worker, depending on the length of service, was paid 10 - 12 base salaries. The company also paid for cargo containers to the mainland in the amount that exceeded the contract-prescribed value.
For comparison: when the Baikalsk Pulp and Paper Mill closed down, only 494 out of 1.6 thousand people retained their jobs. The rest had to look for a job on their own.
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You must have never dealt with a plant closure or you are totally against the shutdown of any production.
However, modern operations are much more efficient than obsolete capacities. Read about post-closure upgrade of production operations.
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You have a pretty good idea of how hard it is to close down large-scale operations and account for the interests of employees, local residents and the business.
To learn more about the effective approach to managing a large business, read an article about changes in Norilsk.
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Great job! You must have had certain experience with the closure of large production facilities.
We hope it was just as positive as in the case with the Nickel Plant. Read about the future of Nornickel’s Copper Plant and the drivers behind it.
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Photos by Nornickel, Design Projects/Shutterstock/FOTODOM
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