environmental impact report - world bank · project of meishan iron and steel company, baosteel...
TRANSCRIPT
Shanghai Meishan Iron and Steel Co., Ltd. 1# and 2# Coke Ovens Relocated Overhaul System Project
Environmental Impact Report
(Simplified Version for World Bank)
Shanghai Meishan Iron and Steel Co., Ltd. Oct. 2005
E1700v 1
Pub
lic D
iscl
osur
e A
utho
rized
Pub
lic D
iscl
osur
e A
utho
rized
Pub
lic D
iscl
osur
e A
utho
rized
Pub
lic D
iscl
osur
e A
utho
rized
Pub
lic D
iscl
osur
e A
utho
rized
Pub
lic D
iscl
osur
e A
utho
rized
Pub
lic D
iscl
osur
e A
utho
rized
Pub
lic D
iscl
osur
e A
utho
rized
Project undertaken by: Nanjing Municipal Environmental Protection Scientific Research Institute
Certificate Grade: Grade A
Certificate No.: Guo Huan Ping Zheng A No. 1907
Director: Feng Xiaoyi (EA) Post Certificate No. A19070002
Responsible deputy director: Lu Ningchuan (EA) Post Certificate No. A19070004
Chief engineer: Lu Zhangyue (EA) Post Certificate No. A19070001
Project responsible persons: Gao Xiaojie (EA) Senior Post Certificate No. JA1907003
Dai Fengsheng (EA) Senior Post Certificate No. JA1907002
Drafting personnel:
Name Certificate No. Chapter Signature
Dai Fengsheng (EA) Post Certificate No. JA1907002 2, 5, 9, 12
Jiang Leping (EA) Post Certificate No. A19070013 6, 7, 8
Liu Bihu (EA) Post Certificate No. A19070006 11, 13, 14
Ji Zhengyu (EA) Post Certificate No. A19070019 7, 8, 10
Gao Xiaojie (EA) Post Certificate No. JA1907003 1, 3, 4, 13, 15
Reviewed by: Liu Chunyang (EA) Senior Post Certificate No.HA1907002
Verified by: Lu Ningchuan (EA) Post Certificate No. A19070004
Approved by: Feng Xiaoyi (EA) Post Certificate No. A19070002
Table of Contents
1. General .................................................................................................................................. 1
1.1 Foreword.......................................................................................................................... 1
1.2 Basis of preparation ......................................................................................................... 2
1.3 Principles for assessment work........................................................................................ 4
1.4 Technical line for the assessment .................................................................................... 4
1.5 Emphasis of assessment and classes of assessment work ............................................... 6
1.6 Scope of assessment ........................................................................................................ 6
1.7 Determination of assessment factors ............................................................................... 6
2. General environmental conditions of and environmental protection targets in the surrounding areas of the project............................................................................................. 8
2.1 Briefs of natural environment.......................................................................................... 8
2.2 Social environmental conditions ..................................................................................... 9
2.3 Regional social development planning............................................................................ 9
2.4 Environmental function zoning ..................................................................................... 18
2.5 Assessment standards .................................................................................................... 18
2.6 Targets for pollution control and environmental protection .......................................... 21
3 Engineering analysis ........................................................................................................ 23
3.1 Status of current enterprises and discharge from pollution sources .............................. 23
3.2 Overview of the construction project ............................................................................ 28
3.3 Engineering analysis of the construction project........................................................... 31
4. Assessment of pollution prevention and control measures ............................................. 59
4.1 Waste gas treatment measures ....................................................................................... 59
4.2 Control and rectification measures for waste water ...................................................... 63
4.3 Noise.............................................................................................................................. 65
4.4 Solid wastes ................................................................................................................... 65
4.5 Hygienic protection distance ......................................................................................... 66
4.6 Normalized setup of discharge ports ............................................................................. 66
4.7 Construction schedule arrangement for environmental protection control and rectification setups and estimation of environmental protection investment ...................... 67
5. Clean production and circulating economy analysis....................................................... 68
5.1 Analysis for clean production ........................................................................................ 68
5.2 Circulating economy analysis........................................................................................ 86
6 Investigation and assessment of regional pollution sources ............................................ 87
6.1 Investigation and assessment of atmospheric pollution source situation ...................... 87
6.2 Wastewater pollution source investigation and assessment........................................... 89
7 Investigation and assessment of environment quality present situation ........................ 91
7.1 Investigation and assessment of atmospheric environment quality present situation ... 91
7.2 Investigation and assessment of surface water environment quality situation.............. 97
7.3 Investigation and assessment of acoustic environment quality situation .................... 101
8 Prediction and assessment of environmental impact ..................................................... 109
8.1 Atmospheric environmental impact assessment .......................................................... 109
8.2 Analysis on environmental impact of surface water.................................................... 111
8.3 Environmental noise impact assessment ..................................................................... 112
8.4 Analysis on environmental impact of solid waste ....................................................... 117
9. Total amount control analysis for pollutant emission ................................................... 118
9.1 Purpose of total amount control................................................................................... 118
9.2 Determination of total amount control factors ............................................................ 118
9.3 Pollutant emission from project................................................................................... 118
9.4 Change in total pollutant emission amount after the implementation of the project... 119
9.5 Analysis and balance plan for total amount control on pollutant emission for project119
10 Analysis of environmental impact during construction period................................... 121
10.1 Analysis of atmospheric environmental impact during construction period ............. 121
10.2 Analysis of construction acoustic environmental impact .......................................... 122
10.3 Analysis of water environmental impact during construction period........................ 122
10.4 Analysis of environmental impact of construction waste.......................................... 123
10.5 Environment management during construction period ............................................. 123
10.6 Construction Schedule............................................................................................... 124
11 Public Poll......................................................................................................................... 125
11.1 Purpose and function of public poll........................................................................... 125
11.2 Investigation method, items and the people to be visited ....................................... 125
11.3 Result of the public poll............................................................................................. 126
12 Analysis of reasonability of the project site selection................................................... 129
12.1 Analysis of conformability of the project site selection with the planning ............... 129
12.2 Analysis of compatibility of the project with environmental planning .................. 130
12.3 Analysis of conditions of site selection ..................................................................... 130
12.4 Analysis of health protection distance ....................................................................... 131
12.5 Influence on the surrounding environment quality after completion of the project131
13. Environmental Risk Evaluation.................................................................................... 132
13.1 Accidental Pollution Analysis.................................................................................... 132
13.2 Accidental Risk Evaluation ....................................................................................... 135
13.3 Relief Solutions and Emergency Preventions for Environment Risk Accidents....... 137
13.4 Accidental Discharge and Countermeasures ............................................................. 141
13.5 Integrated Measures against Environmental Risks.................................................... 142
14 Environmental monitoring and EP Management plan................................................ 144
14.1 Environmental monitoring......................................................................................... 144
14.2 Environmental management system and monitoring instrument .............................. 144
14.3 Suggestions for environmental management system................................................. 146
15. Analysis of economic profit and loss of environment.................................................. 147
15.1 Analysis of economic benefit .................................................................................... 147
15.2 Analysis of social benefit........................................................................................... 148
15.3 Analysis of profit and loss of environmental influence............................................. 148
16 Conclusion and suggestion.............................................................................................. 149
16.1 Conclusion ................................................................................................................. 149
16.2 Suggestions................................................................................................................ 152
Appendices
1
1. General
1.1 Foreword
In Shanghai Meishan Iron and Steel Co., Ltd., coke oven No. 1 was put into operation in 1970 and No. 2 coke oven was put into operation in 1971. Both coke ovens are of type 58-II in 65 ducts and have been operating for over 30 years. They are aged with backward technology, featuring high consumptions and unable to meet the modern environmental protection requirements; No. 3 coke oven is of type JNX43-58 in 65 ducts, and was put into operation in 1996.
Baosteel Chemical Meishan Branch is subordinated to Shanghai Baosteel Chemical Co., Ltd. under the Baosteel Group. The coal gas purifying system of Baosteel Chemical Meishan Branch is the associated production facilities of the 3 coke ovens of Meishan Iron and Steel Company, built in early 1970s. Due to the long history of the Branch, the gas purifying system equipment has become aged, with serious corrosion, backward in technology and low in automatic control level, resulting in many leaking points in the production area that are difficult to control. The existing facilities and production, equipment and environmental protection level cannot meet the daily increasing requirements in environmental protection.
To meet the requirements of modern environmental protection and the admitting conditions set by the state for coking industry, the Company has decided to perform relocated transformation for the three existing 65-duct coke ovens (the site being the newly requisisted land of Meishan Iron and Steel Company), and a new associated gas purifying workshop will also be built. It has been determined that the scale for relocated overhaul of 1# and 2# coke ovens will be 1 million t/a of coke, and the coke ovens will 2×55-duct type JN60−6 composite heating coke ovens, and production facilities and public auxiliary facilities for coal preparation, coke sieving, 1×140t/h dry coke quenching plant and gas purifying workshop will also be constructed. The coal purifying and chemical product recovering sections will be completed by Baosteel Chemical Meishan Branch (i.e., with the construction of the planned project of Meishan Iron and Steel Company, Baosteel Chemical will also construct new associated gas purifying facilities. By-products of tar oil and crude benzene will be processed by the existing plant of Baosteel Chemical Company).
The determination of production scale and selection of product plan for this project conform to the industrial policies of the state.
According to relevant provisions in “Environmental Impact Assessment Law of the People’s Republic of China” and “Environmental protection management decree for construction projects” (State Council Decree No. 98-253), the owner entity entrusted in Feb. 2005 the Nanjing Municipal Environmental Protection Scientific Research Institute to undertake the preparation of the environmental impact report for this project. After accepting this entrustment, we organized relevant technical personnel to conduct site survey and monitoring and analysis of surrounding environmental quality, and prepare this environmental impact report according to the characteristics of this project and relevant information about the natural environment and social and economic conditions of the locality where the project is
2
located. The extent and scope of impact of this project to the surrounding environment was predicted through the environmental impact assessment, and countermeasures for control of environmental pollution were proposed, to provide scientific basis for the engineering design and environmental management of the project.
1.2 Basis of preparation
1.2.1 Laws and regulations on environmental protection and relevant documents
(1) “Environmental Protection Law of the People's Republic of China”;
(2) “Water Pollution Prevention Law of the People's Republic of China”;
(3) “Atmospheric Pollution Prevention Law of the People's Republic of China”;
(4) “Solid Waste Pollution Environment Prevention Law of the People's Republic of China”;
(5) “Environmental Noise Pollution Prevention Law of the People's Republic of China”;
(6) “Environmental Impact Assessment Law of the People's Republic of China”;
(7) “Clean Production Promotion Law of the People's Republic of China”;
(8) “Environmental protection management decree for construction projects” (State Council Decree No. 98-253);
(9) Document of Environment Commission of Jiangsu Province [98] No. 1 “Some provisions on strengthening environmental protection management for construction projects”;
(10) “Tentative regulation on control of total amount of pollutant emission in Jiangsu Province” (Jiangsu Provincial Government Decree [1993] No. 38);
(11) “Circular on printing and distributing the ‘Management measures on pollutant emission port setup and normalized control and rectification in Jiangsu Province” (Su Huan Kong [97] No. 122);
(12) Document Su Zheng Fu (2003) No. 29 “Environmental function zoning for surface water in Jiangsu Province”;
(13) “Technical guideline for environmental impact assessment” HJ/T2.1~2.3-93 and HJ/T2.4-95;
(14) “Circular of opinions on strengthening the industrial water saving work” Document Guo Jing Mao Ziyuan [2000] No. 1015 from six commissions, ministries and bureaus of the state including State Commission of Economic Relations and Foreign Trade;
(15) “Some opinions on implementing clean production” Document [Huan Kong (1997) No. 0232];
(16) “Circular for relevant issues on further strengthening coordination of industrial policies and credit policies to control credit risks” Document Fagai Chanye [2004] No. 746 of the State Commission of Development and Reform, People’s Bank of China and China Banking Regulatory Commission;
(17) Circular from the National Environmental Protection Bureau Decree, State Commission
3
of Economic Relations and Foreign Trade and Ministry of Science and Technology on issuing “Pollution prevention and control technology policies for dangerous wastes”, Document Huan Fa [2001] No. 199;
(18) “Catalogue of major industries, products and technologies currently encouraged by the State” (2000 Revision);
(19) “List for classified environmental protection management for construction projects”, National Environmental Protection Bureau Decree No. 2002-14;
(20) “Reply approval from the State Council on relevant issues concerning acid rain control areas and sulfur dioxide pollution control areas” Guo Han from the State Council [1998] No. 5, Jan. 20, 1998;
(21) “Circular on some opinions to stop blind investment in iron and steel, electrolytic aluminum and cement industries”; Document from General Administration Office of the State Council [2003] No. 103;
(22) “Emergency circular on some opinions about sorting out and normalizing the coke industry”; Extra Urgent Document Fagai Chanye [2004] No. 941 from the State Commission of Development and Reform and others;
(23) “Admission conditions for calcium carbide, iron alloys and coke industries”, Bulletin from the State Commission of Development and Reform, No. 76 of 2004;
(24) “Circular on strengthening the admission management work for coke production enterprises” Document Fagai Chanye [2005] No. 1142 of the State Commission of Development and Reform;
(25) “Circular on some opinions on sorting out projects in the iron and steel, electrolytic aluminum and cement industries”, Document Fagai Gongye [2004] No. 1791 of the State Commission of Development and Reform;
(26) Environmental protection industrial standard of the People's Republic of China “Standard on clean production – Iron and steel industry (draft for comments)” (HJ/T xx-2004);
(27) Environmental protection industrial standard of the People's Republic of China “Standard on clean production – Coking industry” (HJ/T126-2003);
(28) “Catalogue for replacing backward production capacity, processes and products” Batches 1, 2 and 3 (Documents No. 6, 16 and 32 of the State Commission of Economic Relations and Foreign Trade);
(29) “Circular on relevant matters for implementing the national standards for atmospheric environment” (Document Su Huan Ke [96] No. 27);
(30) “Requirements on preparation of main content in environmental impact report for industrial construction projects in Jiangsu Province” (Jiangsu Province Environment Protection Department, May 2005).
4
1.2.2 Documents and information about the project
(1) “Overall urban plan for Nanjing Municipality” (Nanjing Municipal Planning Bureau, Aug. 2001);
(2) “Overall plan for development of areas along the Yangtze River of Nanjing Municipality”;
(3) “Environmental protection plan in development of areas along the Yangtze River of Nanjing Municipality”;
(4) “Overall plan for new town of Banqiao” (Nanjing Municipal Planning and Design Research Institute, July, 2001);
(5) “Development Program for Iron and Steel for Shanghai Meishan Iron and Steel Co., Ltd. During the "Eleventh Five-year Plan" Period” (Shanghai Meishan Iron and Steel Co., Ltd. and Zhongye Saidi Engineering and Technology Co., Ltd., Sept. 2004);
(6) “Feasibility study report for 1# and 2# coke ovens relocated overhaul system project of Meishan Iron and Steel Co., Ltd.” (Zhongye Jiaonai Engineering and Technology Co., Ltd., Apr. 2005);
(7) “Environmental impact declaration form for construction project” and review and approval comments (Jiangsu Provincial Environment Protection Department);
(8) Letter of entrustment for environmental impact assessment work.
1.3 Principles for assessment work
1.3.1 The assessment work shall implement the principles of “clean production”, “emission after meeting standard”, “bringing the existing project to meet standard with new ones” and “total amount control on pollutant emission” shall be carried out;
1.3.2 Engineering analysis for the project shall be done in an earnest manner, the amount of pollutant emission will be clearly calculated through checking the water and materials balance for the project, and the extent and range of impact from the project to the surrounding environment will be analyzed via the environmental impact prediction.
1.3.3 Full use shall be made for the results in environmental monitoring and environmental management obtained in the project area in recent years, to carry out the environmental impact assessment work for the project.
1.4 Technical line for the assessment
The technical line adopted for the current environmental impact assessment is as shown in Fig. 1-1.
5
Letter of entrustment
Data collection and site survey
Preparing assessmentprograme (omitted)
Expert comments (omitted) Environmental quality status quomonitoring and survey
Survey and analysis
Nat
ural
env
ironm
ent
surv
ey
Soci
al e
nviro
nmen
t sur
vey
Engi
neer
ing
anal
ysis
Pollu
tion
sour
ces s
urve
y
Atm
osph
eric
env
ironm
ent
mon
itorin
g
Wat
er e
nviro
nmen
t m
onito
ring
Noi
se e
nviro
nmen
t m
onito
ring
Environmental quality status quoassessment
Environmental impact prediction and assessment
Overall analysis
Preparation or report
Fig. 1-1 Technical line for assessment
Total amount control
Public participation
Clean production and circulation economy analysis
Environmental protectionmeasures description
Others
6
1.5 Emphasis of assessment and classes of assessment work
1.5.1 Emphasis of assessment
The project is for ferrous metal melting and processing in the metallurgical industry, with serious pollution. Therefore the emphasis for the present assessment was laid on engineering analysis, comments on clean production, comments on pollution prevention and control measures and control of total amount of pollutant emission.
1.5.2 Classes of assessment work
(1) Environmental impact assessment class for surface water
As the principles of “recycled use for multiple purposes” and “bringing the existing ones to meet the standard by new ones” will be carried out in the project, the total amount of waste water pollutant emission will not increase after the completion of the project, therefore impact analysis is performed only for the surface water environment.
(2) Environmental impact assessment class for atmosphere
As the principle of “bringing the existing ones to meet the standard by new ones” will be carried out in the project, the atmospheric pollutant emission will reduce after the completion of the project, therefore impact analysis is performed only for the atmospheric environment.
(3) Noise impact assessment class
The noise impact assessment class was set as class III.
1.6 Scope of assessment
The assessment scope for different environmental elements was determined according to the pollutant emission characteristics of the project and the local meteorological conditions and natural environmental status, as shown in Table 1-1.
Table 1-1 Scope of assessment
Scope of assessment Scope of assessment
Regional pollution sources
Main industrial enterprises in the assessment area were surveyed as emphasis.
Atmosphere A range of 9×6 square kilometers with the project as the center
Surface water The Banqiao section in Nanjing of the Yangtze River, from 2500m upstream
the north discharge port of Meishan Company into the Yangtze River to 3300m downstream of this port, for a total length of about 5.8km
Nose Plant boundary of the project
Total amount control To be balanced internally in Shanghai Meishan Co., Ltd.
1.7 Determination of assessment factors
The assessment factors were determined according to the identification of environmental
7
protection factors, as shown in Table 1-2.
Table 1-2 Determination of assessment factors
Environment Status quo assessment factors Impact assessment
factors Total control factors
Atmospheric environment
SO2, NO2, PM10, Bap, TSP, H2S and NH3
Bap and H2S SO2 and dust
Surface water PH, CODcr, petroleum, volatile phenol,
SS, ammonia nitrogen and CN- - CODcr and SS
Noise environment
Continuous equivalent acoustic level at plant boundary Leq (A)
Continuous equivalent acoustic level at plant
boundary Leq (A) -
Solid waste - - Amount of
industrial solid waste emission
8
2. General environmental conditions of and environmental protection targets in the surrounding areas of the project
2.1 Briefs of natural environment
2.1.1 Geographic location
The project is located in the new plant area for Shanghai Meishan Iron and Steel Co., Ltd. of Baosteel Group, in Banqiao Town, Yuhuatai District of Nanjing.
Shanghai Meishan Iron and Steel Co., Ltd. (Meishan Steel) is a sole-funded subsidiary under Baosteel Group, and is a large iron and steel complex with coking, sintering, iron melting, steel making, continuous casting and milling. Located outside Zhonghua Gate of Nanjing, Meishan Steel has access to the railway and expressway from Nanjing to Wuhu, with the Yangtze River to its north and its own dedicated railway line and 10,000t berth, hence quite convenient in transport. The project is about 20km to the city center of Nanjing, with the PLA International Relations Institute and Baoqiao Town at 2.6km to the northeast of the boundary, and closely adjacent to the living quarter for Shanghai Meishan Iron and Steel Co., Ltd. to the east.
The project will be located to the north of the coking plant of Meishan Steel, with the existing plant area of Meishan Steel to the south and a reserved land to the north, a barren land to the east and the road from Meishan Steel plant to the wharf to the west. The project will cover a land area of about 200000m2. The site is now a barren land, with a flat terrain, at a natural ground elevation between 7.45m-10.2 m. Most part of the project land is now vacant, and a small number of buildings and structures have been relocated by the “product restructuring and process equipment upgrading and technical transformation project of Meishan Steel of Baosteel Co., Ltd.” (the original 2 million t/a sheet project) (for relocations, see the appendix).
The land requisition for the site was completed at the same time as for the “product restructuring and process equipment upgrading and technical transformation project of Meishan Steel of Baosteel Co., Ltd.” (the original 2 million t/a sheet project,with project land of 2.75million m2) (for detail, refer to the Appendix: Construction land planning permit of the People's Republic of China, No. Ning Gui Chengnan Land [2005] No. 0015).
The specific geographic location of the project is as shown in Fig. 2-1.
2.1.2 Landform, topography and geology (omitted)
2.1.3 Hydrology
The surface water systems near the project area include Banqiao section in Nanjing of the Yangtze River, Banqiao River and Jiangning River. The waste water from the coking plant of the iron factory of Shanghai Meishan Iron and Steel Co., Ltd. is discharged into the Yangtze River via the north discharge port of the general plant.
The Yangtze River is the largest river in China, with a basin area of 1.8 million square kilometers and a length of about 6300km. Its runoff resource accounts for 37.8% of the national total and it has abundant water flow, with annual average water amount flowing into the sea at 960 billion cu.m., at a maximum flow of 92600m3/s, average flow of 28500m3/s,
9
minimum daily average flow of 5970m3/s and minimum monthly average flow of 6940m3/s.
The ground water in the area is of phreatic water type, directly subject to atmospheric precipitation and surface runoff. The ground water table is shallow, between 0.30m-1.40m, and the ground water quality is good at present.
2.1.4 Climate and meteorology
The project area is in the monsoon climate area of northern subtropical region, featuring a mild climate with clearly divided four seasons and moderate rainfall.
2.2 Social environmental conditions
Banqiao Subdistrict, where the project is located, is to the west of Yangtze River and east of Nanjing Lukou International Airport. It connects Pukou District to the west across Banqiao vehicle ferry, the Ring Highway and national higyway Guo No. 312 to the north, and has ready access to the steel city Maanshan to the south via Nanjing – Maanshan Expressway. The national highway Guo No. 205, the Ningwu, Hutong and Wangan railways, Nanjing No. 3 Yangtze River Bridge and Nanjing No.2 Ring Expressway to be soon completed run across it. Since the reform and opening up, the economy of Banqiao Subdistrict has been growing at an annual rate of 19%. At present, there are fixed assets of 250 million yuan at the subdistrict and village levels, with over 100 enterprises, initially forming five major pillar industries of building materials, chemical, garment, electrical appliances and machine building. The economic pattern with the main characteristics of scale production for good economic gains has also been basically formed. Banqiao Subdistrict covers an area of 58.11 square kilometers, with 9 administrative villages and 3 residents committees, and a population of over 60,000 people. This area has been basically urbanized, with agricultural population reducing every year.
In the surrounding area of Banqiao Subdistrict, there are Baosteel Shanghai Meishan Co., Ltd., Baosteel Shanghai Meishan Iron and Steel Co., Ltd., Nanjing Meibao New Type Building Materials Co., Ltd., Meilin Metal Structural Member Factory, Jiantong Building Materials Factory, Jiangning Agricultural Chemical Factory, Jiangning Cement Works, Ship Auxiliary Equipment Factory, and PLA International Relations Institute.
2.3 Regional social development planning
2.3.1 Overall urban plan for Nanjing Municipality
According to the “Overall urban plan for Nanjing Municipality” (1991-2010), the functional positioning for Banqiao new town (location of the proposed project) is: Banqiao will be a comprehensive industrial town in the metropolitan development zone, and its industrial positioning is: metallurgy, mechanical machining industrial and commercial and circulation industries will be encouraged, and construction of project with serious pollution to water bodies will be prohibited.
2.3.2 Overall plan for development of areas along the Yangtze River of Nanjing
It will stick to the strategy of developing industry as the primary task and take the road of new type industries, push ahead the construction of industrial groups along the Yangtze River, and
10
make big and strong the five major sectors of chemical, IT, automobile, iron and steel and power generation.
For the iron and steel industry, the superiority of the golden waterway and the existing industrial foundation will be brought into play, to speed up the restructuring for the scaled production, internationalization and modernization of the industry, to foster the iron and steel industry as one of the important pillar industries in the city. The product lines will be adjusted and product level upgraded, to form series of products with the emphasis on wide medium and thick plates, hot (cold) rolled stainless steel plates (rolls), plates with anti-corrosion coating and other fine and high quality products.
2.3.3 Development plan for Meishan Steel Company
According to the new industrial policies of the state and the requirements for sustainable development of national economy, and the new round of development strategies of Baosteel Group, Meishan Steel Company will take opportunity of Baosteel Group in speeding up the construction of fine steel product system and further advancing the construction of fine plate products bases, make the upgrading and transformation of pre-iron system equipment as the starting point, and take the world first rate iron and steel technology and research and development capacity of Baosteel as the backup, to introduce new processes, new technologies and new equipment in a rational manner, and to further lower the comprehensive energy consumption per ton of steel, improve the environmental quality and bring up the comprehensive competing power of Meishan Steel Company. To this end, Baosteel has decided to implement the “product restructuring and process equipment upgrading and technical transformation project of Meishan Steel of Baosteel Co., Ltd.” (the original 2 million t/a sheet project) with Meishan Steel Company as the primary investor, mainly in the existing plant area of Meishan Steel Company with little land requisited in the surrounding area.
After the completion of this transformation project, the production scale of Meishan Steel Company will be 5.37 million t/a of pig iron, 5.3 million t/a of converter steel (continuous cast bloom) and 5.03 million t/a of steel, and its sales amount will reach 7832.488 million yuan, with profit of 2132.89 million yuan. Full utilization of resources can be realized and main economic indicators will reach the advanced level in China and in the world.
By demolishing 3 old coke ovens with serious pollution and building 2 new type coke ovens conforming to state policies and a series of technical transformation actions in the project, the waste water produced from coking will all be used for blast furnace slag flushing after meeting the standard, and non-organized emission of large amount of waste gas will be reduced, so as to meet the requirements in the environmental protection planning for development of areas along the Yangtze River in Nanjing that the zero and even negative growth in total amount of pollutant emission be realized, more efforts be made for total amount control of pollutants and in pollution prevention and control and traditional industries such as chemical and metallurgical sectors be transformed with high and new technologies.
The project is for upgrading and transformation of pre-iron system equipment for the “product restructuring and process equipment upgrading and technical transformation project of
11
Meishan Steel of Baosteel Co., Ltd.”. By implementing the principles of “recycled use for multiple purposes” and “bringing the old to meet the standard by new ones”, the total emission amount of waste water and atmospheric pollutants will be reduced after its completion, and the environmental quality will be improved, therefore it conforms to the development plan of Meishan Steel Company.
2.3.4 Necessity for construction of the project
Shanghai Meishan Iron and Steel Co., Ltd. is a holding subsidiary of Baosteel Co., Ltd., and is a full flow iron and steel complex with 3 million t/a of steel and steel materials from coking, sintering, iron melting to steel making and milling, with the qualification of independent corporate.
The coking plant of Meishan Steel Company was first built in 1970, now has three 65-duct coke ovens with retort height as 4.3m. 1# and 2# coke ovens are of type 58-II, respectively completed in 1970 and 1971, and 3# coke oven is of type JNX43-2, put into operation in 1996. the design production capacity of the three coke ovens is 1.35 million t/a of coke. The actual coke output in 2004 was 1.17 million t. The coke produced is mainly supplied to the blast furnace and sintering factories of Meishan Steel Company for self consumption.
The existing gas purifying plant and chemical product recovering system associated with the three coke ovens are designed for annual purifying and processing coke gas at 657 million m3/a, and in 2004, it actually processed coke gas at 538 million m3/a.
According to Appendix III “Admitting conditions for coking industry” to Bulletin No. 2004 – 76 of the State Commission of Development and Reform, we make the following comparison for the items about the project with the admitting conditions for the industry as follows:
2.3.4.1 Layout of production enterprise
(I) Admitting condition requirement for coking industry: The site of a newly constructed and expanded or transformed coking production enterprise should be close to the user and the coking coal raw material base; and it must conform to the development planning of the province (autonomous region and municipality).
The site of the project is close to the user (Meishan Steel Company) and the coking coal raw material base (Xuzhou and Shandong), and it conforms to the coking development plan of Baosteel Group and the relevant content in the document (2005) No. 761 of the Commission of Development and Reform of Jiangsu Province “Overall thinking on the structure adjustment of iron and steel industry in Jiangsu Province”.
(II) Admitting condition requirement for coking industry: No coking production enterprise should be constructed within 2km beyond the boundary of city planned area (except for supplying gas to urban residents), within 1km on both sides of a main river or trunk highway, the peripheral of resident gathered place and enterprises for food and medicine for which strict prevention against pollution is required, and within ecological protection zone, natural reserve, scenit tourist zone, cultural relics protection zone and potable water source protection zone as specified by the State Council, relevant state authorities and people’s government of a province (autonomous region and municipality).
12
Any coking production enterprise that is operating within such areas as mentioned above shall exit step by step through “relocating and product change” according to the planning of such area.
The project (coking plant) is over 2km from the planned boundary of Nanjing, over 1km from the south bank of Banqiao section in Nanjing of the Yangtze River, and 1km from the living quarter for employees of Meishan Steel Company, and there is no environmental sensitive point as mentioned above.
2.3.4.2 Technology and equipment
A newly constructed and expanded or transformed coking production enterprise should meet the requirements for class II standard for production technology and equipment as specified in the standard for clean production for coking industry (HJT126-2003). The main indicators are:
(I) Admitting condition requirement for coking industry: To meet the requirements for energy saving, environmental protection and comprehensive utilization of resources and realize a rational scaled economy, the coke oven retort of newly built, transformed and expanded plant must reach 4.3m (inclusive) and over, and the annual production capacity shall be 600,000 t or over.
The coke oven retort of the project will be 6m and the annual production capacity is 1 million tons.
(II) Admitting condition requirement for coking industry: the capacity to process anhydrous tar of a newly built coal tar plant shall be 100,000 t/a and over, a crude (light) benzene refining plant shall have a scale of 50,000 t/a and over. An existing coal tar plant shall have a scale of 50,000 t/a and over and an existing crude (light) benzene refining plant shall have a scale of 25,000 t/a and over.
The project will make use of the existing chemical production facilities, without newly building coal tar processing plant and crude (light) benzene refining plant. The existing scale of the coal tar processing plant is 100,000 t/a of anhydrous tar for a single plant (two plants), and the existing crude (light) benzene refining plant has a scale of 35,000 t/a.
(III) Admitting condition requirements for coking industry on energy saving process and facilities:
1. For a newly constructed and expanded coke oven, in principle a dry coke quenching plant shall be constructed concurrently (in areas lacking in water and for iron and steel enterprises).
2. For a newly constructed and expanded coke oven, the coke gas must be fully recovered for use, and must not be discharged directly or burnt at a flare.
3. For a newly constructed and expanded coke oven, advanced coal batching process shall be adopted, and coal for coking shall be batched in a rational manner, to minimize the use of high quality coking coal.
A dry coke quenching plant will be constructed concurrently with the project, all coke gas will be recovered for use without direct discharge or burning at a flare. Advanced coal batching
13
process has been adopted, and coal for coking is batched in a rational manner, to minimize the use of high quality coking coal (as detailed in Table 5-1 Equipment for coal preparation).
As it is an old plant and due to the historical economic and technological reasons at the time, it has no associated dry coke quenching plant; the coke ovens are heated by gas produced by its own, by directly feeding into the coke oven after removing benzene for heating, without desulfurization. This part accounts for about 40% of the total amount of gas. The remaining 60% of gas is supplied to Nanjing Municipality for use after desulfurization and decyanation. For the environmental protection control of the coal preparation system, there is dust removal equipment only in the coal pulverizing system.
The existing facilities of the project cannot meet the above-mentioned admitting condition requirement for coking industry. Therefore, it is necessary to construct this project.
(IV) Admitting condition requirements for coking industry on environmental protection process and facilities:
1. For a newly built or transformed coke oven, the pulverizing, coal loading, coke pushing, sieving and transport and dust removal units and the gas purifying (including desulfurization and decyanation processes) and recovering and waste water biological treatment facilities shall be constructed concurrently. The provisions of “three simultaneousness” for environmental protection facilities shall be strictly implemented, and they must reach the standard specified in design 6 months and be continuously operational after the main equipment is put into operation.
2. The waste water biological treatment process and equipment and the coal washing and dressing equipment shall be reliable at advanced level, be completed concurrently with the main production equipment and be continuous operational. There shall be sufficient reserve tanks for accident waste water treatment in case of fault or repair of equipment, to ensure that waste water not meeting the standard will not be discharged. The coking waste water shall be recycled internally after treatment.
In this project, pulverizing, coal loading, coke pushing, sieving and transport and dust removal units (ground dust removing station) have been built concurrently according to the above requirements, and all gas is recovered for use. The most advanced process and equipment in the world is adopted according to the requirements in Baosteel for waste water biological treatment, therefore no waste water not meeting the standard will be discharged. All waste water from coking is used for blast furnace slag flushing after treatment, thus realizing recycled internal use (as detailed in Table 5-1 Equipment for coal preparation).
The existing facilities of the project consist only of the dust removal equipment for coke sieving and coke transport station, and a plant for spraying the anthracite coal with high pressure ammonia water was built and put into operation in 1984, but there is no dust removal equipment for coal loading and coke discharge ground station. For the phenol and cyanogen containing waste water produced from coking, a biological treatment plant with a capacity of 200t/h has been built, but the waste water after the biological treatment cannot steadily meet
14
the class I indicators in Table 3 of “Standard for water pollutant emission in iron and steel industry” (GB13456-92) at the discharge port of the treatment facility.
Some existing facilities of the project cannot meet the above-mentioned admitting condition requirement for coking industry. Therefore, it is necessary to construct this project.
2.3.4.3 Quality of main products
(I) Admitting condition requirements for coking industry on product coke:
The metallurgical coke produced by a newly constructed and expanded coke oven shall meet the standard of class II metallurgical coke or over as specified in GBT1996-2003, and the foundry coke shall meet the standard of class II foundry coke or over as specified in GBT8729-1988.
The metallurgical coke shall meet the standard of class III metallurgical coke or over as specified in GBT1996-2003, and the foundry coke shall meet the standard of class III foundry coke or over as specified in GBT8729-1988.
The product coke from the project can meet the quality requirements for metallurgical coke produced by a newly constructed and expanded coke oven (as detailed in Table 5-3 product indicators).
The product coke from existing facilities can meet the quality requirements of metallurgical coke from the above-mentioned existing coke ovens.
(I) Admitting condition requirements for coking industry on product coke gas:
1. Town gas for civilian use
The gas produced from a coking production enterprise for urban civilian use shall meet the indicators for urban civilian gas product as specified in the standard for clean production of coking industry (HJT126-2003).
2. Gas for industrial or other purposes
In the gas produced by a coking enterprise for industrial or other purpose, H2S ≤500mg/m3.
The product coke gas of the project and existing facilities can meet the above-mentioned quality requirement.
(III) Admitting condition requirements for coking industry on other coking or chemical products:
Production shall be organized according to national or metallurgical industrial standards.
1. Sulfur ammonium shall conform to the standard GB535-1995 (Grade I)
2. Crude tar shall conform to the standard YBT5075-1993
3. Crude benzene shall conform to the standard YBT5022-1993
The products of the project and existing facilities can all meet the above-mentioned quality requirement. In the project, sulfuric acid will be produced instead of sulfur ammonium in the
15
existing facilities.
2.3.4.4 Comprehensive utilization of resources, energy consumption and by-products
(I) Admitting condition requirements for coking industry on utilization of resources and energy:
A newly constructed, transformed and expanded coking production enterprise shall meet the class II indicators for utilizing resources in the standard for clean production of coking industry (HJT126-2003). The main indicators are:
1. Washed clean coal (dry coal) consumed per ton of coke ≤1.33t (i.e. total coke rate≥75%);
2. Energy consumption in coking section ≤170kg standard coal per ton of coke;
3. Heat consumption in coking, ≤2250kjkg coal (7% water content as converted) when heated with coke gas; and ≤2550kjkg coal (7% water content as converted) when heated by blast furnace gas;
4. Fresh water consumption per ton of coke ≤3.5t;
5. Power consumption per ton of coke ≤35KWh;
6. Coke gas utilization rate ≥95%;
7. Water recycled utilization rate ≥85%.
In the project, the washed clean coal (dry coal) consumed per ton of coke is ≤1.33t (i.e. total coke rate≥75%), and all other indicators can meet the above-mentioned requirements (as detailed in Table 5-2 Resources and energy utilization indicators).
Conditions of existing facilities:
1. In 2004, the washed clean coal (dry coal) consumed per ton of coke 1.347t, slightly higher than the indicator 1.33t in the admitting conditions, and the main cause is that the washed clean coal used by our Company has high volatile content, and the total coke rate is lower than 75%.
2. In 2004, the energy consumption in coking section was 140kg standard coal/t coke, meeting the indicator 170kg standard coal/t coke in the admitting conditions.
3. In the Company, the coke ovens are heated by the mixed coke gas with blast furnace gas, and the heat consumption for coking in 2004 was 2262kj/kg coal, meeting the coking heat consumption indicator 2400kj/kg coal required in the admitting conditions (taking the average value of 2400kj/kg coal for 2250kj/kg coal for heating by coke gas and 2550kj/kg coal for heating by blast furnace gas).
4. In 2004, water consumption per ton of coke was 2.6t, meeting the indicator 3.5t required in the admitting conditions;
5. In 2004, power consumption per ton of coke was 7.2KWh, meeting the indicator 35 KWh required in the admitting conditions;
16
6. In 2004, the coke gas utilization rate was 99.2%, meeting the indicator 95% required in the admitting conditions;
7. In 2004, the water recycling utilization rate was 78%, failing to reach the indicator 85% required in the admitting conditions.
Among the above indicators, except the coal consumption per ton of coke and water recycling utilization rate, all others are better than the indicators required in the admitting conditions for resources and energy utilization.
The existing facilities cannot meet the requirements in 1 and 7 for the admitting conditions of coking industry. Therefore, it is necessary to construct this project.
(II) Comprehensive utilization of by-products
1. The coke gas produces from a coking production enterprise should have users; if there is surplus gas, facilities for comprehensive utilization of gas must be constructed, such as methanol synthesizing, hydrogen peroxide, hydrogen extraction from gas or power generation with gas, to convert all the surplus gas. In normal operation, gas must not be discharged directly or burnt at a flare.
2. Coal tar and benzene chemical products shall be effectively recovered.
The project and existing facilities can meet the above-mentioned requirements.
2.3.4.5 Environmental protection indicators and clean production
(I) Standard for clean production
The various pollutants produced from a newly constructed, transformed and expanded coking production enterprise must not exceed the class II indicators specified in the standard for clean production for coking industry (HJT126-2003), and the indicators for waste recovery and utilization shall meet the indicators specified in standard for clean production for coking industry (HJT126-2003).
All the pollutant generation indicators and waste recovery and utilization indicators of the project can meet the above-mentioned requirements (as detailed in Tables 5-4 and 5-5).
The existing 1# and 2# coke ovens have been in service for over 30 years, with equipment aged and serious leakage in oven walls, producing black smoke from the ovens. The 3# coke oven was put into operation in 1996, but no dust removal device was provided for coal loading and coke pushing ground stations, therefore non-organized discharge of large amount of smoke and dust takes place at coal loading and coke discharge, and massive toxic and harmful substance escape into the atmospheric environment at coke quenching, resulting in serious atmospheric pollution.
At present, the phenol and cyanogen containing waste water is treated with biological and chemical method, but this method cannot remove COD and ammonia nitrogen, therefore the treated phenol and cyanogen containing waste water basically cannot meet the standard for COD and ammonia nitrogen at the discharge port of the treatment facilities. In addition, this part of the waste water is not in recycled internal use, and is discharged into the Yangtze River
17
with other industrial waste water of the coking plant via the main discharge pipe. This does not conform to the requirements that “phenol and cyanogen containing waste water shall be recycled for internal use without discharge to the outside” in the admitting conditions for the coking industry.
Part of the coking slag is not used up in the enterprise.
In the existing facilities, the indicators for generation of waste water, waste gas and waste slag and their recovery and utilization cannot meet the above-mentioned admitting condition requirement for coking industry (requirements in Tables 5-4 and 5-5). Therefore, it is necessary to construct this project.
(II) Pollutant emission standard
1. A newly constructed, transformed and expanded coking production enterprise shall implement the “Atmospheric pollutant emission standard for coke ovens” (GB16171-1996) for atmospheric pollutant emission.
2. Phenol and cyanogen containing waste water shall be recycled for internal use after treatment, and discharged waste water shall meet the class II standard in “Pollutant emission standard for iron and steel industry” (GB13456-1992) and class II standard in “Integrated wastewater discharge standard” (GB8978-1996) or requirements specified by the locating area.
3. Waste water for coke quenching: coke quenching water shall be recycled for use in closed loops and must not be discharged.
The pollutant discharge from the project can meet the above-mentioned requirements.
The phenol and cyanogen containing waste water of the existing facilities is not recycled for internal use in the plant, failing to meet the above-mentioned admitting condition requirement for coking industry. Therefore, it is necessary to construct this project.
(III) Waste slag
All waste slag from a coking production enterprise, including dust collected from coal batching, coke pushing, coal loading, coke quenching and sieving dust collectors, tar slag (including washing slag from tar tanks), crude benzene regenerative slag and remaining sludge and all other waste slag produced from coking shall be fully treated and utilized in the plant, without discharging to the outside.
All the above-mentioned waste slag produced in the project will be fully treated and used in the plant and the above-mentioned requirements can be met.
In the existing facilities, part of the slag from coking can not be used in the enterprise. Therefore, it is necessary to construct this project.
(IV) For the construction and expansion of a coking production enterprise, the emission of pollutants must not exceed the permissible total amount of emission in the environment of the area.
Neither the project nor the existing facilities have exceeded the permissible total amount of
18
emission in the environment of the area, and the above-mentioned requirements can be met.
2.4 Environmental function zoning
2.4.1 Atmospheric environmental function zoning
In the “Ambient air quality function zoning for Nanjing Municipality” prepared by Nanjing Municipal Environmental Protection Bureau in 1997, it is specified that the existing production plant area of Baosteel Group Shanghai Meishan Co., Ltd. is class III area, and shall follow the class III standard in “Ambient air quality standard” (GB3095-1996). Other areas beyond the existing production plant area shall follow class II standard for ambient air quality. The area of the project is outside the existing production plant area (as it is newly requisited land), therefore the function zoning for its atmospheric environment is class II area, and its atmospheric environmental quality shall follow class II standard in “Ambient air quality standard” (GB3095-1996).
2.4.2 Water environmental function zoning
According to the water environmental function zoning in Jiangsu Province, the Banqiao section of Yangtze River in Nanjing is class II water body, and its water quality shall follow class II standard in “Environmental quality standard for surface water” (GB3838 - 2002), and the water environment sensitive protection target for this project is Banqiao section of Yangtze River in Nanjing.
2.4.3 Noise environmental function zoning
According to “Division and adjustment plan for environmental noise standard application zones in Nanjing Municipality” (Document Ning Zheng Fa [2004] No. 273), the plant area of the project is class III noise function zone, for which the assessment shall follow the class 3 standard in “Standard of environmental noise of urban area” (GB3096-93) and the class III standard in “Standard of noise at boundary of industrial enterprises” (GB12348-90), and the surrounding area of the plant area of the project is class II noise function zone, which shall follow the class 2 standard in “Standard of environmental noise of urban area” (GB3096-93).
2.5 Assessment standards
2.5.1 Atmospheric environmental quality standard and pollutant emission standard
The project is located in the new plant area (newly requisited land) of Meishan Steel Company, and for the new plant area and its surrounding area, the SO2, TSP, PM10 and NO2
shall follow class II standard in “Ambient air quality standard” (GB3095-1996), the benzo (a) pyrene (Bap) shall follow the standard in “Ambient air quality standard” (GB3095-1996), and H2S and ammonia shall follow the maximum permissible concentration of harmful substance in atmosphere in residential areas in “Sanitation standard for design of industrial enterprises” (TJ36-79). See table 2-2 for details.
The non-organized discharged waste gas pollutants from coke ovens shall follow class II standard in Table 2 of “Standard for emission of atmospheric pollutants from coke ovens” (GB16171-1996), and H2S and ammonia shall follow the class II standard in Table 1 for newly built and expanded projects in “Emission standard for odor pollutants”.
19
The organized waste gas discharged from coke oven stack and the dust containing waste gas discharged from other sections (coal preparing system, coal loading, coke discharge, dry coke quenching dust removal system, coke reservoir in front of oven and coke sieving) shall follow class II standard in Table 2 of “Integrated emission standard of air pollutants” (GB16297 - 1996); the benzo (a) pyrene (Bap) discharged from coal loading and coke discharge shall refer to “Bitumen and carbon product production and processing standard”; the SO2 containing waste gas discharged from tubular oven stacks shall follow class II standard in Table 4 of “Atmospheric pollutant emission standard for industrial furnaces and kilns” (GB9078-1996), and the hygienic protection distance from coke ovens shall follow the “Standard for hygienic protection distance in coking plant” (GB11661-89). For details, refer to Tables 2-3 and 2-4.
Table 2-2 Ambient air quality standard
Description of pollutant
Value taking time Limit of concentration (mg/m3) Source of standard
Annual average 0.06 (Class II standard)
Daily average 0.15 (Class II standard) SO2
hourly average 0.50 (Class II standard)
Annual average 0.20 (Class II standard) TSP
Daily average 0.30 (Class II standard)
Annual average 0.10 (Class II standard) PM10
Daily average 0.15 (Class II standard)
Annual average 0.08 (Class II standard)
Daily average 0.12 (Class II standard) NO2
hourly average 0.24 (Class II standard)
BaP Daily average 0.01ug/m3
GB3095-1996 and National Environmental
Protection Bureau Decree (2000) No. 1 Document, Circular on modification
sheet to “Ambient air quality standard” (GB3095-1996)
Once 0.01 H2S
Daily average 0.10
Ammonia Once 0.2
TJ36-79
Table 2-3 Atmospheric pollutant emission standard
Pollution source Pollution factor Limit of concentration
(mg/Nm3) Source of standard
Coke oven stack SO2 550 (266kg/h)
Dust containing waste gas from other sections
Dust 120 GB16297-96
20
Pollution source Pollution factor Limit of concentration
(mg/Nm3) Source of standard
Coal loading and coke discharge
Benzo (a) pyrene (Bap)
0.3×10-3
(0.29×10-3 kg/h)
Bitumen and carbon product production
and processing standard
Tubular oven stack SO2 850 GB9078-96
Particles 2.5
Benzene soluble objects (BSO)
0.60
Benzo (a) pyrene (Bap)
0.0025
GB16171-96
H2S 0.06
Waste gas discharged from mechanical coke oven (non-organized)
Ammonia 1.5 GB14554-93
Table 2-4 Standard of hygienic protection distance for construction project
Category Wind speed (m/s) Distance (m) Source of standard
Coking plant 2-4 1000 GB11661-89
2.5.2 Environmental quality standard for surface water and waste water emission standard
For the water quality of Banqiao section of the Yangtze River to receive the waste water discharged from the project, the class II standard in “Environmental quality standard for surface water” (GB3838-2002) shall be implemented, and the waste gas discharge from the project shall follow the class I standard in Table 3 of “Water pollutant emission standard for iron and steel industry” (GB13456-92), as detailed in Table 2-5.
Table 2-5 Surface water quality standard and waste water discharge standard (mg/L)
Item Environmental quality standard value
Class II in (GB3838-2002)
Water pollutant emission standard for iron and steel industry
Class I in (GB13456-92)
PH 6-9 6-9
COD ≤15 100
SS ≤20* 70
Petroleum ≤0.05 8
21
Item Environmental quality standard value
Class II in (GB3838-2002)
Water pollutant emission standard for iron and steel industry
Class I in (GB13456-92)
Volatile phenol ≤0.002 0.5
Cyanide ≤0.05 0.5
Ammonia nitrogen ≤0.5 15
Note: * Standard of the Ministry of Water Conservancy shall be referenced for SS.
2.5.3 Noise assessment standard
According to “Division and adjustment plan for environmental noise standard application zones in Nanjing Municipality” (Document Ning Zheng Fa [2004] No. 273), noise assessment for the plant area of the proposed project shall follow class 3 standard in “Standard of environmental noise of urban area” (GB3096-93) and class III standard in “Standard of noise at boundary of industrial enterprises” (GB12348-90), and the surrounding area of the plant area of the proposed project shall follow class 2 standard in “Standard of environmental noise of urban area” (GB3096-93), as detailed in Table 2-6.
Table 2-6 Noise assessment standard
Standard class Daytime dB(A) Night dB(A)
Class 3 in Standard of environmental noise of urban area 65 55
Class III in Standard of noise at boundary of industrial enterprises 65 55
Class 2 in Standard of environmental noise of urban area 60 50
2.6 Targets for pollution control and environmental protection
The pollution control target of this project is that pollutant emission will meet the standards after its completion, the total amount of pollutant emission will be controlled within the permissible total amount, and the discharge ports setup conforms to the requirements specified in “Management measures on pollutant emission port setup and normalized control and rectification in Jiangsu Province”.
The sensitive environmental protection targets in the area where the project is located are shown in Table 2-7 and Figs. 2-3 and 7-1.
22
Table 2-7 Sensitive environmental protection targets in the area where project is located
Environment Distance from
reference point
Environmental protection target
Direction and distance
Environmental quality
PLA International Relations Institute and Banqiao Town
NE 4.7km
Residential area to the east of Banqiao town
SE 2.6km-5.4 km
Living quarter of Meishan Company
SE 1.44km
Huangnitang Village resident point (100 households)
E 1.20km
Sunjia Village resident point (50 households)
S 2.48 km
Gujiabian resident point (30 households)
SW 3.12 km
Lijiabian resident point (25 households)
SW 3.14 km
Atmospheric environment
Coke oven
Caocun Village resident point (30 households)
SW 2.37 km
Air all shall meet class II standard in
“Ambient air quality standard” (GB3095-1996)
Surface water
environment
North discharge port
Water source for Meishan Company
Near Sanshanying, at
2.56 km upstream
Water quality shall meet the class II requirement in
“Environmental quality standard for
surface water”
Living quarter of Meishan Company
E 0.15km
Huangnitang Village resident point (100 households)
NE 0.29km
Sunjia Village resident point (50 households)
S 0.38 km
Gujiabian resident point (30 households)
SW 0.10 km
Lijiabian resident point (25 households)
W 0.05 km
Acoustic environment
Plant boundary
Caocun Village resident point (30 households)
W 0.10 km
Noise environment shall meet class 2
standard in “Standard of
environmental noise of urban
area” (GB3096 - 93)
23
3 Engineering analysis
3.1 Status of current enterprises and discharge from pollution sources
3.1.1 Status of current enterprises (1) Shanghai Meishan Iron & Steel Co., Ltd.
Shanghai Meishan Iron & Steel Co., Ltd. (hereinafter referred to as “Meishan Iron & Steel”) is a wholly-owned subsidiary of Baosteel Group and a large iron & steel conglomerate engaged in coking, sintering, ironmaking, steelmaking, continuous casting and steel rolling. The company is located outside Zhonghua Gate of Nanjing City, connected to Ningwu Railway and Ningwu Highway to the east and adjacent to the Yangtze River to the north and has internal rail lines and wharf with 10,000-tonnage berths, enjoying very convenient transport. After years’ constant, timely and well-planned technology innovation, particularly the completion of the systematic project for the overhaul of steelmaking, continuous casting and steel rolling facilities and No. 2 BF as well as the supporting projects, its production equipment, technical equipment and auto-control level all have reached national advanced level, some of them have reached international advanced level and a great headway has been made in its actual production capacity, and the technology content and added value of its products.
Covering an area of 4.2 km2, the company registered 5357 employees including 1772 technical personnel, RMB13.225 billion of total assets and RMB11.409 billion of original value of fixed assets by the end of 2004. In that year, it produced 2.980 million tons of pig iron, 3.000 million tons of continuously cast blooms and 2.9388 million tons of hot rolled coils and realized RMB6.177 billion of product sales revenue, RMB1.1019 billion of profit and tax (including RMB547.8 million of profit) and 560t steel/person*year of labor productivity.
The company comprises sintering plant, ironmaking plant (including coking), steelmaking plant (including continuous casting), rolling mill, power department, transport department and so on. By the end of 2004, it owned the following main production facilities:
2×130m2+1×180m2 sinter machines, 3×65-hole coke ovens, 3×1250m3+1×1280m3 BFs, 2×150t converters, 1×1300t hot metal mixer, a set of molten iron desulphurization unit, 1×152t LF ladle refining furnace, 1×150t RH vacuum treatment unit, a 1320mm two-machine-two-strand CCM, a 1320mm high-performance one-machine-one-strand CCM, and a set of 1422mm continuous hot rolling mill.
�Output in 2004: 4.75 million tons of sinter, 1.17 million tons of coke, 2.980 million tons of pig iron, 3.00 million tons of continuously cast blooms, and 2.92 million tons of hot rolled coils.
(2) Current coke plant (including Meishan Branch of Shanghai Baosteel Chemical Engineering Co., Ltd. (hereinafter referred to as Baosteel Chemical))
The coke plant currently has three 65-hole coke ovens of which carbonization chambers are all 4.3m high. The 1# and 2# coke ovens are of 58-II Model and were built in 1970 and 1971, respectively. The 3# coke oven is of JNX43-2 Model and was put into service in 1996. These
24
three coke ovens all adopt CWQ (coke wet quenching) method during production (there are 2 CWQ towers in total. The 1# and 2# coke ovens share one. The 3# coke oven uses another alone). In 2004, the plant produced 1.205 million tons of coke, mostly supplied to BF for self use of the company. Currently, the plant has 417 employees.
The gas cleaning and chemical product recovery of the current three coke ovens are all undertaken by Baosteel Chemical.
Baosteel Chemical is subordinate to Shanghai Baosteel Chemical Engineering Co.; Ltd. of Baosteel Group. In 2004, it cleaned and treated 538 million m3/a of coke oven gas. At present, it has 700 employees and a capacity of annually processing 0.3 million tons of tar. It is technically advantageous in the fine processing of tar and assumes a leading position in China’s coking industry. It has two sets of tar processing units with a design capacity of annually processing 0.2 million tons of tar. The current wastewater biochemical treatment unit with a design capacity of 200m3/h adopts common activated sludge production technology. 1.086 million m3/a of wastewater was treated in 2004.
As Baosteel Chemical and Meishan Iron & Steel are closely related in such aspects as production flow and infrastructure facilities, they are still regarded as one entity when doing environmental assessment. Therefore in this assessment, we also regarded them as one and didn’t make any strict separation. The location of the current coke plant is shown in Fig 2-3.
3.1.2 Status of discharge from pollution sources
(1) Wastewater
West Discharge Outlet: the wastewater discharged from West Discharge Outlet at present mainly includes the wastewater generated from the cleaning of BF gas, wastewater from sintering, wastewater from steelmaking and continuous casting, wastewater from the cleaning of converter gas, wastewater from hot rolling, domestic sewage and wastewater from thermal power plant. The total discharge volume of wastewater is 1908.0×104m3/a. As the plants of Meishan Iron & Steel are far from each other, the wastewater generated by each plant is treated by its own sewage treatment plant and the pollutant concentration in the outflow water is up to Grade 1 Standard as stated in Table 1 of the Discharge standard of water pollutants for iron and steel industry (GB13456-92). The domestic sewage generated by each plant is treated in a septic tank at first and then sent to the company’s domestic sewage treatment plant where it is settled and bio-chemically treated. The pollutant concentration in the outflow water is up to Grade 1 Standard as stated in Table 2 of the Integrated wastewater discharge standard (GB8978-1996). The wastewater generated from the thermal power plant (boiler blowdown water, wash water in coal conveyance system and so on) is treated in the sedimentation and oil separation tank, and the pollutant concentration in the outflow water is up to Grade 1 Standard as stated in Table 4 of the Integrated wastewater discharge standard (GB8978-1996). The above wastewater is discharged from West Discharge Outlet along West Open Channel to the Yangtze River.
North Discharge Outlet: the wastewater discharged from North Discharge Outlet at present mainly includes equipment cooling water of current coke ovens and floor wash water,
25
wastewater from the biochemical unit of Baosteel Chemical, equipment cooling water and wastewater from tar processing. In 2004, the discharge amounts and average concentrations of pollutants in wastewater are listed in Table 3-1.
From Table 3-1, we can see that in the wastewater discharged from North Discharge Outlet, all indicators are up to standard except COD which exceeds limit.
Table 3-1 Current status of pollutant discharge in wastewater
Wastewater from Meishan Iron &
Steel
Wastewater from West Discharge
Outlet
Wastewater from North Discharge
Outlet (coke plant and Baosteel Chemical)
Pollutant
Ave. C mg/l
Dis. amt. t/a
Ave. C mg/l
Dis. amt. t/a
Ave. C mg/l
Dis. amt. t/a
Total discharge
t/a
Aggregate limit set by
Nanjing Environmental
Protection Bureau t/a
Wastewater — 1908
0000 —
4891
0800 —
9688
560
5859
9360 —
PH 6-9 — 7.5 — 7.6 — — —
CODCr 56.5 1078 57.1 2792.8 125.9 1220 4012.81 5400
SS 55.0 1049 76.0 3717.2 43.2 418.5 4135.72 10500
NH3-N 3.4 66.8 8 391.29 11.5 111.4 502.69 —
Petroleum 2.5 47.7 2.09 102.22 1.3 12.6 114.82 320
Phenol volatile
0.023 0.44 — 0.44 — 0.369 0.809 4.0
Cyanide 0.044 0.83 — 0.83 — 0.239 1.069 6.0
*: The wastewater at West Discharge Outlet still includes domestic sewage from Meishan Domestic Area and nearby surface runoff.
The wastewater at North Discharge Outlet is made of 60t/h of clean sewage discharged from the current 3 coke ovens (mostly equipment cooling water) and 3.8t/h of floor wash water, and the status of pollutant discharge is described in Table 3-2. Baosteel Chemical generates 124t/h of wastewater from biochemical unit and 918.2t/h of equipment cooling water and steam condensed water and the status of pollutant discharge is described in Table 3-3.
26
Table 3-2 Status of wastewater discharge from current coke production facilities
COD SS Petroleum Item
Wastewater
(t/a) mg/l t/a mg/l t/a mg/l t/a
Equipment cooling water 525600 50 26.28 - - - -
Floor wash water 33288 150 4.99 100 3.33 1.30 0.04
Total 558888 - 31.27 - 3.33 - 0.04
From Table 3-3, we can see that COD, SS and NH3-N in the wastewater treated by current biochemical unit all exceed the set limits.
Table 3-3 Current status of discharge of product ion wastewater in Baosteel Chemical
Wastewater from biochemical unit Equipment cooling water Item
mg/l t/a mg/l t/a Total (t/a)
Wastewater - 1086240 - 8043432 9129672
PH 6-9 - 6-9 - -
CODCr 513 557.2 78.5 631.53 1188.73
SS 110 119.5 36.8 295.67 415.17
NH3-N 102.6 111.4 - - 111.4
Petroleum 1.3 1.41 1.40 11.15 12.56
Phenol volatile 0.34 0.369 - - 0.369
Cyanide 0.22 0.239 - - 0.239
(2) Waste gas
In Meishan Iron & Steel, the current air pollution sources mainly include coke oven, coke quenching tower, sinter machine, ironmaking BF, limekiln, steelmaking converter, heating furnace for hot rolling and thermal power plant. The fuels used include coke, coke oven gas, BF gas, converter gas, hard coal and so on. In 2004, Meishan Iron & Steel and Baosteel Chemical emitted 7206225×104m3/a of non-fugitive waste gas, 999t/a of smoke gas, 2725t/a of dust, 18156t/a of SO2 and 7637 t/a of NOx. The pollutants contained in the fugitively emitted gas are dust and SO2 with an emission amount of 6965t/a and 412t/a, respectively. 10689t/a of smoke (dust) and 18568t/a of SO2 are emitted in total. See Table 3-4. The status of the fugitive emission of characteristic pollutants in the waste gas generated from the current coke plant (including Baosteel Chemical) is described in Table 3-5.
27
Table 3-4 Emission amount of air pollutants generated by Meishan Iron & Steel in 2004 (t/a)
Pollutant Non-fugitive emission Fugitive emission Total Aggregate limit
Dust 2725
(coking: 190+2.4*)
6965
(coking: 4425+0) 9690
Smoke gas 999
(coking: 49+1.0) - 999
10600
SO2 18156
(coking: 2140+24.6)
412
(coking: 412+0) 18568 19000
NOx
7637
(coking: 85+3.0) - 7637 -
* Coking + Chemical product
Table 3-5 Fugitive emission of characteristic air pollutants generated by coke plant in 2004 (t/a)
Pollutant HCN NH3 H2S BSO BaP Phenol (NH4)2SO4waste gas
Emission 0.36 8.00 25.2 1.80 0.100 1.86 17.5
3.1.3 Current environmental problems
The coke plant (including Baosteel Chemical) of Shanghai Meishan Co., Ltd. has the following environmental problems at present:
(1) The 1# and 2# coke ovens have been in service for more than 30 years. They are old with seriously leaked walls and give off black smoke. The 3# coke oven was put into service in 1996, but no dust collection unit is installed at the coal charging and coke pushing ground station. None of the three coke ovens is provided with CDQ (coke dry quenching) unit, so no one meets the environmental protection requirement in the “access condition of coke industry” which requires that as supporting facilities, dust collection unit and CDQ unit shall be synchronously built for coal charging and coke pushing ground station. A large amount of smoke gas is emitted fugitively during coal charging and coke discharging and a lot of harmful substance goes out to atmosphere together with steam during coke quenching, resulting in serious air pollution;
(2) Phenol-cyanogen wastewater is treated by biochemical method, which however can’t remove COD and NH3-N. As a result, COD, SS and NH3-N in the phenol-cyanogen wastewater treated by this method are far from reaching standard. Besides, this part of wastewater is yet to be reused inside the company for the time being. It together with other
28
industrial wastewater generated from coke plant is discharged into the main drain and finally into the Yangtze River. Such practice is against the requirement of the “access condition of coke industry” which requires phenol-cyanogen wastewater shall be reused and not discharged to outside world.
(3) The present desulphurization rate of coke oven gas is low, only 63%, indicating about 1/3 of the gas is directly used as recycled gas in coke oven without desulphurization.
(4) In Baosteel Chemical, a large amount of equipment cooling water is consumed, the water is directly supplied with fresh water, the water reutilization rate is low and too much clean sewage is discharged, resulting in waste of water resources. Currently, a considerable amount of indirect cooling water is still directly discharged to the outside world during gas de-benzene production process. The reutilization rate of industrial water is only 76.63%, not up to Grade 2 Standard as defined in the Cleaner production standard - Coking industry.
(5) The current noise level at plant boundary is found exceeding the set limit.
(6) The backward production process of Baosteel Chemical results in low comprehensive utilization rate of resources, a large amount of hazardous waste and high disposal cost. The tar residues generated during the primary cooling of gas and the mechanical clarification and separation of tar are yet to be rationally utilized, resulting in resource waste and environmental pollution.
(7) Rainwater and sewage use same sewerage at North Discharge Outlet. In recent years, the branch company increased investment in environmental protection and upgraded workshop sections one after another by separating clean water from dirty water, but the work on building separate networks for clean water and sewage inside the plant is not thorough enough. The drain network has been in service for more than three decades since the establishment of the plant. Part of the network is seriously eroded and imposing certain threat to environmental protection and safe production.
The foresaid environmental problems form the main content of “pushing ahead old by new” of this project.
3.2 Overview of the construction project
3.2.1 Name, nature, location and total investment
Name: Systematic project for relocated overhaul of the #1 and #2 coke ovens of Shanghai Meishan Iron & Steel Co., Ltd.
Nature: Technology innovation
Location: In the new plant area of Shanghai Meishan Iron & Steel Co., Ltd. (north of the original coke plant, it is newly requisitioned land. After this project is implemented, the original site will be used as reserve land for future development of the company).
Total investment: the total investment of the project is RMB1300.5072 million, of which RMB160 million is for environmental protection, accounting for 12.3% of the total investment.
29
3.2.2 Floor space, number of employees and plant layout
Floor space: 200000m2.
Number of employees: 417 (all from the original plant and no new employees).
General layout: the general layout of the buildings, structures, transport routes, pipelines and landscaping of the plant shall be practically and pertinently designed on the precondition of meeting the requirement of production process and in light of the requirements of traffic, transport, fire protection, safety, sanitation, landscaping, general pipeline network and construction. Meanwhile the design shall give full consideration to the organic linkage of works in different phases and the natural conditions in the plant area such as topography, geology and meteorology. Great effort shall be made to ensure a compact and reasonable layout, save land, reduce investment, create favorable condition for production and provide convenience for management. Moreover, in the design, workshops and sections shall be arranged in different zones or combined together according to their functions.
The general layout of the project is shown in Fig 3-1.
3.2.3 Production scale, product scheme, product quality and work system
(1) Production scale and product scheme
The project has a production scale of annually producing one million t/a of coke and adopts 2×55-hole JN60−6 reheating coke ovens and their supporting devices for coal preparation, coke sieving, CDQ (1×140t/h), gas refining and chemical product recovery (the total design capacity of gas cleaning: 50160m3/h). The output of main products in this project and their changes before and after technology innovation are described in Table 3-6.
Table 3-6 Output of main products and their changes before and after technology innovation
No. Product Unit Before technology
innovation After technology
innovation Increase/
decrease (+-)
1 Coke (dry base) 104t/a 120.5 100 -20.5
2 Coke oven gas 104m3/a 53800 45007 -8793
3 Tar t/a 69264 48180 -21084
4 Crude benzol t/a 8514 13724 +5210
5 Sodium phenolate (9%) t/a 1372 4895 +3523
6 Sodium thiocyanate t/a 113 - -
7 Hypo soda t/a 496 - -
8 Ammonium sulfate t/a 19316 - -
9 Sulfuric acid (98%) t/a 445 (sulfur) 9156 -
10 Anhydrous ammonia t/a - 2900 -
11 Power generation 104kWh - 9532.0 -
12 Steam t/a - 196337 -
30
(2) Quality standard for main products and byproducts
The quality standard for the main products and byproducts of the project is described in Table 3-7.
Table 3-7 Quality standard for the main products and byproducts of the construction project
Main quality indicators for Class I metallurgical coke (GB/T1996-2003)
Item Indicator
Ash content Ad ≤12 %
Sulfur content Stad ≤0.6 %
M40 >92 %
M10 ≤7 %
Volatile content Vdaf ≤1.8 %
Content of impurities in gas before and after cleaning
Impurity content (g/m3) Before cleaning After cleaning
Tar - 0.05
NH3 6-9 0.1
H2S 4-8 0.2
HCN 1.5 0.15
BTX 30-40 3
Naphthalene - 0.1
Tar ——meets YB/T5075-1993 (#1 indicator)
Density (20°C) 1.15∼1.21g/cm3
Toluene insoluble material (TIM) (non-water base)
3.5∼7%
Ash content ≤0.13%
Water content ≤4.0%
Viscosity (E80) ≤4
H2SO4
Concentration in winter (non-winter) 95±0.5%(98±0.5%)(Wt)
Sulfated ash ≤0.05%(Wt)
Fe ≤0.03%(Wt)
Dissolved rate of SO2 ≤0.03%(Wt)
31
Dissolved rate of NOX ≤0.005%(Wt)
Sodium phenolate
Phenol ≥9%
Free alkali ≤5%
Neutral oil ≤3%
Crude benzol
Appearance Yellow transparent liquid
Density (20°C) 0.870~0.880g/cm3
Distillate amount before 180℃ (Wt) 91%~93%
Temperature for 96% distillation ≤150℃
Anhydrous ammonia
Ammonia ≥99.8%
Water ≤0.2%
Color Colorless
(3) Work system
The project operates 365D a year and 24h a day. Its CDQ unit operates 340D a year and 24h a day.
3.3 Engineering analysis of the construction project
3.3.1 Project composition
With respect to the systematic project for relocated overhaul of the #1 and #2 coke ovens of Meishan Iron & Steel, its construction involves such production facilities as coal preparation workshop, coking workshop (including coke sieving), CDQ workshop and gas cleaning workshop as well as corresponding public auxiliary facilities.
After completion of this project, all of the main production facilities in the current coke plant will be eliminated at one time without transitional period.
The composition of the construction project is described in Table 3-8.
(1) Production facilities
a. Coal preparation workshop: consist of coal blending room, pulverizer room and top layer of coal tower as well as corresponding belt conveyer, transfer tower and etc;
b. Coking workshop: consist of 2×55-hole JN60−6 coke ovens, coke quenching and coke sieving and storage facilities as well as corresponding belt conveyer, transfer tower and etc. The main machinery equipment for coke ovens is described in Table 3-9.
32
c. CDQ workshop (CWQ unit is standby): consist of process equipment, CDQ boiler, power generation system, dust collection system and etc. The main equipment in CDQ unit is described in Table 3-10.
d. Gas cleaning workshop: consist of gas conveyance unit, inter-cooling naphthalene scrubber, FRC desulphurization and acid preparation unit, anhydrous ammonia unit, light oil trap, light oil distillation unit, solvent de-phenol unit, ammonia distillation unit and tank area (tar processing and crude benzol refining use original units).
(2) Public auxiliary facilities
Include transport facilities, water supply and drainage system, circulating water system, heating power facilities, telecom facilities, instruments and process automation facilities, ventilation and dust collection facilities, LiBr refrigeration station, compressed air station, deoxygenation water supply pump station, power distribution and supply facilities and etc.
Table 3-8 Composition of the construction project*
Works Composition
Coal preparation workshop: consist of coal blending room, pulverizer room and top layer of coal tower as well as corresponding belt conveyer, transfer tower and etc
Coking workshop: consist of 2×55-hole JN60−6 coke ovens, coke quenching and coke sieving and storage facilities as well as corresponding belt conveyer, transfer tower and etc
CDQ unit: consist of process equipment, CDQ boiler, power generation system, dust collection system and etc. (CWQ unit is standby)
Main works
(production facilities)
Gas cleaning workshop: consist of gas conveyance unit, inter-cooling naphthalene scrubber, FRC desulphurization and acid preparation unit, anhydrous ammonia unit, light oil trap, light oil distillation unit, solvent de-phenol unit, ammonia distillation unit and tank area (tar processing and crude benzol refining use original units)
Public auxiliary facilities
Include transport facilities, water supply and drainage system, circulating water system, heating power facilities, instruments and process automation facilities, ventilation and dust collection facilities, LiBr refrigeration station, compressed air station, deoxygenation water supply pump station, power distribution and supply facilities, telecom facilities and etc
*: After completion of the project, all of the main production facilities in the current coke plant will be eliminated at one time without transitional period.
33
Table 3-9 Main machinery equipment for coke oven
Quantity (set) No. Name
In service Standby
1 Coal car 1 1
2 Pusher machine 1 1
3 Coke guide machine 1 1
4 Electric locomotive (shared by CDQ and CWQ) 1 1
5 Coke car 0 1
6 Hydraulic reversing device 2 0
Table 3-10 Main equipment for CDQ process
No. Name & Spec. Unit Quantity Remarks
1 Feeder Set 1
2 Carrier vehicle Set 3 2 in service 1 standby
3 Rotary coke drum Piece 3 2 in service 1 standby
4 Gas supply unit Set 1
5 Shell of CDQ boiler Set 1
6 Lift Set 1
7 Primary dust collector Piece 1
8 Secondary dust collector Piece 1
9 Heat-pipe exchanger Piece 1
10 Elevator Piece 1
11 Coke discharging unit Set 1
12 High temperature compensator Set 2
13 Alignment unit Set 1
3.3.2 Public works
(1) Water supply and drainage
The water used by the construction project is supplied by Shanghai Meishan Co., Ltd. in a unified manner. The total water consumption of coking production is 5133.3 m3/h, including 50m3/h of desalinated water (fresh water from the desalination station of Meishan Iron &
34
Steel for steam production by CDQ boiler), 83.3 m3/h of reuse water (from the general sewage treatment plant of Meishan Iron & Steel) and 5000 m3/h of circulating water. The water circulation rate is 97.4%.
The coking step discharges 50.5 m3/h of production wastewater which is mostly equipment cooling water, and steam condensed water of DCQ boiler (the collected floor wash water is used to prepare coal and mix materials) into the Yangtze River from North Discharge Outlet of Meishan Iron & Steel. The water balance at coking step of the project is shown in Fig 3-2.
Simultaneous with the systematic project for relocated overhaul of coke ovens of Meishan Iron & Steel, a new gas cleaning workshop of Baosteel Chemical will be built, too, and the water consumption system, phenol-cyanogen sewage treatment plant and general layout all will undergo thorough upgrading: redesign general layout, significantly reduce the consumption of indirect cooling water and rebuild phenol-cyanogen sewage treatment plant of which design capacity is 300 m3/h and discharged water will be used to flush BF slag after meeting Grade 1 discharge standard. After the project is completed, the total water consumption of Baosteel Chemical will reach 8246 m3/h, including 200m3/h of fresh water, 7 m3/h of desalinated water and 8039 m3/h of circulating water, and the water circulation rate is 97.5%. 98.2m3/h of phenol-cyanogen wastewater will discharged into BF to flush slag (at present, the #1, #2 and #3 BFs of Meishan Iron & Steel consume 1.74, 1.73 and 1.09 million t/a of fresh water to flush slag, respectively, totaling 4.56 million t/a. This project will discharge about 0.86 million t/a of phenol-cyanogen wastewater, which can all be used as supplemented slag flushing water of the current #1, #2 and #3 BFs). 62m3/h of process and equipment cooling water is discharged into the Yangtze River from North Discharge Outlet. Comparing with the condition before technology innovation, the volume of discharged wastewater is cut by 94%. The balance of water consumption and discharge in the intended project of Baosteel Chemical is shown in Fig 3-3.
As the construction project won’t increase the total number of employees of the company and all production staff will be solved inside the company, it increases neither the consumption of domestic water nor the discharge amount of domestic sewage. The domestic sewage in the project area is treated in a septic tank at first and then sent to the domestic sewage treatment plant of Meishan Iron & Steel for further treatment. In the plant, when the concentrations of pollutants in the outflow water are up to Grade 1 Standard as defined in the Integrated wastewater discharge standard (GB8978-1996), the water will be discharged into the Yangtze River from West Discharge Outlet.
35
Fig 3-2 Water balance at coking step of the construction project (unit: m3/h)
3
Coal preparation (including coal blending and pulverizing
Dust collection and humidification at ground
station
Dust collection and humidification
Floor wash water
CDQ equipment cooling water and other equipment cooling
water
Cooling water reservoir
Cooling tower
CDQ boiler
5000
32.5
21.2
7
12
3.3 2.8
Supplemented reuse water 83.3
Desalinated water：50
d 50
North Discharge Outlet
Steam user
5
21.2
12
0.5
43.5
7.3
5 27
18
5000
Coal preparation and material mixing
2
36
Fig 3-3 Balance of water consumption and discharge in the intended project of Baosteel Chemical (m3/h)
North Discharge Outlet: 62
0.4
Other water consumption
Floor wash water
Process water
phenol-cyanogen sewage treatment station
1.5
1.4
5.6
11.9
9.8
12.1
Steam used by all processes
Supplementary water for landscaping and manmade lake
17
12.1
28.9
Steam 30
Gas final cooling blowdown water
2.2
1.1
Remove phenol by solvent
0.9 Tar separating water
46.0
8.3
54.3
Circulating water 36.8
1.5
8.3
89.3
0.5 enter product
Remaining ammonia water
35.4
Gas sealing water1.4
Flushing of BF slag: 98.2
52.5 4747
Equipment cooling water
85.4
37.5
47.9
3292
59.8
Fresh water: 200
Desalinated water: 7
7
10.3
1.4
Ammonia distillation
37
(2) Thermodynamics
The thermodynamic media that coking needs in the construction project include: steam, compressed air, purified compressed air, nitrogen and so on. Their consumption is listed in Table 3-11.
Table 3-11 Summary of thermodynamic media coking needs
Parameter Consumption
No. Medium Pressure
(MPa)
Temperature (℃)
Unit consumption
Annual consumption
Remarks
0.4~0.6 250 10.97t/h Self supplied by CDQ
system
1 Steam
0.8~1.0 Saturated 5.25t/h
74953 t Used during startup of CDQ and supplied by Meishan Iron & Steel
2 Compressed
air 0.7 40 16.4m3/min 4594200m3
Standard state, supplied by Meishan Iron &
Steel
3 Purified
compressed air 0.6 40 45m3/min 23652000m3
Standard state, supplied by Meishan Iron &
Steel
4 Nitrogen 0.5 Normal
temperature7m3/min 3427200m3
Standard state, supplied by Meishan Iron &
Steel
The thermodynamic media that the gas cleaning section needs include: steam, compressed air, purified compressed air, nitrogen, low-temperature water, soft water, condensed water and so on. Their consumption is listed in Table 3-12.
Table 3-12 Summary of thermodynamic media gas cleaning needs
Parameter Consumption
No. Medium Pressure
(MPa)
Temperature (℃)
Unit consumptionAnnual
consumption
Remarks
0.4~0.6 250 24.75t/h
Summer 16.01t/h0.8~1.0 Saturated
Winter 1.05t/h
216810t 1 Steam
3.5 Saturated 5.25t/h 45990t
38
Parameter Consumption
No. Medium Pressure
(MPa)
Temperature (℃)
Unit consumptionAnnual
consumption
Remarks
2 Compressed air 0.7 40 7.2m3/min 525600m3 Standard state
3 Purified
compressed air 0.6 40 8m3/min 4204800m3 Standard state
4 Nitrogen 0.5 Normal
temperature11.1m3/min 2067360m3 Standard state
5 Desalinated
water 0.4
Normal temperature
7t/h 61320t
(3) Electric power
In light of load distribution, two comprehensive electric rooms (with 10kV power distribution units): coke comprehensive electric room and CDQ comprehensive electric room are designed. Each of the 10kV power distribution units has two independent 10kV power sources led out from an upper-level transformer substation. Each of the power sources can undertake 100% of the load of the power distribution substation in question.
A waste heat power station is set up for CDQ. The station is installed with a 10.5kV 12000kW extraction condensing turbo-generator set. The steam turbine power station observes the principle of “generating power based on heat demand”. The generator runs according to heat load. The amount of power generation is restricted by the amount of heat supply. The generator in the steam turbine generator room is connected to the CDQ 10kV power distribution unit 10kV system by mode of automatic quasi synchronization.
The gas cleaning workshop and the water system of this project have a gas cleaning comprehensive electric room in which there are 10 kV power distribution unit room, transformer room, LP power distribution room, PLC cabinet room, PLC operation room, cable room and auxiliary room. The two 10kV power sources of the 10kV power distribution unit are led out from two 10kV bus bars of an upper-level transformer substation. The 10kV power distribution unit is principally wired by single bus bar on a section-by-section manner and supplies power to the water treatment electric room, the 10/0.4kV transformer substation in gas cleaning area, the 10kV HV motors and so on.
The 10kV power distribution units of comprehensive electric rooms adopt 10kV indoor armored withdrawable closed metal AC switch cabinets to receive and distribute power. The operating power source of HV equipment adopts 220V DC power source provided by microcomputer controlled maintenance-free battery panel.
The balance of electric power in this project is described in Table 3-13.
39
Table 3-13 Balance of electric power Unit: kW.h
Annual power generation 9532.0×104
Annual power consumption 9712.5×104
Annual power purchase from outside 180.5×104
3.3.3 Consumption of main raw materials and fuels
The consumption of main raw materials and fuels in the project is described in Table 3-14.
Table 3-14 Consumption of main raw materials and fuels in the construction project
1 Cleaned coal (dry) t/a 1373130
2 NaOH (40%) t/a 6261.7
3 Washing oil t/a 1372
4 Phosphoric acid (75%) t/a 35
5 Picric acid t/a 25.6
6 Liquid ammonia kg/a 86.5
7 Demulsifier kg/a 2482
8 Polymer kg/a 840
9 Trisodium phosphate kg/a 952
10 PFS t/a 700
11 Sodium carbonate t/a 2190
12 PAM t/a 2
13 Phosphate t/a 35
14 Coke oven gas 104m3/a 8110
For heating of coke oven 104m3/a 6705
For CDQ boiler 104m3/a 48
For tube furnace 104m3/a 1139
For burner 104m3/a 216
Of which
For lab 104m3/a 1.6
15 BF gas 104m3/a 9864
Energy consumption at process steps
Kg standard coal/t*J
133.55
40
The cleaned coal for coking mainly includes prime coking coal, fat coal and lean coal. Water transport is adopted. The designed quality of coke-oven coal for the production of quality metallurgical coke is described in Table 3-15.
Table 3-15 Requirements on the quality of coke-oven coal
Item Indicator
Water content Mt ≤10%
Ash content Ad ≤9%
Sulfur content St.d <0.6%
Volatile Vd 23-26%
Granularity (<3mm) 72-80%
Caking index G 75
The balance of main materials in the construction project is described in Table 3-16, the gas balance in Table 3-17, the sulfur balance in Table 3-18, the ammonia balance in Table 3-19 and the steam balance in Table 3-20.
Table 3-16 Balance of main materials in the construction project
Input Output
Name t/a Name t/a
Cleaned coal (dry) 1248300 Coke (dry base) 1000000
NaOH (40%) 6261.7 Externally supplied coke
oven gas 221382
Washing oil 1372 Tar 48180
Phosphoric acid (75%) 35 Crude benzol 13724
Picric acid 25.6 Sodium phenolate (9%) 4895
Liquid ammonia 0.086 Sulfuric acid (98%) 9156
Demulsifier 2.5 Anhydrous ammonia 2900
Polymer 0.84 COD 400
Trisodium phosphate 0.95 Pollutants in waste gas 17431
PFS 700 Waste residue 39.4
Sodium carbonate 2190 - -
PAM 2 - -
Phosphate 35 - -
BF gas 59181.7 - -
Total 1318107.4 - 1318107.4
41
Table 3-17 Balance of coke oven gas in the construction project
Item No. Gas source or user Unit Yield/consumption
Income (gas yield) 1 2×55-hole coke ovens Million m3/a 450.07
1 2×55-hole coke ovens Million m3/a 67.05
2 CDQ boiler Million m3/a 0.48
3 Chemical product tube Million m3/a 13.56
4 3×blast furnaces Million m3/a 3.36
5 3×hot stoves Million m3/a 18.00
6 3×sinter machines Million m3/a 20.32
7 Heating furnace for hot Million m3/a 152.20
8 For steel-melting plant Million m3/a 21.75
9 Urban gas Million m3/a 152.90
10 Others Million m3/a 0.45
Expenditure (consumption)
Total Million m3/a 450.07
Table 3-18 Sulfur balance in the construction project
Income Output (discharge)
Name of input
material
Input amount
(million t/a)
Sulfur content
(%)
Sulfur amount
(t/a)
Name of output material
Output amount
(million t/a)
Sulfur content
(%)
Sulfur amount
(t/a)
Raw coal 1.3731 0.58 7964 Coke 1.000 0.50 5000
BF gas 864.13 115* 93.4 Coke oven gas 368.97 200 69.4
Coke oven gas
81.10 200* 15.2 Desulfurized coke
oven gas 368.97 — 2929.8
— — — — Externally
discharged waste gas— — ▲72.8
8072.6 8072.6
*The unit of gas amount is million m3/a. The sulfur content refers to the content of H2S (mg/m3).
42
Table 3-19 Ammonia balance in the construction project
Input Output (t/a)
Name Quantity
Ammonia content
(g/m3)
Ammonia amount
(t/a) Name Quantity
Ammonia content
(g/m3)
Ammonia amount
(t/a)
Inlet
gas
450.07
(million m3/a)
7.0 3150.5 Outlet
gas
450.07
(million m3/a)
0.1 45.0
Liquid ammonia
- - 0.08 Anhydrous ammonia
- - 2900
- - - - Fugitive emission
- - 7.98
- - - - Wastewater 812928(t/a) 200*(mg/l) 197.6
Total 3150.58 Total 3150.58
*Concentration of NH3-N in wastewater.
Table 3-20 Steam balance in the construction project
Income (t/a) Consumption (t/a)
Self produced by coke plant 196337 Coking step 74953
Supplied by the thermal power plant of Meishan Iron & Steel
141416 Gas cleaning 262800
Total 337753 Total 337753
3.3.4 Main production process flow and pollution sources in the construction project
(1) Coal preparation
The task of the coal preparation workshop is to store externally supplied coking coal and process it into coke-oven coal that meets the production requirement of coke oven. From the coal receiver, the cleaned coal is delivered to the coal blending room where it is blended. After blending, it is sent to the pulverizer room where it is pulverized. In the end, via vestibule and transfer tower, the coal is transported by a belt conveyer to coal storage tower where it is to be added into coke oven.
(2) Coking
The coking coal sent to coal storage tower from coal preparation workshop is weighed and charged by dust-catching coal car into carbonization chamber inside which the coal is
43
carbonized into coke at high temperature and meanwhile generates raw gas. The raw gas goes up to the top of the carbonization chamber where it enters gas collecting tube via uptake and axle tube. Raw gas is cooled by sprayed ammonia water in the axle tube and then sent to gas cleaning workshop for further treatment. The coke oven gas and BF gas used to heat coke ovens are led in through external pipelines. The waste gas generated during heating of coke oven is emitted into the atmosphere through chimney.
(3) CDQ process
When the coke inside the carbonization chamber is matured, it will be pushed out by pusher machine and led into coke drum cars by coke guide machine. The coke drum cars fully loaded with red coke will be towed by electric locomotive to the bottom of the frame of the hoisting shaft in CDQ unit, where the hoisting machine will hoist coke drums to the top of CDQ boiler. At the top, the feeder adds coke into the CDQ boiler. In the boiler, coke and inert gas make direct heat exchange. After being cooled, the coke is unloaded by coke discharging unit onto belt conveyer by which it is delivered to coke sieving system. After dust collection and heat exchange, the inert gas will be reused. The steam generated during heat exchange of CDQ boiler (waste heat boiler) is used for power generation. The schematic diagram for CDQ process flow is shown in Fig 3-4.
(4) Gas cleaning
The gas cleaning process in the construction project is undertaken by Baosteel Chemical.
a. Gas conveyance: indirect/direct cooling mode is adopted for preliminary cooling of gas. At the same time of cooling and preliminary de-naphthalene of gas, granular impurities like coal powder will be washed off from gas, thus effectively avoiding blockage of facilities at later steps. The electrostatic tar precipitator is installed in front of gas fan. Tar is removed through two-level separation by tar-ammonia separation channel and super centrifuge. The concrete flow: Tar and ammonia water are separated from the 81∼82°C raw coke oven gas by gas-liquid separator. After that, the gas enters a cross-tube primary gas cooler which operates in parallel. In the cooler, the gas is cooled by circulating water to 40-45°C and then enters direct cooling tower. In the tower, it inversely meets the circulating cooling water sprayed down from tower top and is cooled to 25-30°C. After cooling, the gas enters via a trap into the electrostatic tar precipitator which operates in parallel. The precipitator will remove the tar from the gas. After that, the gas is blown into inter-cooling naphthalene scrubber by gas fan.
b. Inter-cooling naphthalene scrubbing: the inter-cooling naphthalene scrubber consists of three sections, which from top to bottom are after-cooling section, naphthalene scrubbing section and pre-cooling section. The 45-50°C coke oven gas coming from fan enters the pre-cooling section where it is cooled by the ammonia flowing down from the after-cooling section or self-circulated ammonia to 35-36°C. Then, the gas enters the naphthalene scrubbing section where the absorbing oil sent from light oil distillation unit is heated and used to scrub naphthalene. Part of the naphthalene-enriched washing oil after absorbing naphthalene is reused and the rest is sent to light oil distillation unit for treatment. After naphthalene scrubbing, the gas enters the after-cooling section where it is cooled by ammonia water to 35°C and then sent to gas desulphurization unit.
44
c. Desulphurization and decyanogen: in order to ensure continuous and stable supply of acceptable coke oven gas and meet the requirement of steel rolling for the production of quality steel products, FRC desulphurization and decyanogene and sulfuric acid preparation technology is adopted to ensure the content of H2S in the cleaned gas is ≤0.2g/m3. The concrete flow: the gas coming out of the inter-cooling naphthalene scrubber enters absorption tower where it is removed off H2S and HCN by being sprayed with absorption liquid and then sent to anhydrous ammonia unit.
The absorption liquid at tower bottom is sent to the premix nozzle at the bottom of the regeneration tower where it is mixed with air and enters the regeneration tower. After sulfur foam is separated from the regeneration liquid by the foam separator in the middle part of the tower, the regeneration liquid is pumped back to the absorption tower for reuse via a heat exchanger where it is cooled. The separated sulfur foam rises to the top of the regeneration tower where it is discharged to a buffer tank through overflow hole. The regenerated tail gas can be directly sent to the gas pipeline behind the regeneration tower.
The suspension liquid in the buffer tank is pumped to super centrifuge for separation. The sulfur mortar separated out and the filtrate are collected into mortar tank and filtrate tank, respectively. The filtrate is pumped to a concentrating unit where it is concentrated and then sent back to the mortar tank. In the mortar tank, the filtrate is mixed with sulfur mortar and the mixture is sent to acid preparation unit. The ammonia-containing tail gas discharged from concentration tower is sent to gas absorption pipeline 吸煤气管道.
d. De-ammonia: PHOSAM method is adopted to produce anhydrous ammonia. It features advanced technology, simple process, high product quality and relatively good economic benefit. The desulphurized gas enters absorption tower from bottom and inversely meets the barren ammonium phosphate solution sprayed down from tower top. After removing ammonia, the gas is forwarded to light oil trap. A circulation pump is installed to ensure needed spray density. A certain amount of pregnant solution is continuously drawn out and sent to desorption system. Thick ammonia water is pumped into rectification tower (operating pressure is 1.5MPa). From tower bottom, direct steam (1.6MPa) is input to strip and rectify ammonia water. The pure ammonia vapor obtained from tower top is condensed into liquid anhydrous ammonia in the condenser of the rectification tower and flows into backflash. Part of it is sent to anhydrous ammonia storage tank and the rest returns to tower top as backflow. The wastewater discharged from tower bottom can be sent to ammonia distillation tower where its heat will be recovered.
e. De-benzene (light oil recovery): After desulphurization and de-ammonia treatment, the gas is hot. Before benzene washing, it has to be cooled down. Direct cooling and close-circuit circulation method is adopted. Excessive wastewater is discharged to ammonia storage tank. Tar washing oil is used to absorb the benzene contained in the gas. The benzene washer is a packed column with high efficiency and low energy consumption.
Benzene distillation (light oil distillation) adopts the process of heating and producing benzene by tube furnace method. 50-layer de-benzene tower is selected. It is characterized by high thermal efficiency, low content of benzene and naphthalene in the lean oil at tower
45
bottom, and simple operation.
f. Treatment of remaining ammonia water: the remaining ammonia water is removed off phenol by solvent, and then sent to ammonia distillation unit. The phenol in the ammonia water is extracted with light benzene. The sodium phenolate generated is sent to tar processing unit. The ammonia vapor behind the ammonia distillation tower returns to gas system, as it is good for the absorption of H2S. After de-phenol and distillation, the wastewater is sent to phenol-cyanogen wastewater treatment plant, providing reliable guarantee for the satisfaction of discharge index after further treatment.
The main production process flow and pollution sources of the construction project are shown in Fig 3-5.
Fig 3-4 Schematic diagram for CDQ process flow
Load to truck and transport to outside
Charging unit
Coke drum car
CDQ boiler
Powdery coke storage tank
Circulation fan
Discharging unitPrimary dust collector
Secondary dust collector
CDQ boiler
N2 gas
N2 gas
Coke powder
coke
Dust collecting ground station
Red coke
Smoke gasSteam power
generation
Heat-pipe exchanger
Atmosphere
Coke storage tank
Desalinated water
Water supply unit
Smoke gas Smoke gas
Smoke gas
N2 gas
46
Fig 3-5 Schematic diagram for the process flow and pollution sources of coking
Dust collection of coke warehouse
Coke sieving building
Exhaust tube
coal blending room
Coal sampling room
Coal storage tower
Dust collecting ground station
Dust collecting pipeline
Dust catching coal car
CDQ boiler
Coke carrying vehicle
Coke guide
machine
coke oven
Dust collector
Exhaust tube
Remove phenol by solvent
Electrostatic tar precipitator
cross-tube primary gas cooler
G5
G6、noise
G6
G3
G4 (containing fugitive waste gas) and noise
Gas-liquid separator
Tar-ammonia water separator Super centrifuge
Tar residues (sent to coal yard)
tank area
Inter-cooling tower
Desulphurization tower
Ammonia absorption tower
Final cooling tower
Benzol washer
Acid preparation unit
Ammonia distillation
Desorption and rectification
Anhydrous ammonia tank
Gas blower
Direct cooling tower
Oven-front coke warehouse
Wastewater and asphalt residues
Light oil distillation
NaOH
Clean gas leaves factory
Lean oil
Crude benzol
Washing oil
Liquid ammonia
H2SO4
H3PO4
Sulfur mortar
Ammonia vapor
tar Crude benzol
Phenolate Light benzene
Raw gas
Tar and ammonia
water
Circulating
amm
onia water
Rem
aining am
monia w
ater
Picric acid
Coking coal
G2 noise
G1 noise
G 3
Coke powder
NH3 and other fugitive waste gas and noise
Fugitive gas:NH3、H2S
G7 Regenerated
residues, H2S and noise
noise
noise
Coal powder
noiseFinished coke
noisenoise
Dust collecting pipeline
Dust collecting ground station
Fugitive gas:NH3、H2S
47
production
3.3.5 Status of discharge from pollution sources
3.3.5.1 Waste gas
(1) Heating of coke oven
The fuels used to heat and burn coke oven are coke oven gas and BF gas. The key pollutant in flue gas is SO2 in addition to a small amount of smoke gas. The flue gas is emitted from a 125m high chimney. The emission concentrations and speeds of smoke gas and SO2 are all up to Grade 2 Standard as stated in Table 2 of the Integrated emission standard of air pollutants.
(2) Coal preparation system
The coal preparation system involves coal transport, proportioning, even mixing and storage, and belt conveyance transfer point. During material transfer in the coal preparation system, dust suppression through sprinkling water and closed mechanical ventilation are adopted. Moreover, all dust generating points are confined and forcibly drafted, a centralized mechanical dust collection system is installed and a capturing hood is installed at each dust generating point in the coal pulverizer room to control dust emission. High-performance low-resistance DZW93 pulse bag type dust collector is adopted. The collection rate of its waste gas trap is 98%. The dust collection efficiency exceeds 99.5%. The concentration of coal dust is 2000-5000mg/m3. The dust concentration in the flue gas emitted after dust collection is about 40mg/m3. The dust emission concentration and speed are both up to Grade 2 Standard as stated in Table 2 of the Integrated emission standard of air pollutants.
(3) Flue gas generated during coal charging and coke discharging in coke oven
a. During coal charging, single gas collecting tube and high-pressure ammonia jets are used to collect dust. With the spray of high-pressure ammonia water, negative pressure is generated in the uptake to suck some of the smoke gas generated during coal charging into the gas collecting tube. The rest of the smoke gas is sent to ground station for dust collection via the flue gas suction and lead-out device on dust collecting coal car, and via dust collecting trunk. The final emission concentration of dust is lower than 40mg/m3. In order to increase the collection effect of coal dust generated during coal charging, a sealing device for small oven door is installed on pusher machine (making the collection rate of the waste gas trap reach 98%).
b. Dust collection during coke discharging: adopt ground station dust collection system, install dust hood on coke guide machine, and suck the flue gas generated during coke discharging to the ground station via the dust hood and dust collecting trunk, where the flue gas is purified and emitted to atmosphere.
c. Auto blow-off ignition unit (standby for emergency): install auto blow-off ignition unit on the gas collecting tube, which can burn down the raw gas blown off from the gas collecting tube.
(4) Smoke gas fugitively emitted during coking
The pollutants fugitively emitted from coking system are mostly granular substances, BaP,
48
BSO, H2S, NH3 and SO2, mainly resulting from the continuous leakage from the body of coke oven, and the remittent emission during coal charging, coke pushing and coke quenching. The design adopts the following control measures:
a. The coal charging cover adopts spherical sealing to facilitate a spherical contact between the cover and seat and increase the tightness of coal charging cover.
b. The oven door adopts elastic knife edges. The edges are evenly pressed by springs, resulting in a good sealing effect.
c. The sockets connecting oven-top uptake cover and axle tube to valve bodies all adopt water sealing structure, which can eliminate the phenomenon that smoke rises from the sockets of uptake cover and axle tube.
d. The root of the uptake adopts cast iron base which is sealed with woven asbestos filled with slurry to eliminate the phenomenon that smoke or fire rises from the damaged root.
After the body of coke oven adopts the above control measures, the concentrations of granular substances, BSO (benzene-soluble organics) and BaP (benzene and pyrene) are all up to Grade 2 Standard for newly built mechanized coke oven as stated in the Emission standard of air pollutants for coke oven.
(5) CDQ flue gas and dust collection system
The high-temperature flue gas generated from the top of the coke drum and the blow-off outlet of the circulation fan is captured by capturing hood (collection rate reaches 98%). After that, the flue gas is cooled down in cooler at first and then mixed with low-temperature dust generated at the coke discharging outlet, the belt conveyor of the coke discharging outlet and the new coke transfer tower. The temperature of flue gas is below 110℃ after mixing. It enters the 24000m2 pulse bag type dust collector for purification. The air volume of the system is 130000m3/h. The dust collection efficiency is 99.5%. The emission concentration is 35mg/m3. The purified gas is emitted to the atmosphere via fan and muffler. The dust collected by dust collector converges with the dust collected by primary and secondary dust collectors through scraper conveyor. The converged dust is delivered by bucket elevator to dust storage tank where it is humidified by humidifier and then cleared by truck on a regular basis.
(6) Coke sieving, and dust collection of the oven-front coke warehouse
In this production system, the main dust sources are transfer tower of belt conveyor, coke tank, vibration feeder, oven-front coke warehouse, and truck forwarding and unloading points. As different production devices have different production time, electric valve is installed on the wind pipe of each capturing hood to reduce energy consumption. The dusty gas collected by capturing hood (collection rate reaches 98%) enters 50000m2 pulse bag type dust collector and is emitted to the atmosphere via fan and muffler. The air volume of the system is 210000m3/h. The emission concentration is 40mg/m2. The dust collected by dust collectors is converged through scraper conveyor and then sent to dust storage tank by bucket elevator where it is humidified by humidifier and taken away by special-purpose truck.
49
(7) Air pollutants generated by gas cleaning workshop
The pollutants emitted to the atmosphere from the gas cleaning workshop are mainly from the bleeders and exhaust outlets of equipment and the leakage of equipment pipelines. The main pollutants emitted are volatile substances of raw materials, combustion waste gas and other harmful substances. To be specific, they are: NH3, H2S, SO2 and so on.
It is designed to mix the tail gas discharged from the regeneration tower into coke oven gas at a proper ratio. With respect to the gas emitted from bleeders of oil tank separators at crude benzol distillation workshop section, measures of installing breathing valves and charging nitrogen to tank top are adopted to reduce external emission. The gas cleaning process adopts gas F.R.C desulphurization technology to reduce the emission of such pollutants as SO2 when gas is burned as fuel. Tube furnace uses the cleaned gas as fuel. The combustion waste gas is emitted from a 25m high chimney.
The status of non-fugitive emission of waste gas in the construction project is described in Table 3-21. The status of fugitive emission of waste gas from non-point sources such as the body of coke oven is descried in Table 3-22. The yield, reduction and emission of pollutants in the construction project are described in Table 3-23.
From Table 3-21, we can see all non-fugitive waste gases are up to emission standard.
50
Tabl
e 3-
21 A
naly
sis o
f air
pol
lutio
n so
urce
stre
ngth
(non
-fug
itive
em
issi
on so
urce
s) in
cok
e pl
ant
Emis
sion
par
amet
er
Gen
erat
ion
Emis
sion
A
sses
smen
t sta
ndar
d
No.
Em
issi
on
sour
ce
Emis
sion
heig
ht
(m)
Chi
mne
y
diam
eter
(m)
Emis
sion
T(℃
)
Am
ount
of
was
te g
as
m3 /h
Cou
nter
mea
sure
s
Rem
oval
rate
Po
lluta
nt
mg/
m3
kg/h
m
g/m
3kg
/h
t/a
Emis
sion
mod
e m
g/m
3kg
/h
Sour
ce
G1
Coa
l ble
ndin
g
room
25
1.
2 25
50
000
Puls
e ba
g ty
pe
dust
col
lect
ion
≥99
%
Dus
t 50
00
250
40
2.0
17.5
C
ontin
uous
12
0 14
.45
G2
Coa
l
sam
plin
g
room
25
1.2
35
7500
Pu
lse
bag
type
dust
col
lect
ion
≥99
%
Dus
t 50
00
37.5
40
0.
3 2.
6 C
ontin
uous
12
0 14
.45
≥99
%
Dus
t 10
000
2200
40
8.8
77.1
12
0 14
.45
0 SO
2 13
.5
3.0
13.5
3.
0 26
.0
G3
Coa
l cha
rgin
g
and
coke
disc
harg
ing
25
0.7
35
2200
00
Gro
und
stat
ion
and
bag
type
dust
col
lect
ion
40%
B
aP
0.5
×10-3
1.1×
10-4
0.3
×10-3
6.6
×10-5
0.58
×10-3
Inte
rmitt
ent
0.3
×10-3
0.29
×
10-3
SO2
38.2
6.
5 38
.2
6.5
56.6
55
0 26
6
Smok
e ga
s 10
1.
6 10
1.
6 14
.0
Con
tinuo
us
120
133
G4
Cok
e ov
en
chim
ney
125
3.0
108
1622
78
Mix
ed g
as
-
NO
x 16
2.
6 16
2.
6 22
.4
G5
CD
Q d
ust
colle
ctio
n
syst
em
40
1.5
150
1300
00
Bag
type
dus
t
colle
ctio
n ≥
99%
D
ust
1000
013
0 35
4.
6 40
.0
- 12
0 39
G6
Ove
n-fr
ont
coke
war
ehou
se
Cok
e si
evin
g
30
1.2
80
1050
00
Bag
type
dus
t
colle
ctio
n ≥
99%
D
ust
1000
010
5 40
4.
2 36
.8
- 12
0 23
GB
1629
7-19
96
Tabl
e 2
Gra
de 2
SO2
42.8
0.
5 42
.8
0.5
4.3
850
- G
B90
78—
96
Smok
e ga
s 10
0.
1 10
0.
1 1.
0 12
0 13
3
G7
Tube
furn
ace
25
0.7
108
1166
6 C
lean
ed c
oke
oven
gas
-
NO
x 16
0.
2 16
0.
2 1.
6
Con
tinuo
us
51
Table 3-22 Fugitive emission of air pollutants in the construction project (t/a)
No. Pollution source Dust SO2 H2S NH3 HCN Phenol BSO BaP
Side length of non-point source
(m)
1 Body and door of coke oven
40 20 16.2 6.8 0.12 1.1 0.6 0.03 32.5×10
×2 sets
2 Coking material
yard 10 - - - - - - - 240×160
3 Gas cleaning - - 4.5 0.6 - - - - -
Total - 50 20 20.7 7.4 0.12 1.1 0.6 0.03 -
Table 3-23 Yield, reduction and emission of air pollutants in the construction project (t/a)
Pollutant Yield Reduction Emission
Dust 4035.5 3811.5 224
Smoke gas 15.0(Baosteel Chemical 1.0) - 15.0(Baosteel Chemical 1.0)
SO2 106.9(Baosteel Chemical 4.3) - 106.9(Baosteel Chemical 4.3)
NOx 24.0(Baosteel Chemical 1.6) - 24.0(Baosteel Chemical 1.6)
H2S 20.7(Baosteel Chemical 4.5) - 20.7(Baosteel Chemical 4.5)
BSO 0.6 - 0.6
BaP 0.031 0.39 ×10-3 0.0306
NH3 7.4(Baosteel Chemical 0.6) - 7.4(Baosteel Chemical 0.6)
HCN 0.12 - 0.12
Phenol 1.1 - 1.1
3.3.5.2 Wastewater
(1) Coking
The coking step discharges 50.5 m3/h of production wastewater in total, including 32.5 m3/h of equipment cooling water and 18.0 m3/h of steam condensed water from CDQ boiler. The wastewater is discharged into the Yangtze River from North Discharge Outlet of Meishan Iron & Steel. The collected floor wash water is used to prepare coal and mix materials and isn’t discharged to outside world.
52
(2) Gas cleaning workshop
The gas cleaning workshop of the construction project generates 98.2 m3/h of phenol-cyanogen wastewater, including 54.3 m3/h of ammonia distillation wastewater, 36.8 m3/h of circulating direct cooling blowdown water from gas final-cooling system, 5.6 m3/h of floor wash water and 1.5 m3/h of production process drain.
The production sewage mainly contains volatile phenol, petroleum, NH3-N, CODcr and other water-borne pollutants. It is treated at the phenol-cyanogen wastewater treatment plant (the upgraded phenol-cyanogen sewage treatment plant, which has a design capacity of 300 m3/h). When the outflow water is up to Grade 1 Standard as stated in Table 3 of the Discharge standard of water pollutants for iron and steel industry (GB13456—92), it will be used to flush BF slag (currently, the #1, #2 and # 3 BFs of Meishan Iron & Steel use 1.74, 1.73 and 1.09 million t/a of fresh water to flush slag, respectively, i.e. 4.56 million t/a in total. This project discharges about 0.86 million t/a of phenol-cyanogen wastewater, which all can be used as supplementary slag flushing water for the current #1, #2 and # 3 BFs of Meishan Iron & Steel).
The gas cleaning workshop discharges 62m3/h of wastewater in total, including 47.9 m3/h of equipment cooling water, 11.9 m3/h of steam condensed water and 2.2 m3/h of other wastewater. The wastewater is discharged into the Yangtze River from North Discharge Outlet of Meishan Iron & Steel. The status of wastewater discharge in the construction project is described in Table 3-24.
As the construction project won’t increase the total number of employees of the company, it doesn’t increase the consumption of domestic sewage. The domestic sewage in the project area is treated in septic tank at first and then sent to the domestic sewage treatment plant of Meishan Iron & Steel for further treatment. In the plant, when the concentrations of pollutants in the outflow water are up to Grade 1 Standard as defined in the Integrated wastewater discharge standard (GB8978-1996), the water will be discharged into the Yangtze River from West Discharge Outlet.
Initial rainwater: the initial rainwater (rainwater in the first 15 minutes of rainstorm) in such places as the gas cleaning unit area of this project contains pollutants. According to comparison, it is predicted 30 m3/time of initial rainwater will be generated. The collected initial rainwater is automatically led into the phenol-cyanogen wastewater treatment plant where it is treated and then sent to BFs to flush slag (not included the calculation of water balance).
Table 3-24 Status of discharge of production wastewater in the construction project
COD Item Wastewater (t/a)
mg/l t/a
Coking step 442380 40 17.7
Gas cleaning 543120 40 21.7
Total 985500 - 39.4
53
3.3.5.3 Solid waste
The main solid waste generated in this project includes the dust recovered by dust (coke dust) collecting equipment, tar residues generated at gas conveyance section, asphalt residues generated by ammonia distillation tower, regenerator residues generated in light oil distillation section and remaining sludge generated by phenol-cyanogen sewage treatment system. Among them, tar residues, asphalt residues, regenerator residues and remaining sludge are hazardous solid wastes. The yield and disposal of solid waste are described in Table 3-25.
Table 3-25 Yield and disposing measures of solid waste in the construction project
No. Solid waste Code Yield (t/a) Disposing measures
1 Dust in dust collectors
(coal dust) 84 10310
Humidified and then transported by truck to coal yard for coal preparation
2 DCQ dust collection etc.
(coke dust) 84 5000 Sent to sinter plant for material blending
3 Residues of crude benzol 11 612 In tar drum
4 Asphalt residues 11 30 Coal blending
6 Dry sludge 11 210 Coal blending
7 Tar residues 11 1269 Coal blending
Gas is cleaned in Baosteel Chemical
3.3.5.4 Noise:
The noise generated by this project refers to the mechanical noise due to mechanical collision, friction, rotation and other types of movements, and the aerodynamic noise due to fluctuation of air currents or aerodynamic force. The main noise sources include: pulverizer, induced-draft fan, dust collection fan, air ventilation unit, blower, CDQ coke discharging unit, CDQ circulation fan, circulating gas pipeline, exhaust unit of the safety valve of CDQ boiler, and pumps.
The noise source strength and countermeasures of main noise-generating equipment in the construction project are described in Table 3-26.
Table 3-26 Main noise sources in the construction project
Workshop Noise generating
equipment
Measuring distance
(m)
Noise level dB(A)
Countermeasures Effect
Coal pulverizing room pulverizer 2 88-97
Coke sieving equipment
2 92-99
Sound insulation and vibration reduction
Gas fan 2 91-96 Muffler Coking
workshop Coke pusher 3 86 Sound attenuation
and insulation
Up to standard on
plant boundary
54
Workshop Noise generating
equipment
Measuring distance
(m)
Noise level dB(A)
Countermeasures Effect
Air compressor 1
90-100 Sound insulation,
vibration reduction and muffler
Water pump 1
85-96 Sound insulation and vibration reduction
Dust collection fan 2 97 Muffler
Power generator 1
92 Sound insulation and vibration reduction of machine room
Auxiliary works
Cooling tower 1 80 Reasonable layout
3.3.5.5 Source strength of accidental emission
Possible accidents of the construction project: (1) Blow-off of coke oven gas: a large amount of gas is blown off from oven top in a short time (direction emission for 10min) and causes air pollution. (2) Accident of CDQ unit: temporarily use the standby CWQ unit. The main reasons for such accident are equipment failure and power outage.
Through analogous analysis, the source strength of accidental emission is described in Table 3-27.
Table 3-27 Source strength of accidental emission in the construction project
Pollutant Gas volume (m3) Smoke (dust) (kg) SO2 (kg)
Direct blow-off of coke oven gas 8563 Smoke gas 59.0 80.5
Dust from coke quenching tower - Dust 3.50 -
3.3.5.6 Summary of pollutant discharge amount in the construction project
The Summary of pollutant discharge amount in the construction project is described in Table 3-28.
55
Table 3-28 Summary of pollutant discharge amount in the construction project (t/a)
Type Discharge
mode Pollutant Yield Reduction Discharge
Dust 3985.5 3811.5 174
Smoke gas 15 (Baosteel Chemical
1.0) -
15 (Baosteel Chemical 1.0)
SO2 86.9 (Baosteel Chemical 4.3)
- 86.9 (Baosteel Chemical 4.3)
NOx 24.0 (Baosteel Chemical 1.6)
- 24.0 (Baosteel Chemical 1.6)
Non-fugitive
BaP 0.97 ×10-3 0.39 ×10-3 0.58 ×10-3
Dust 50 - 50
SO2 20 - 20
H2S 20.7 (Baosteel Chemical 4.5)
- 20.7 (Baosteel Chemical 4.5)
BSO 0.6 - 0.6
BaP 0.03 - 0.03
NH3 7.4 (Baosteel Chemical 0.6)
- 7.4 (Baosteel Chemical 0.6)
HCN 0.12 - 0.12
Waste gas
Fugitive
Phenol 1.1 - 1.1
Waste water
Continuous COD 39.4 (Baosteel Chemical 21.7)
- 39.4 (Baosteel Chemical 21.7)
Solid waste - - - - 0
3.3.5.7 Analysis on the measure of “pushing ahead old by new” of the construction project
(1) By demolishing 3 old coke ovens and building 2 new ones as well as their supporting CDQ unit and ground station dust collection unit, the fugitive emission of smoke and dust is significantly reduced and that of other air pollutants is brought under control, too.
(2) The adoption of FRC desulphurization and sulfuric acid preparation technology significantly raises the desulphurization rate of coke oven gas (above 95%), ensures the content of H2S in the cleaned gas is ≤0.2g/m3, and greatly reduces the emission of SO2.
(3) Simultaneous with the systematic project for relocated overhaul of coke ovens of Meishan Iron & Steel, a new gas cleaning workshop of Baosteel Chemical will be built, too,
56
and the water consumption system, phenol-cyanogen sewage treatment plant and general layout all will undergo thorough upgrading: redesign general layout, significantly reduce the consumption of indirect cooling water and rebuild phenol-cyanogen sewage treatment plant of which design capacity is 300 m3/h and discharged water will be used to flush BF slag after meeting Grade 1 discharge standard. The project thoroughly solves the problem that COD, SS and NH3-N in the phenol-cyanogen wastewater are not up to standard. It meets the requirement of the “access condition of coke industry” which requires phenol-cyanogen wastewater shall be reused and not be discharged to outside world. Meanwhile, it also significantly reduces the external discharge of equipment cooling water (down by about 94%).
The new gas cleaning workshop also eliminates current fugitive emission of waste gas, leakage and loss from valves, pipelines, pumps and other equipment.
(4) Tar residues and other hazardous waste in the construction project are appropriately disposed (coal blending), avoiding environmental pollution and resource waste.
(5) Through upgrading pipelines and discharge outlets, this project further improves the network of drainage and the separation of clean and waste water inside the plant. Rainwater and sewage use separate sewers at North Discharge Outlet.
(6) The construction project adopts vibration reduction and sound attenuation and insulation measures for noise generating equipment and can ensure the noise at the boundary of the plant is up to standard, thus solving the current problem that the noise level at No. 11 measurement point during night exceeds the set limit.
3.3.5.8 Changes of pollutant discharge amount before and after the completion of the project
The changes of pollutant discharge amount of the coke plant (including coking and chemical product sections) before and after the completion of the project are described in Table 3-29. From the table, we can see that after the systematic project for relocated overhaul of the # 1 and #2 coke ovens is completed, the fugitive emission of smoke and dust, the emission of SO2, the discharge of clean sewage generated in chemical product section and the discharge of COD in the coke plant all decrease significantly.
Changes of pollutant discharge amount from Shanghai Meishan Co., Ltd. before and after the completion of the construction project are described in Table 3-30.
Table 3-29 Changes of pollutant discharge amount before and after the completion of the construction project (t/a)
Type Discharge
mode Pollutant Before overhaul After overhaul Reduction
Dust 192.4 174 18.4
Smoke gas 50.0 15.0 35.0
SO2 2164.6 86.9 2077.7
NOx 88.0 24.0 64.0
Waste gas
Non-fugitive
BaP - 0.58 ×10-3 -
57
Type Discharge
mode Pollutant Before overhaul After overhaul Reduction
Dust 4425 50 4375
SO2 412 20 392
H2S 25.2 20.7 4.5
BSO 1.80 0.6 1.20
BaP 0.10 0.03 0.07
NH3 8.00 7.4 0.60
HCN 0.36 0.12 0.24
Phenol 1.86 1.1 0.76
Fugitive
Waste gas of (NH4)2SO4 17.5 - 17.5
Clean sewage from coking section
558888 442380 116508
Clean sewage from chemical product section
8043432 543120 7500312
Phenol-cyanogen wastewater
1086240 860232 (no
external discharge)
1086240
COD 1220 39.4 1180.6
Waste water
Continuous
SS 418.5 - 418.5
58
Tabl
e 3-
30 C
hang
es o
f pol
luta
nt d
isch
arge
am
ount
from
Sha
ngha
i Mei
shan
Co.
, Ltd
. bef
ore
and
afte
r th
e co
mpl
etio
n of
the
cons
truc
tion
proj
ect (
t/a)
Type
Po
lluta
nt
Exis
ting
proj
ects
Th
is p
roje
ct
Red
uctio
n of
dis
char
ge b
y th
is p
roje
ct
thro
ugh
mea
sure
of “
push
ing
ahea
d ol
d by
ne
w”
Fina
l dis
char
ge a
mou
nt o
f Sh
angh
ai M
eish
an C
o., L
td.
Incr
ease
/dec
reas
e (
+ -)
Dus
t 96
90
224.
0 43
93.4
55
20.6
-4
169.
4
Smok
e ga
s 99
9 15
.0
35.0
97
9 -2
0.0
SO2
1856
8 10
6.9
2469
.7
1620
5.2
2362
.8
Was
te g
as
NO
x 76
37
24.0
64
.0
7597
.0
-40
CO
D
4012
.8
39.4
11
80.6
28
72
-114
1 W
aste
wat
erSS
41
35.7
-
418.
5 37
17.2
-4
18.5
59
4. Assessment of pollution prevention and control measures
4.1 Waste gas treatment measures
(1) Coal preparation
The coal pulverizer room is provided with pulse bag filters, with waste gas trapping rate of 98% and dust removal rate of over 99.5%. The coal handling station, pulverizer room and coal conveying corridors are in enclosed structure, and the coal yard is provided with water spraying facilities to suppress dust, to prevent spreading of coal dust to cause secondary pollution.
(2) Heating of coke ovens
The coke ovens are heated with fuel of coke gas and blast furnace gas, and the main pollutants in flue gas are SO2, NOX and a small amount of smoky dust. At present, exhausting in coking plants in China is mainly via high stacks, and this practice is also adopted in this project, with the stack height as 125m.
(3) Smoke and gas in coke oven coal loading and coke discharge and control measures
a. For dust removal in coal loading, ammonia water at high pressure is sprayed in single gas collecting pipe, to form a negative pressure in the riser, to suck part of the smoky dust generated during coal loading into the collecting pipe, and the remaining smoky dust passes through the gas suction and leading out mechanism of the coal loading dust removing cart or is sent to the ground station via the dust collecting trunk for dust removal, to reduce the escaping dust by 60%. For better dust trapping effect in coal loading, a sealing device for oven coal gate is provided on the coke pusher (to raise the waste gas trapping rate to 98%).
b. Dust removal for coke discharge: the smoke produced during coke discharge flows through the dust collecting hood on the coke pusher (with a waste gas trapping rate of 98%) and sucked via the dust collecting trunk to the ground station for cleaning before exhausting.
After the cleaning, the smoke can meet the requirements of class II standard in “Integrated emission standard of air pollutants” in terms of discharge concentration and rate. The equipment is based on advanced and reliable technology, and the emission can steadily meet the standard after treatment of pollutants.
The ground dust removing station system for coal loading and coke discharge is as shown in Fig. 4-1.
60
Fig. 4-1 Ground dust removing station system for coal loading and coke discharge
(4) Smoke and dust control measures for coking
a. Spherical sealing is used for the coal loading port cap, to provide spherical contact between the cap and the base, to provide additional seal-tightness for the coal loading cap.
b. Elastic edge is provided for the oven gate, and the edge is backed by spring for sealing, to provide a homogeneous force onto the edge for good sealing effect.
c. Water sealing structure is adopted for riser cap and bridge pipe socket for valve body on the oven top, to prevent smoke escaping from the riser cap and bridge pipe socket.
With the above control measures adopted for the coke oven, the concentration of particles, benzene dissolvable and benzo (a) pyrene (BaP) discharged all meet the requirements of class II standard in “Emission standard for atmospheric pollutants from coke ovens” for newly built mechanical coke ovens.
(5) Dry coke quenching dust removal system
After the hot smoke from the coke tank top and circulating fan discharge is trapped by the sucking hood (with a waste gas trapping rate of 98%), the gas temperature is first reduced in a cooler, and the gas is then mixed from the dust-containing gas from the coke discharge, discharge belt conveyor and from the fresh coke conveying station. The gas temperature after mixing is below 110℃. The mixture then flows into the 24000m2 pulse bag filters for
Coke oven coal loader suction hood
Connecting pipe
Pulse bag filters in ground station
Ventilator
Silencer
Stack
Ash handling system
Shipped to ash silo
Humidifying ash unloader
Shipped out by trucks
Pre-spray device
Coke dischargesuction hood
Connecting pipe
Cooling and separating flame arrestor for gust of hot dust-containing smoke
Coal yard
61
cleaning at a dust removal efficiency of 99.5%. The cleaned gas is discharged into the atmosphere via fans and silencer. The dust emission concentration and rate at the discharge port of dust collectors conform to the class II requirement in “Integrated emission standard of air pollutants” (GB16297-1996). Anti-electrostatic materials are used as the filtering materials of the dust collectors. The coke dust collected from dust collectors and that from the scrapers and from primary and secondary process dust collection is collected and conveyed to the dust silo by bucket lifters, where it is humidified and then shipped out by trucks periodically to the coal yard for batching. The process flow is as shown in Fig. 4-2.
(6) Dust removal for coke sieving and coke silo in front of oven
In this production system, dust is produced mainly from the belt conveyor stations, coke chutes, vibrating feeders, coke silo in front of oven and truck transport unloading points. As the equipment are not running at the same time, motor-driven valves are provided on the ducts for different sucking hoods to reduce energy consumption. The dust-containing gas collected from the hoods (with a waste gas trapping rate of 98%) enters the 50000m2 pulse bag dust collector before being discharged to the outside via fans and silencers. The dust emission concentration and rate conform to the class III requirements in “Integrated emission standard of air pollutants” (GB16297-1996). The dust collected from dust collectors is collected and conveyed to the dust silo by a bucket lifter, where it is humidified and then shipped out by trucks periodically to the coal yard for batching. The process flow is as shown in Fig. 4-3.
Discharge port at dry quenching tank top and
circulating fan Cooler
Pulse bag dust collector
Coke discharge port and belt conveyor at the port, and
fresh coke conveying station
Main exhauster
Silencer
Stack
Ash handling system
Shipped out by trucks
Discharge after meeting standard
Dry coke quenching circulating gas primary and
secondary dust removal
Fig. 4-2 Dust removal flow diagram for dry coke quenching
Coal yard
62
(7) Coke gas cleaning
In the design, the tail gas from the regenerative tower is refluxed to the coke gas, and for the gas discharged from oil tank separators in crude benzene distilling section, measures such as breather valves and nitrogen filling at the tank top are adopted to reduce the amount of discharge. In the gas purifying process, the F.R.C desulfurization technique is adopted to reduce the discharge of pollutant such as SO2 produced when gas is burnt as fuel; for ammonia removal, the PHOSAM process to produce anhydrous ammonia is an advanced technology in the world, with the advantages of simple process flow, high product quality, high output value and good economic gains.
(8) Desulfurization measures for coke gas
The representative wet desulfurization processes adopted for coking plants now in operation (including those imported) in China can be classified into wet oxidizing process and wet absorbing process. The former includes: T.H process (with ammonia as alkali source), F.R.C process (with ammonia as alkali source), A.D.A process (with sodium as alkali source) and H.P.F process (with ammonia as alkali source); and the latter includes: Sulfiban process (mono ethanolamine process), A.S process (combined ammonia and sulfur scrubbing process) and vacuum carbonation process.
In this project, three scenarios have been considered for the coal gas desulfurization process: the first being the F.R.C process for desulfurization and acid production as used in Phase III of Baosteel, the second being the Sulfiban process for desulfurization and production of sulfuric acid as used in Phase II of Baosteel, and the third being the T.H process desulfurization process as used in Phase I of Baosteel.
Coke cutting chamber and conveying station
转运站
Pulse bag dust collector
Ash handling system
Shipped out by trucks
Main exhauster
Silencer
Stack Discharge after meeting standard
Fig. 4-3 Dust removal flow diagram for coke silo in front of oven
Coke sieving plant Coke silo in front of oven
Humidifying
Coal yard
63
In terms of desulfurization and decyanation efficiency, scenario I is the highest and the second and third are lower. In terms of operation stability, scenario I is more reliable in desulfurization and regenerative production. In terms of position to the plant, equipment for desulfurization in scenarios I and III is located in front of those for removing ammonia and benzene, and it is possible to completely enclose the loop for direct final cooling, so it can reduce corrosion to equipment. In environmental protection point of view, with scenario I, regenerated air flow is low and it can be directly mixed into the post tower gas, thus eliminating secondary pollution.
All three scenarios can meet the requirements for desulfurization and decyanation, but scenarios II and III have fairly outstanding problems. In scenario II, the operation cost is high, the acidic gas has no discharge route when the sulfuric acid plant is serviced and the steam consumption is high. Scenario III requires many components for high temperature and high pressure, demanding high grade of materials and high maintenance cost, and the quality of output gas will be affected when the regenerating tower is in service. In comparison, scenario I, the F.R.C process for desulfurization and acid production as used in Phase III of Baosteel, has more advantages, which is therefore recommended for this project. This process can realize desulfurization of over 96% for the coke gas in this project. It has eliminated the pollution from sulfur and ammonia waste gas in the previous process, and can also greatly reduce the pollution from non-organized emission of SO2.
In summary of the above, the waste gas control and rectification measures for the project are feasible.
4.2 Control and rectification measures for waste water
(1) Clean discharge water
The coking section of the project will discharge clean discharge water of 50.5 m3/h in total (the ground flushing water will not be discharged as being collected for coal preparation and); the clean discharge water from gas purifying workshop will be 62m3/h. Clean discharge water consists mainly consists of component cooling water and steam condensate, and will be discharged into the Yangtze River from the north discharge port of Meishan Steel Company.
(2) Phenol and cyanogen containing waste water
The gas purifying workshop of the project will produce phenol and cyanogen containing waste water at 98.2 m3/h, mainly from: waste water from ammonia distillation, direct cooling and blowdown water for gas final cooling, and floor flushing water.
The main pollutants in production waste water are volatile phenol, petroleum, ammonia nitrogen and CODcr. After treatment by the transformed phenol and cyanogen containing waste water treatment station (with design capacity of 300 m3/h), the discharged water can meet class I standard in Table 3 of “Water pollutant emission standard for iron and steel industry” (GB13456-92) for blast furnace slag flushing purpose. The treatment process flow for phenol and cyanogen containing waste water is as shown in Fig. 4-4.
The phenol and cyanogen containing waste water treatment station consists of the pre-treatment, biochemical treatment, post mixing and coagulating treatment and sludge
64
treatment sections. The pre-treatment section is comprised of the floating tank and conditioning tank.
In biochemical treatment, the A/O2 biological denitrification process is adopted, comprising of the anaerobic tank, aerobic tank (O1;O2), reflux sedimentation tank, secondary sedimentation tank and blower. The treatment capacity is 300 m3/h.
In post mixing and coagulating treatment, the water from the secondary sedimentation tank is further treated with physical and chemical methods. The treated phenol and cyanogen containing waste water is supplied for blast furnace slag flushing. The remaining sludge and sludge in the sedimentation tank is condensed and dewatered to make into cakes, and disposed in coal batching.
The pollutant concentration and removal rate of the phenol and cyanogen containing waste water effluent after removing phenol and biochemical treatment are as shown in Table 4-1.
There are a number of examples in the metallurgical enterprises in China in treating the phenol and cyanogen containing waste water from coking with A/O2 process. For example, in using this process in coking plant of Jiuquan Iron and Steel Works, the waste water after treatment is used for blast furnace slag flushing (at present, the fresh water consumption for blast furnace slag flushing for 1#, 2# and 3# blast furnaces of Meishan Steel Company is respectively 1.74, 1.73 and 1.09 million t/a, making a total of 4.56 million t/a. The phenol and cyanogen containing waste water to be discharged from this project will be 860,000 t/a and can all be used for blast furnace slag flushing in these three blast furnaces in Meishan Steel Company). Practice has proved that this process is economic, practical and feasible.
Pre-exposing tank
Conditioning tank
Anaerobic tank
Aerobic tank
Sedimentation tank
Biochemical sedimentation
tank
Refluxed waste water
Clean water discharged to environment Refluxed waste
water
Air
Sludge concentration
tank
Mixing and coagulating reaction tank
Coagulation and sedimentation
tank
Sludge tank Remaining sludge
Condensed waste water
Sludge
FilterEffluent for blast furnace slag flushing
Coagulant A
Coagulant B
Sludge dewatering machine
Sludge cake to coal preparation
Fig. 4-4 Process flow diagram for phenol and cyanogen containing waste water treatment (unit: m3/h)
Phenol & cyanogen containing waste
water
65
Table 4-1 Pollutant concentration and removal rate of phenol and cyanogen containing waste water after treatment (unit: mg/l)
Pollutant pH SS COD Ammonia nitrogen
Volatile phenol
Cyanide Petroleum
Inlet concentration 6-9 ≤150 ≤2000 ≤200 ≤700 ≤12 ≤50
Effluent concentration 6-9 ≤70 ≤100 ≤14 ≤0.5 ≤0.5 ≤7
Removal rate (%) - 53.3 95 93 99.9 95.8 86
The project will not recruit new employees, therefore domestic sewage amount will not be increased. The domestic sewage in the area of the project is treated in the septic tanks before treatment in the domestic sewage treatment plant of Meishan Steel Company, and the effluent is discharged into the treatment with the concentration meeting the class I standard in “Integrated wastewater discharge standard” (GB8978-1996).
At present, the north discharge port of Meishan Steel Company is for both rainwater and waste water, and after this technical transformation, rainwater will be separated from waste water.
In summary of the above, the waste water treatment measures for this project are feasible.
4.3 Noise
All motors, fans and pumps to be used in the project will be low noise products while meeting the process design requirements. Silencers will be provided at the discharge of blowers, dust removing fans and dispersing valves.
Noise produced by mechanical equipment will spread not only with air as medium, it can also spread in foundation, floors, walls and pipes in the form of elastic waves by directly inducing vibration in solid structural members, and radiating noise both internally and externally during spreading. To prevent noise pollution resulted from vibration, separate foundations are provided for pulverizers, gas blowers, dust removing fans and pumps, or vibration reduction provisions are made. For equipment with intensive vibration, flexible connections are used with pipes. In the project, effective noise prevention and control measures are taken for all types of noise producing equipment, so that the impact of noise to surrounding environment can be substantially reduced, and the noise level at the plant boundary can meet the limit values of class III in “Standard of noise at boundary of industrial enterprises”. Therefore, the noise treatment measures are feasible.
4.4 Solid wastes
All dust (coal dust) collected from dust removal system in the coking process of the project will be humidified and transported back by trucks to the coal yard for re-use in the coal preparing system.
The coke dust recovered by the coke oven coke discharge dust collecting system, by the coke
66
sieving dust collecting system and by the dry coke quenching dust collecting system will be humidified and then transported out with tankers for batching for sintering.
The tar slag from the mechanical ammonia water separating tank, the bitumen slag from the ammonia distilling tower and waste liquid from desulfurization is collected to the coal preparation workshop for batching into the coal for coking.
The slag from the regenerator of the crude benzene distilling section is batched into the tar tank.
Slag from tar separation and processing is batched into the coal for coking.
Most waste slag produced from this project is raw material for coking, coking product or organic compounds, and is mostly returned into the process system for re-use, selling out, burning in the coking coal or for recycled use. In general, the discharged slag is used in a comprehensive way or properly disposed. The control measures are those in general use in the coking industry in China, and are economic, practical and effective, conforming to the relevant regulation on disposal of waste slag. Therefore, the control measures for the solid wastes in coking and chemical processing are feasible.
These solid waste disposal measures are feasible and will not produce secondary pollution to the environment.
4.5 Hygienic protection distance
The average wind speed in Nanjing during the recent five years is 2-4m/s, and according to the provision in “Standard for hygienic protection distance in coking plant” (GB11661-89), it has been determined that the hygienic protection distance for the project is 1000m, as shown in Fig. 2-3. Residents within the hygienic protection distance have been relocated in the “product restructuring and process equipment upgrading and technical transformation project of Meishan Steel of Baosteel Co., Ltd.”.
4.6 Normalized setup of discharge ports
According to the relevant provisions in “Management measures on pollutant emission port setup and normalized control and rectification in Jiangsu Province” [Document Su Huan Kong (97) No. 122] and “Circular on normalized control and rectification work requirements for discharge ports in Nanjing Municipality” from Nanjing Municipal Environmental Protection Bureau (Document Ning Huan Fa [1999] No. 135), as well as the definite requirements from the industrial waste water conformity acceptance group of Jiangsu Province, the discharge ports of enterprises shall be set up in a normalized manner, and the drain system of factory areas must follow the principle of separating rainwater from waste water, to meet the requirements of environmental management.
Due to historical reasons, rainwater and waste water is merged for the north discharge port of Meishan Steel Company now. In this overhaul project, this port will be transformed to separate rainwater from waste water. Also, signboard and corresponding metering devices concentration COD online monitoring
Conspicuous signboards shall be set up in a temporary solid waste storage place for a project,
67
and water should be sprayed from time to time to prevent secondary dust lifting.
In this project, 7 exhaust masts (table 3-21) will be set up. According to “Management measures on pollutant emission port setup and normalized control and rectification in Jiangsu Province” [Document Su Huan Kong (97) No. 122], signboard and sampling and monitoring platform must be set up for the waste gas discharge port of a project, to allow sampling, monitoring and management.
4.7 Construction schedule arrangement for environmental protection control and rectification setups and estimation of environmental protection investment
In this project, investment for environmental protection arranged will be about 160 million yuan, accounting for 12.3% of the total project investment. The environmental protection control and rectification setups for the project should have been completed when the project is completed. Estimation of environmental protection investment breakdown and construction schedule arrangement is as shown in Table 4-1.
Table 4-1 Environmental protection investment and simultaneous completion of environmental protection control and rectification setups
Category Treatment setups Investment (10000 y)
Effect Remarks
Pipe networks for separating clean and dirty flows and rainwater and waste water
Setting up normalized discharge port Waste water
Phenol and cyanogen containing waste water treatment station
300
Separation of rainwater from waste water and discharge after
meeting standard
Dust removal in coal preparation section 200 Coke oven coal loading dust removing
station 870
Coke oven coke discharge dust removing station
1000
Dust removal for coke sieving and coke silo in front of oven
500
Powder and dust ≤120mg/m3
Gas desulfurization plant 450 H2S≤
100mg/m3
Waste gas
Energy saving items such as dry coke quenching
12470 Saving energy and reducing
pollution Low noise equipment
Noise Noise suppression, isolation and vibration reduction foundation
180
Plantation Green areas in the plant area 30
Meeting the standard at boundary
Simultaneous as the project is completed
Total 16000
68
5. Clean production and circulating economy analysis
Implementing clean production and circulating economy is to realize control over the full process of production, so that resources and energy can be used to the maximum extent in production, with minimum wastes produces and hence minimum harm to the environment, and it also requires that a product can bring its value into play while making no harm to the environment from the raw materials to the final digestion of the finished product. Therefore, implementing clean production and circulating economy is the need for realizing the sustainable development strategy, an effective means to control environmental pollution as it can greatly mitigate the burden of final control and rectification, and the optimum way to raise the market competing power of an enterprise.
5.1 Analysis for clean production
According to IV Main points in clean production review in “Guideline in environmental impact technical assessment for construction project (for trial implementation)” and the actual conditions of this project, for the clean production for this project, detailed analysis was performed mainly in terms of the industrial policies of the state, the quality of main raw materials and materials and fuel, reasons for selection, characteristics of production process and its advanced performance, and on aspects in reducing raw materials, materials, energy, water resources and pollutant emission and in circulating economy. Quantitative comparisons and analytic assessment were also performed with reference to “standard for clean production in coking industry” (HJ/T 126-2003), which is applicable to the review, performance appraisal and performance publicizing system for clean production in the coking industry.
5.1.1 Industrial policies of the state
(1) The project conforms to Item 47 in Category III of environmental protection and comprehensive utilization projects of “Guideline (catalogue) of major fields of high-tech industries to be developed in priority at present” issued by the State Planning Commission and State Ministry of Science and Technology: industrialization of dry coke quenching units in large and medium coking plants;
(2) The technologies selected by the project conform to the following for metallurgical industry (batches I and II) in the “Directory catalogue for clean production technologies of the nation” as issued by the State Commission of Economic Relations and Trade:
The technology for batch I in metallurgical industry: 1.dry coke quenching technology;
The technology for batch II in metallurgical industry: 9. smoke and dust cleaning technology for coke ovens;
(3) The project conforms to the following technologies in Category XIV of “Catalogue of major industries, products and technologies encouraged for development by the state at present (revised in 2000)” issued by the State Commission of Economic Relations and Trade: 4. technological development of humidifying for coking coal, coking with briquette, tamped coking and dry coke quenching;
(4) A construction project shall conform to the following on main clean production
69
technologies currently recommended in point 2, items 5 of IV Main points in clean production review in “Guideline in environmental impact technical assessment for construction project (for trial implementation)”:
1. Application of covering agent in the coal yard;
2. Control of water content for coal loaded into the oven;
3. Computerized control for coke oven heating;
4. Dust removal measures in dust removing ground station for coke oven coal loading and coke pushing;
5. Dry coke quenching.
(5) The project is not in the category of prohibiting and limiting as specified in the “Circular on further strengthening coordination and matching of industrial policies and credit policies to control credit risk (Document Fagai Chanye [2004] No. 746)” in terms of product, production scale and process and production equipment used. The project is also not included in the “Catalogue of production capacity, processes and products to be restricted and replaced in industrial and commercial circles of Jiangsu Province” (2005) in terms of production capacity and process and products.
(6) The project conforms to the relevant content in Appendix III “Admitting conditions for coking industry” to “Bulletin (2004) No. 76” of the State Commission of Development and Reform (including requirements of relevant policies on coal gas desulfurization, see P16-P23 2.3.4).
In summary of the above, the implementation of this project is in line with the relevant industrial policies of the state.
5.1.2 Clean production analysis in main raw materials, materials and fuel
The coking coal for use in coke ovens will be high quality washed coal, and blast furnace gas and coke gas will be used as fuel. The coke gas will be clean gas with sulfur removed, at a H2S content less than 200mg/m3. Both are clean fuel and produce a small amount of SO2 and smoky dust.
5.1.3 Analysis of characteristics and advanced performance of production process
5.1.3.1 Structure and characteristics of coke ovens
For the project, single manifold top mounted Type JN60-6 coke ovens will be used. This type of coke oven is in the compound heating structure of dual fire duct, waste gas circulation, downward coke gas spray and lateral feeding of blast furnace gas. It was designed on the basis of the production experience summarized from dozens of 6m coke ovens in the country and by adopting new technologies, new materials and new experience, with the characteristics of compact structure, rational and homogeneous heating and high thermal efficiency. The coke oven has the following main features and characteristics:
a) The regenerator main wall is constructed with profile bricks with three grooved tongues mutually engaged, and has no direct linking seam between the gas duct and the regenerator.
70
The single wall of regenerator is of single-grooved tongue structure, and is made with mutually engaged profile bricks.
b) The regenerator has embedded thin-wall checker bricks with large heat reserving area.
c) The inner sealing wall of the regenerator is built with silicon bricks, and its outer sealing wall is plastered with new type insulation material instead of using a heat isolating shroud.
d) The sectional area of the inclined duct at the head is increased, for more gas output at the oven head. e) To ensure homogeneous heating in vertical direction of the retort, the design has adopted such measures as increasing the circulating flow of waste gas and high coke gas burner (which is 400mm from the bottom of retort).
f) The retort wall is in “pagoda” brick structure, which has eliminated the direct linking seams between the retort and burning chamber.
g) The horizontal heating level is 1005mm.
h) The coal loading port and riser port at the top of the oven are formed with large profile bricks with grooved tongues, and hoop iron is provided on the holder bricks of the coal loading port and riser port, to ensure its integrity.
i) The inclining angle of the bottom masonry for coal loading port and riser port is reduced, so that it is close to the angle of repose for the feeding coal, to achieve free gas flow during coal loading. As the design is a coke oven with single gas manifold at the machine side, special provision has been made to increase the top space between the first coal loading port and riser on the machine side, and also the bottom area of the riser port, so that the flow rate of raw gas through this area is reduced.
5.1.3.2 New technologies adopted on the coke ovens
Spherical sealing is used for the coal loading port cap, to provide spherical contact between the cap and the base, to provide additional seal-tightness for the coal loading cap. Elastic edge is provided for the oven gate, and the edge is backed by spring for sealing, to provide a homogeneous force onto the edge for good sealing effect. Water sealing structure is adopted for riser cap and bridge pipe socket for valve body on the oven top, to prevent smoke escaping from the riser cap and bridge pipe socket. A cast iron base is provided at the riser root, to avoid smoke and flame leakage resulted from damage to the riser root.
A ground dust removing system with dust removal efficiency of 99.5% is used for coal loading and coke discharge, to greatly improve the operation environment of the coke oven. To match with this dust removal system, major improvement has been made to the coal loading cart and coke pusher, and mechanical feeding device with converter drive and sealed guiding sleeves are used for the coal loading cart.
Automatic computer control is adopted for heating the coke oven; basic control level for computer integrated production control and management system (DCS) is adopted for coke oven operation management; and automatic pressure control for the coke oven system has been realized.
71
New coke quenching process (dry coke quenching) is adopted, not only shortening the coke quenching time, but also reducing the water content in the coke after coke quenching.
5.1.3.3 New technologies adopted for gas cleaning devices
The gas cleaning devices include the following: gas discharge and conveying device, inter-cooking naphthalin washing device, FRC desulfurization and acid making device, anhydrous ammonia device, light oil trapping device, light oil distilling device, solvent dephenolizing device and ammonia distilling device.
(1) Gas discharge and conveying device
Direct inter-cooling is adopted for initial cooling of gas, with the following features:
a) It can effectively reduce the gas temperature, and also effectively remove foreign matter such as coal dust from the gas, to facilitate stable subsequent operations.
b) Tar separation is performed in two stages: the first being tar and ammonia separating tank and the second being super centrifugal machine. After these two stages of separation, the tar has a slag content of 0.3% (>100um) with a removing efficiency of 97%.
c) High efficiency electrical tar trapper is used, with a efficiency of over 99%.
d) An exhaust scrubbing tower is provided to receive gas from all tanks. The top of the tower is sprayed with waste water from ammonia distilling, and the waste water is delivered to the phenol and cyanogen containing waste water treatment station.
(2) Inter-cooking naphthalin washing device
The inter-cooking naphthalin washing device has the following features:
a) The effective water – oil – water naphthalin washing process is adopted, with good naphthalin removal effect.
b) Cyclone mist catchers are provided at both the pre-cooling section outlet and post-cooling section outlet of the inter-cooking naphthalin washing tower.
c) The circulation cooling water can flow through the post-cooling section or bypass this section according to need.
(3) Desulfurization and acid making device
The representative wet desulfurization processes adopted for coking plants now in operation (including those imported) in China can be classified into wet oxidizing process and wet absorbing process. The former includes: T.H process (with ammonia as alkali source), F.R.C process (with ammonia as alkali source), A.D.A process (with sodium as alkali source) and H.P.F process (with ammonia as alkali source); and the latter includes: Sulfiban process (mono ethanolamine process), A.S process (combined ammonia and sulfur scrubbing process) and vacuum carbonation process.
In this project, the F.R.C process for desulfurization and sulfuric acid production as used in Phase III of Baosteel will be adopted, and the desulfurization plant has the following features:
a) High efficiency in desulfurization and decyanation
72
b) High efficiency pre-mixing nozzles are used in the regenerating tower, to reduce the amount of compressed air, and the regenerated tail gas can be directly mixed into the gas, to eliminate secondary pollution.
c) Ammonia in the gas is used as the alkali source without further feeding, thus saving the operation cost.
The acid making device has the following features:
a) Simultaneous combustion of liquid fuel and assisting fuel (coke gas) and segmented combustion mode are adopted to strictly control the production of SO3 and NOX.
b) Concentrated sulfuric acid at 98% in good quality is produced with dry contact process.
c) A heat recovery steam generator is provided to recover the residual heat from the combustion flue gas, to produce steam at 3.0MPa, and to control the flue gas temperature above the condensing point of SO3.
d) The tail gas from the absorbing tower contains a small amount of SO2 and SO3, which should be removed with ammonia and dilute sulfuric acid before discharge to prevent pollution to the atmosphere.
The F.R.C process for desulfurization, decyanation and sulfuric acid production will be used, to ensure that the H2S content in the purified gas is ≤0.2g/m3.
(4) Anhydrous ammonia device
The main ammonia removal processes currently applied in the coking industry are: water washing ammonia distilling concentrated ammonia process, water washing ammonia distilling ammonia decomposing process, cold process for anhydrous ammonia, hot process for anhydrous ammonia, semi-direct process with submerged saturator for sulfur ammonia, semi-direct process with spray type saturator for sulfur ammonia, direct process with submerged saturator for sulfur ammonia and acid washing process for sulfur ammonia.
The project will adopt the PHOSAM process for anhydrous ammonia, and the anhydrous ammonia device has the following features:
a) It produces anhydrous ammonia with patented UEC technology and the product will be in high quality.
b) It is provided with a rich liquid tar remover, to remove tar, naphthalin and other impurities by air suspension, to ensure product quality.
c) This process can not only eliminate the pollution of waste gas to the atmosphere in the former processes, but also greatly reduce pollution from the non-organized discharge of SO2.
The PHOSAM process for producing anhydrous ammonia has the characteristics of advanced technology, simple process flow, high product quality and relatively good economic gains.
(5) Light oil trapping device
The light oil trapping device has the following features:
a) Direct cooling is adopted for final cooling, with low primary investment.
73
b) The benzene scrubbing tower is of packing type, featuring high efficiency and low consumption.
(6) Light oil distilling device
The light oil distilling device has the following features:
a) The benzole scrubber is a 50-layer bubble column, with good benzene and naphthalin removal effect and the lean oil has a low benzene and naphthalin content.
b) There is no water separating device at the top, and naphthalin is distilled out from the top together with water vapor and crude benzene, featuring convenient operation.
c) Crude benzene is produced with a tubular oven, saving steam.
(7) Solvent dephenolizing device
The solvent dephenolizing device has the following features:
a) Ammonia is pre-treated in three segments: ammonia tank sedimentation, filtering via coke filter and extraction with small amount of light benzene in the upper section of extracting column, for high tar removal efficiency.
b) A desulfurizer is provided to remove the H2S and HCN from phenol sodium salt and improve the operation conditions for decomposing phenol salt and prevent equipment corrosion.
c) An irradiating cooler is provided to avoid light benzene from volatizing and polluting the environment.
(8) Ammonia distilling device
The ammonia distilling device has the following features:
a) NaOH is used to decompose and fix ammonium, to increase the ammonia recovery rate and the ammonia nitrogen content in the waste water.
The project has embodied the requirements for clean production and reduced the pollutant emission by adopting advanced production processes.
5.1.4 Assessment on measures to save water and energy and reduce consumption
The project will adopt the following measures to save energy and reduce consumption:
(1) For the project, single manifold top mounted Type JN60-6 coke ovens will be used. This type of coke oven is in the compound heating structure of dual fire duct, waste gas circulation, downward coke gas spray and lateral feeding of blast furnace gas. It was designed on the basis of the production experience summarized from dozens of 6m coke ovens in the country and by adopting new technologies, new materials and new experience, with the characteristics of compact structure, rational and homogeneous heating and high thermal efficiency.
(2) As compared with traditional coke ovens, the regenerator sealing wall design has been improved, and the wall is built with silicon bricks, clay bricks, high aluminum bricks, high strength heat insulating bricks, clinker, floating bead bricks and red bricks according to the
74
operating characteristics of different parts of the coke oven, thus significantly improving the sealing effect.
(3) In body design, the structural compactness has been improved and strengthened insulation adopted, to reduce gas leakage and heat dissipation from the body; thin wall checkers are used for the regenerator to increase the heat reserving area and reduce the heat carried away by waste gas.
(4) Coke oven heating parameters are measured automatically and are input into the computer system for data processing, and this plus manual adjustment can enable convenient and accurate adjustment to the heating system, helping reducing the heat rate in coking process.
(5) The horizontal heating design for the coke oven is appropriate, as it reduces the top space temperature and the heat carried away by raw gas and dissipated from the top of the oven.
(6) Smoke free coal loading is realized by spraying with high pressure ammonia instead of steam, to save steam.
(7) Dry coke quenching process is used to recover heat from red coke to produce high pressure steam.
(8) The waste water from the coking plant will all be used for blast furnace slag flushing after meeting the standard, without discharge, to save water consumption.
5.1.5 Comparison and analysis of raw and auxiliary materials, energy consumption and pollutant emission per unit product
The consumption of resources, such as fresh water, energy and materials (raw and auxiliary) per unit product can reflect the technological and management level of an enterprise. Under identical conditions, more resources consumption means more impact to the environment. High pollutant production means backward process flow or low management level.
In this assessment, indicators of raw and auxiliary materials consumption of the project were analyzed by comparison of the indicators for unit consumption of raw and auxiliary materials of this project and those as required in the clean production technology in the environmental protection industrial standard of the People's Republic of China “standard for clean production in coking industry” (HJ/T 126-2003).
Comparison and analysis of the raw and auxiliary materials, energy consumption and pollutant emission per unit product of the project and the environmental protection industrial standard of the People's Republic of China “standard for clean production in coking industry” (HJ/T 126-2003) as well as the existing plant are as shown in Tables 5-1 ~ 5-5.
75
Tabl
e 5-
1 P
rodu
ctio
n pr
oces
s and
equ
ipm
ent r
equi
rem
ents
In
dica
tor
Cla
ss I
Cla
ss II
C
lass
III
Proj
ect
Exis
ting
plan
t
Cle
an c
oal
stor
age
Indo
or c
oal s
tore
or o
pen
coal
ya
rd w
ith la
rge
stac
ker-r
ecla
imer
, and
with
w
ater
spra
ying
faci
litie
s
Mec
hani
cal o
pen
coal
yar
d w
ith st
acke
r-rec
laim
er, a
nd
with
wat
er sp
rayi
ng fa
cilit
ies
Smal
l ope
n co
al y
ard
with
wat
er
spra
ying
faci
litie
s C
lass
I M
echa
nica
l ope
n co
al
yard
with
out w
ater
sp
ray
equi
pmen
t
Cle
an c
oal
conv
eyin
g B
elt c
onve
ying
, enc
lose
d co
nvey
ing
corr
idor
and
hou
sing
, with
nat
ural
ven
tilat
ion
faci
litie
s C
onfo
rm to
re
quire
men
t C
onfo
rm to
re
quire
men
t
Coa
l bat
chin
g A
utom
atic
acc
urat
e ba
tchi
ng
Con
form
to
requ
irem
ent
Con
form
to
requ
irem
ent
Coal preparation and process equipment
Cle
an c
oal
pulv
eriz
ing
Impa
ct h
amm
er p
ulve
rizer
, with
impu
lse
dust
rem
ovin
g fa
cilit
ies,
with
dus
t rem
oval
effi
cien
cy ≥
95%
C
onfo
rm to
re
quire
men
t C
onfo
rm to
re
quire
men
t Pr
oduc
tion
scal
e ≥
1,00
0,00
0t/a
≥
600,
000t
/a
≥40
0,00
0t/a
10
0000
0t/a
12
5.50
000t
/a
Coa
l loa
ding
Gro
und
stat
ion
gas c
olle
ctin
g an
d du
st re
mov
ing
faci
litie
s, w
ith d
ust r
emov
al e
ffici
ency
≥
99%
and
trap
ping
rate
≥95
%, w
ith a
dvan
ced
and
relia
ble
PLC
aut
omat
ic c
ontro
l sy
stem
Gro
und
stat
ion
gas c
olle
ctin
g an
d du
st re
mov
ing
faci
litie
s, w
ith d
ust r
emov
al e
ffici
ency
≥
95%
and
trap
ping
rate
≥93
%, w
ith a
dvan
ced
and
relia
ble
auto
mat
ic c
ontro
l sy
stem
Hig
h ef
ficie
ncy
dust
rem
ovin
g fa
cilit
ies s
uch
as H
P am
mon
ia
spra
y fo
r sm
oke
free
coa
l loa
ding
an
d sm
oke
supp
ress
ing
and
dust
re
mov
ing
vehi
cle,
or o
rdin
ary
cont
rol f
acili
ties s
uch
as c
oal
load
ing
cart
was
hing
and
bur
ning
un
it an
d du
st c
olle
ctin
g ho
od
Cla
ss I
HP
amm
onia
spra
y fo
r sm
oke
free
coa
l lo
adin
g, C
lass
III
Ret
ort h
eigh
t (m
) ≥
6.0
≥4.
0 6.
0 4.
3
Ret
ort e
ffect
ive
volu
me
(m3 )
≥38
.5
≥23
.9
38.5
1#
and
2#
coke
ove
n 21
.6 m
3 3#
cok
e ov
en 2
3.9
m3
Coking process and equipment
Ove
n do
or
Elas
tic e
dge
side
doo
r R
appi
ng e
dge
side
doo
r El
astic
edg
e si
de d
oor
Rap
ping
edg
e si
de
door
76
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
Con
trol f
or
heat
ing
syst
em
Aut
omat
ic c
ontro
l by
com
pute
rC
ontro
l by
inst
rum
ents
C
lass
I
Inst
rum
ent c
ontro
l for
1#
and
2#
coke
ove
ns;
com
pute
r aut
omat
ic
cont
rol f
or 3
# ov
en
Ris
er a
nd b
ridge
pi
pe
Wat
er se
alin
g pr
ovis
ion
Con
form
to
requ
irem
ent
Con
form
to
requ
irem
ent
Cok
e ov
en
mac
hine
ry
PLC
con
trol s
yste
m fo
r cok
e pu
sher
and
coa
l loa
ding
car
t, an
d in
terlo
ck d
evic
e fo
r oth
er m
echa
nica
l ope
ratio
n
Adv
ance
d m
echa
nica
l ope
ratio
n w
ith in
terlo
ck d
evic
es
Cla
ss I
Elec
trica
l con
trol f
or
1# a
nd 2
# co
ke o
vens
, PL
C c
ontro
l for
3#
coke
ove
n, a
ll w
ith
inte
rlock
s R
aw g
as
disc
harg
e Eq
uipp
ed w
ith ra
w g
as a
utom
atic
igni
tion
devi
ce
Con
form
to
requ
irem
ent
Con
form
to
requ
irem
ent
Doo
r and
fram
e cl
eani
ng d
evic
e
Cle
anin
g de
vice
shou
ld b
e pr
ovid
ed to
ens
ure
free
of t
ar sl
ag
Con
form
to
requ
irem
ent
Not
pro
vide
d fo
r 1#
and
2# c
oke
oven
s, an
d cl
eani
ng d
evic
e pr
ovid
ed fo
r 3#
coke
ov
en b
ut n
ot in
nor
mal
us
e R
iser
pre
ssur
e co
ntro
l R
ELIA
BLE
CO
NTR
OL
REG
ULA
TIO
N
Con
form
to
requ
irem
ent
Con
form
to
requ
irem
ent
Coking process and equipment
Hea
ting
gas t
otal
flo
w, c
oal
load
ing
flow
per
du
ct, c
oke
push
ing
oper
atio
n an
d ov
en te
mpe
ratu
re
mon
itorin
g
Aut
omat
ic re
cord
ing
and
auto
mat
ic c
ontro
l A
utom
atic
reco
rdin
g C
lass
I
Aut
omat
ic re
cord
ing
for h
eatin
g ga
s tot
al
flow
, coa
l loa
ding
flow
pe
r duc
t and
cok
e pu
shin
g op
erat
ion
77
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
Cok
e di
scha
rge
proc
ess
Gro
und
stat
ion
gas c
olle
ctin
g an
d du
st re
mov
ing
faci
litie
s, w
ith
dust
rem
oval
effi
cien
cy ≥
99%
and
trap
ping
rate
≥90
%
Dus
t rem
oval
faci
litie
s with
fairl
y hi
gh e
ffici
ency
such
as h
ot
float
ing
hood
C
lass
I N
o
Cok
e qu
ench
ing
proc
ess
Dry
cok
e qu
ench
ing,
with
bag
du
st c
olle
ctin
g fa
cilit
ies,
at d
ust
rem
oval
effi
cien
cy ≥
99%
W
et c
oke
quen
chin
g, c
oke
quen
chin
g to
wer
with
baf
fles
Cla
ss I
Wet
cok
e qu
ench
ing,
an
d co
ke q
uenc
hing
to
wer
with
baf
fle fo
r 3#
cok
e ov
en
Cok
e si
evin
g an
d tra
nsfe
r B
ag d
ust c
olle
ctin
g fa
cilit
ies,
with
rem
oval
effi
cien
cy ≥
99%
Impu
lse
or fo
am d
ust r
emov
ing
equi
pmen
t, w
ith d
ust r
emov
al
effic
ienc
y ≥
90%
C
lass
I W
et d
ust f
ilter
, with
ef
ficie
ncy
at ≥
90%
Proc
ess
requ
irem
ents
In
clud
ing
sect
ions
of c
old
drum
, des
ulfu
rizat
ion,
dec
yana
tion,
am
mon
ia w
ashi
ng, b
enze
ne
was
hing
and
nap
htha
lin w
ashi
ng
Con
form
to
requ
irem
ent
Des
ulfu
rizat
ion
for
abou
t 1/3
gas
, but
not
fo
r rec
ycle
d co
ke g
as,
the
requ
irem
ent i
s met
in
oth
er se
ctio
ns
Prim
ary
gas
cool
er
Hor
izon
tal t
ube
prim
ary
cool
er o
r hor
izon
tal t
ube
prim
ary
cool
er +
dire
ct c
oole
r C
onfo
rm to
re
quire
men
t H
oriz
onta
l tub
e pr
imar
y co
oler
Gas
blo
wer
C
onve
rter o
r hyd
raul
ic c
oupl
er sp
eed
regu
latio
n
Con
form
to
requ
irem
ent
Hyd
raul
ic c
oupl
er
spee
d re
gula
tion
for 1
# fa
n an
d no
regu
latio
n fo
r oth
ers
Ener
gy
utili
zatio
n
Gra
ded
utili
zatio
n of
reso
urce
s su
ch a
s wat
er a
nd st
eam
, and
w
ith re
frig
erat
ing
faci
litie
s
Gra
ded
utili
zatio
n of
reso
urce
s suc
h as
wat
er a
nd st
eam
, or
cool
ing
by se
a w
ater
C
lass
I G
rade
d ut
iliza
tion
of
part
of w
ater
and
st
eam
Des
ulfu
rizat
ion
sect
ion
Prov
ided
with
des
ulfu
rizat
ion
and
sulfu
r rec
over
y an
d ut
iliza
tion
faci
litie
s
Con
form
to
requ
irem
ent
AD
A d
esul
furiz
atio
n an
d PD
S de
sulfu
rizat
ion
Gas cleaning unit
Am
mon
ia
rem
ovin
g se
ctio
n A
ssoc
iate
d am
mon
ia w
ashi
ng, d
istil
ling
and
deco
mpo
sing
pro
cess
es o
r sul
fur a
mm
onia
pro
cess
or
anhy
drou
s am
mon
ia p
roce
ss
Con
form
to
requ
irem
ent
Am
mon
ia d
istil
ling
by
addi
ng a
lkal
i, as
soci
ated
sulfu
r
78
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
amm
onia
pro
cess
C
rude
ben
zene
di
still
ing
met
hod
Cru
de b
enze
ne tu
bula
r ove
n C
onfo
rm to
re
quire
men
t C
rude
ben
zene
tubu
lar
oven
A
mm
onia
and
ni
troge
n co
ncen
tratio
n in
am
mon
ia
dist
illin
g w
aste
w
ater
≤20
0mg/
l 19
0mg/
l 40
0-60
0 m
g/l
Gas
from
tank
s of
diff
eren
t se
ctio
ns
Was
te g
as is
reco
vere
d an
d cl
eane
d w
ith p
ress
ure
bala
nce
or
exha
ust s
crub
ber s
yste
m
Use
bre
athe
rs to
redu
ce w
aste
gas
di
scha
rge
Mee
t cla
ss II
re
quire
men
t So
me
with
no
exha
ust
clea
ning
faci
litie
s
Phen
ol a
nd
cyan
ogen
co
ntai
ning
was
te
wat
er
Bio
logi
cal d
enitr
ifica
tion
and
coag
ulat
ing
sedi
men
tatio
n tre
atm
ent p
roce
ss, a
nd th
e w
ater
af
ter t
reat
men
t can
mee
t cla
ss I
stan
dard
in “
Wat
er p
ollu
tant
em
issi
on st
anda
rd fo
r iro
n an
d st
eel i
ndus
try”
Bio
logi
cal d
enitr
ifica
tion
and
coag
ulat
ing
sedi
men
tatio
n tre
atm
ent p
roce
ss, a
nd th
e w
ater
afte
r tre
atm
ent c
an m
eet c
lass
II
stan
dard
in “
Wat
er p
ollu
tant
em
issi
on st
anda
rd fo
r iro
n an
d st
eel i
ndus
try”
Mee
t cla
ss II
re
quire
men
t
Ord
inar
y ac
tive
slud
ge
proc
ess,
unab
le to
ef
fect
ivel
y re
mov
e ni
troge
n, n
o co
agul
atin
g se
dim
enta
tion
treat
men
t, C
OD
and
am
mon
ia a
nd n
itrog
en
cann
ot m
eet s
tand
ard
afte
r tre
atm
ent,
and
othe
rs m
eet c
lass
I st
anda
rd o
f G
B13
456-
92
79
Tabl
e 5-
2 R
esou
rces
and
ene
rgy
utili
zatio
n in
dica
tors
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
Ener
gy c
onsu
mpt
ion
(kg
stan
dard
coa
l/t c
oke)
≤
150
≤17
0 ≤
180
134
(Cla
ss I)
14
0
Fres
h w
ater
con
sum
ptio
n pe
r t c
oke
(m3 /t
coke
) ≤
2.5
≤3.
5 2.
3 (C
lass
I)
2.6
Stea
m c
onsu
mpt
ion
per t
cok
e (t/
t cok
e)
≤0.
20
≤0.
25
≤0.
40
0.21
(Cla
ss II
) 0.
28
Pow
er c
onsu
mpt
ion
per t
cok
e (k
W·h
/t co
ke)
≤30
≤
35
≤40
1.
8 (C
lass
I)
7.2
Cok
e ga
s ≤
2150
≤
2250
≤
2350
≤
2250
H
eat c
onsu
mpt
ion
in
coki
ng (7
%H
2O) k
j/kg
stan
dard
coa
l B
last
furn
ace
gas
≤24
50
≤25
50
≤26
50
≤25
50
Gas
of m
ixed
cok
e ga
s and
bla
st fu
rnac
e ga
s, 22
62kj
/kg
coal
Cok
e ga
s util
izat
ion
rate
(%)
100
≥95
≥
80
100
99.2
Wat
er c
ircul
atio
n ut
iliza
tion
rate
(%)
≥95
≥
85
≥75
98
.1 (C
lass
I)
78
Not
e: E
xpla
natio
n of
indi
cato
r cal
cula
tion
is g
iven
in 5
.1.6
.1.
80
Tabl
e 5-
3 P
rodu
ct in
dica
tors
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
Gra
nula
rity
and
stre
ngth
m
eet u
ser r
equi
rem
ents
, with
qu
alifi
catio
n ra
te >
98%
.
Gra
nula
rity
and
stre
ngth
m
eet u
ser r
equi
rem
ents
, with
qu
alifi
catio
n ra
te a
t 95
%-9
8%.
Gra
nula
rity
and
stre
ngth
m
eet u
ser r
equi
rem
ents
, w
ith q
ualif
icat
ion
rate
at
93%
-95%
.
Con
form
to
clas
s I
requ
irem
ent
Con
form
to c
lass
I re
quire
men
t
Hig
h qu
ality
cok
e w
ill
prod
uce
little
pol
luta
nt in
iro
n m
eltin
g, c
astin
g an
d iro
n al
loy
prod
uctio
n, w
ith
little
impa
ct to
the
envi
ronm
ent
Cok
e ha
s fai
rly lo
w im
pact
to
env
ironm
ent i
n th
e ap
plic
atio
n
Cok
e ha
s fai
rly si
gnifi
cant
im
pact
to e
nviro
nmen
t in
the
appl
icat
ion
Con
form
to
clas
s I
requ
irem
ent
Con
form
to c
lass
I re
quire
men
t C
oke
Littl
e im
pact
to e
nviro
nmen
t in
stor
age,
han
dlin
g an
d tra
nspo
rt
Fairl
y lo
w im
pact
to
envi
ronm
ent i
n st
orag
e,
hand
ling
and
trans
port
Fairl
y lo
w im
pact
to
envi
ronm
ent i
n st
orag
e,
hand
ling
and
trans
port
Con
form
to
clas
s I
requ
irem
ent
Con
form
to c
lass
I re
quire
men
t
As t
own
gas
H2S≤
20m
g/m
3 , NH
3≤50
mg/
m3 , n
apht
halin
≤50
mg/
m3 (w
inte
r)
naph
thal
in ≤
100m
g/m
3 (sum
mer
) -
H2S
=8.2
mg/
m3 ,
NH
3=3.
7mg/
m3 ,
naph
thal
in =
76m
g/m
3 (w
inte
r), n
apht
halin
=3
57m
g/m
3 (sum
mer
)
Cok
e ga
s
Oth
er
appl
icat
ions
H
2S≤
200m
g/m
3 H
2S≤
500m
g/m
3 20
0 H
2S=2
740m
g/m
3
81
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
Tar
Use
qua
lifie
d ta
r tan
ks, w
ith w
ater
and
slag
rem
ovin
g de
vice
s for
mec
hani
cal s
lag
rem
oval
, uni
ts a
nd p
ipes
for s
tora
ge a
nd c
onve
ying
shal
l be
mad
e w
ith m
ater
ials
pr
even
ting
corr
osio
n, le
akag
e an
d se
epag
e, a
nd ta
nker
veh
icle
s sha
ll be
enc
lose
d
Con
form
to
requ
irem
ent
Qua
lifie
d ta
r tan
ks a
re
used
and
slag
rem
oved
in
mec
hani
cal
sedi
men
tatio
n ta
nks.
Tar
is c
onve
yed
to ta
r pr
oces
sing
uni
t via
pi
ping
, to
rem
ove
wat
er
by h
eatin
g an
d pl
acin
g st
ands
till.
Am
mon
ium
pro
duct
M
easu
res a
gain
st c
orro
sion
and
leak
age
shal
l be
take
n fo
r sto
rage
, pac
kagi
ng a
nd
trans
port
Con
form
to
requ
irem
ent
It is
pac
kage
d w
ith
wov
en b
ags a
nd st
orag
e m
eets
requ
irem
ents
Cru
de b
enze
ne
It sh
all b
e en
clos
ed a
nd a
nti-e
xplo
sion
pro
visi
ons s
hall
be m
ade
in p
rodu
ctio
n, st
orag
e an
d tra
nspo
rt, a
nd n
o di
rect
con
tact
with
peo
ple
shal
l be
ensu
red.
C
onfo
rm to
re
quire
men
t
Gas
from
stor
age
tank
s is
col
lect
ed to
rem
ove
mis
t bef
ore
disc
harg
e
82
Tabl
e 5-
4 P
ollu
tant
pro
duct
ion
indi
cato
rs
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
Coa
l loa
ding
≤
0.5
≤0.
8 -
≤0.
6 (C
lass
II)
Parti
cles
kg/t
coke
C
oke
push
ing
≤0.
5 ≤
1.2
- ≤
0.9
(Cla
ss II
) 5.
0
Coa
l loa
ding
≤
1.0
≤1.
5 -
3.9×
10-4
(Cla
ss I)
N
o st
atis
tics
benz
o (a
) pyr
ene
g/t c
oke
Cok
e pu
shin
g ≤
0.01
8 ≤
0.04
0 -
5.8×
10-4
(Cla
ss I)
N
o st
atis
tics
Coa
l loa
ding
≤
0.01
≤
0.02
≤
0.01
(C
lass
I)
No
stat
istic
s
Cok
e pu
shin
g ≤
0.01
≤
0.01
5 -
≤0.
014
(Cla
ss II
) N
o st
atis
tics
SO2
kg/t
coke
C
oke
oven
stac
k ≤
0.03
5 ≤
0.10
5 0.
057
(Cla
ss II
) 1.
45
Parti
cles
2.
5 3.
5 ≤
3.5
benz
o (a
) pyr
ene
0.00
25
0.00
40
Not
mon
itore
d
Air
pollu
tant
Non
-org
aniz
ed e
mis
sion
of c
oke
oven
was
te g
as p
ollu
tant
mg/
m3
BSO
0.
6 0.
8
To b
e m
onito
red
at p
lant
bo
unda
ry a
fter
com
plet
ion
of p
roje
ct
Not
mon
itore
d
Am
ount
of a
mm
onia
dis
tillin
g w
aste
wat
er (t
/t co
ke)
≤0.
50
≤1.
0 0.
48
0.50
CO
Dcr
(kg/
t cok
e)
≤1.
2 ≤
2.0
≤4.
0 ≤
0.95
1.
83
NH
3-N
(kg/
t cok
e)
≤0.
06
≤0.
10
≤0.
20
≤0.
095
0.36
Tota
l cya
nide
(kg/
t cok
e)
≤0.
008
≤0.
012
≤0.
025
≤0.
006
0.00
7
Vola
tile
phen
ol (k
g/t c
oke)
≤
0.24
≤
0.40
≤
0.80
≤
0.33
0.
10
Wat
er
pollu
tant
A
mm
onia
di
still
ing
Sulfi
de (k
g/t c
oke)
≤
0.02
≤
0.03
≤
0.06
≤
0.01
9 N
ot m
onito
red
Not
e: E
xpla
natio
n of
indi
cato
r cal
cula
tion
is g
iven
in 5
.1.6
.2.
83
Tabl
e 5-
5 I
ndic
ator
s of w
aste
s rec
over
y an
d ut
iliza
tion
Indi
cato
r C
lass
I C
lass
II
Cla
ss II
I Pr
ojec
t Ex
istin
g pl
ant
Phen
ol a
nd c
yano
gen
cont
aini
ng
was
te w
ater
Was
te w
ater
afte
r tre
atm
ent w
ill b
e re
used
as f
ar a
s po
ssib
le a
nd su
rplu
s was
te w
ater
can
be
disc
harg
ed a
fter
mee
ting
the
stan
dard
.
Ord
inar
y ac
tive
slud
ge p
roce
ss,
unab
le to
effe
ctiv
ely
rem
ove
nitro
gen,
no
coag
ulat
ing
sedi
men
tatio
n tre
atm
ent,
CO
D a
nd
amm
onia
and
nitr
ogen
can
not m
eet
stan
dard
afte
r tre
atm
ent,
and
phen
ol
and
cyan
ogen
mee
t the
stan
dard
. It i
s di
scha
rged
dire
ctly
with
out
recy
clin
g.
Was
te
wat
er
Was
te w
ater
from
cok
e qu
ench
ing
Wat
er fr
om c
oke
quen
chin
g is
recy
cled
in a
clo
sed
loop
w
ithou
t dis
char
ging
to th
e ou
tsid
e.
Con
form
to re
quire
men
t
Coa
l dus
t fro
m d
ust c
olle
ctor
of
coal
pre
para
tion
sect
ion
All
can
be re
cove
red
for u
tiliz
atio
n A
ll ca
n be
reco
vere
d fo
r util
izat
ion
Dus
t fro
m d
ust c
olle
ctin
g sy
stem
s fo
r coa
l loa
ding
and
cok
e pu
shin
g A
ll ca
n be
reco
vere
d fo
r util
izat
ion
No
dust
rem
oval
uni
t for
coa
l loa
ding
an
d co
ke d
isch
arge
Dus
t fro
m c
oke
quen
chin
g an
d si
evin
g sy
stem
s A
ll ca
n be
reco
vere
d fo
r util
izat
ion
(suc
h as
raw
mat
eria
ls
for i
ron
and
stee
l ind
ustry
and
for m
akin
g br
ique
tte)
All
can
be re
cove
red
for u
tiliz
atio
n
Tar s
lag
(incl
udin
g sl
ag fr
om ta
r ta
nks)
N
othi
ng fa
lls o
n gr
ound
and
all
is b
atch
ed in
to c
okin
g co
al o
r for
mak
ing
briq
uette
Fa
lls o
n gr
ound
and
not
recy
cled
for
use
Slag
from
rege
nera
tion
of c
rude
be
nzen
e N
othi
ng fa
lls o
n gr
ound
and
all
is b
atch
ed in
to c
okin
g co
al o
r tar
or f
or m
akin
g br
ique
tte
Bat
ched
into
tar
Slag
Rem
aini
ng sl
udge
Fo
r cov
erin
g on
the
coal
yar
d or
bat
chin
g in
to c
okin
g co
al
All
requ
irem
ents
ar
e m
et
No
treat
men
t uni
t for
rem
aini
ng
slud
ge
84
It can be seen from Table 5-1~Table 5-5 that, from the selection of raw materials, energy saving, selection of production process, pollution control in production up to the performance of products for the project, the principle of clean production has been carried out at all times, and the production and emission of pollutant will be controlled at the beginning of processes, thus greatly reducing the pollutant emission from the project. All the clean production indicators of the project have met the requirements of class II standard in the environmental protection industrial standard of the People's Republic of China “standard for clean production in coking industry” (HJ/T 126-2003), i.e. the advanced level in China, and some indicators can meet the international class I level.
Some existing facilities of the project cannot meet requirements of class II standard in the environmental protection industrial standard of the People's Republic of China “standard for clean production in coking industry” (HJ/T 126-2003). Therefore, it is necessary to construct this project.
It can be known from the above analysis that the construction of this project will meet the requirements for clean production, and it can reach the advanced level of clean production in the country.
5.1.6 Explanation of indicator calculation
5.1.6.1 Calculation of indicators of resources and energy utilization
(1) Energy consumption of sections (kg standard coal /t coke): provided by the design institute for the project.
(2) Fresh water consumption per t coke (m3/t coke): the fresh water consumption is 257t/h (or 2251320t/a), the coke output is 100×104t/a, and the fresh water consumption per t coke is 2.3 (m3/t coke).
(3) Steam consumption per t coke (t/t coke): steam consumption in production is 30t/h (or 210240t/a), the coke output is 100×104t/a, and the steam consumption per t coke is 0.21 (t/t coke).
(4) Power consumption per t coke (kW·h/t coke): the power consumption of the project is 180.5×104 kW·h, the coke output is 100×104t/a, and the power consumption per t coke is 1.8 (kW·h/t coke).
(5) Heat consumption for coking (7%H2O) kj/kg standard coal (coke gas): the project will use the mixed coke gas and blast furnace gas, and the value given in the table was provided by the project design institute after conversion.
(6) Heat consumption for coking (7%H2O) kj/kg standard coal (blast furnace gas): the project will use the mixed coke gas and blast furnace gas, and the value given in the table was provided by the project design institute after conversion.
(7) Coke gas utilization rate (%): the project will use 8110×104m3/a of coke gas, and the remaining will be used by other plants of Meishan Steel Company and as town gas, as detailed in Table 3-17 Coke gas balance for project. The coke gas utilization rate of the project will be 100%.
85
(8) Water circulation utilization rate (%): the fresh water consumption is 257m3/h, the circulating water flow is 13039 m3/h, and the total water consumption is 13296m3/h, giving a water circulation rate of 98.1%.
The calculation is based on 8760 operating hours a year for the project.
5.1.6.2 Calculation of pollutant output
(1) Air pollutant particle output:
In this project, one exhaust mast will be provided for the organized waste gas discharge from coal loading and coke pushing. For one load of coke, it takes about 0.63h (41s×55 ducts) to load the coal, about 0.94h (1 min or more×55 ducts) to push the coke, and the coking duration is 20h, so a total of 438 loads of coke can be made during a year. The waste gas discharge time is 272.7h/a for coal loading and 409.1h/a for coke pushing, the particle output from coal loading and coke pushing is respectively 600t/a and 900t/a (at a rate of 2200 kg/h), so the particle output per unit product from coal loading and coke pushing is respectively 0.6kg/t coke and 0.9kg/t coke.
(2) Air pollutant benzo (a) pyrene output:
The benzo (a) pyrene output from coal loading and coke pushing is respectively 3.9×10-4t/a and 5.8×10-4t/a, and the output per unit product is respectively 3.9×10-4g/t coke and 5.8×10-4g/t coke.
(3) Air pollutant SO2 output:
The SO2 output from coal loading and coke pushing is respectively 11.4t/a and 14.6t/a, and the SO2 output from coke oven stack is 56.6t/a. The SO2 output per unit product from coal loading and coke pushing is respectively 0.01kg/t coke and 0.014kg/t coke, and the SO2 output per unit product from the coke oven stack is 0.057kg/t coke.
(4) Non-organized leaking output of air pollutant coke oven waste air pollutant: it is necessary to perform monitoring at the boundary after the completion of the project.
The source intensity of ammonia distilling waste water pollutant from the ammonia distilling section is given in Table 5-6.
Table 5-6 Source intensity of ammonia distilling waste water from ammonia distilling section
Ammonia distilling waste
water output (t/a) CODcr NH3-N
Total cyanogen
Volatile phenol Sulfide
2000 (mg/L) 200 (mg/L) 12 (mg/L) 700 (mg/L) 40 (mg/L) 475668
951336 (kg/a) 95134 (kg/a) 5720 (kg/a) 332968 (kg/a) 19027 (kg/a)
(5) Output of water pollutant distilling waste water from ammonia distilling section (t/t coke): 0.48
86
(6) Output of water pollutant CODcr from ammonia distilling section (kg/t coke): 0.95
(7) Output of water pollutant NH3-N from ammonia distilling section (kg/t coke): 0.095 (8) Output of water pollutant total cyanogen from ammonia distilling section (kg/t coke): 0.006
(9) Output of water pollutant volatile phenol from ammonia distilling section (kg/t coke): 0.33
(10) Output of water pollutant sulfide from ammonia distilling section (kg/t coke): 0.019
It can be known from the above analysis that the construction of this project will meet the requirements for clean production, and it can reach the advanced level of clean production in the country.
5.2 Circulating economy analysis
Circulating economy is a closed-loop model “resources consuming → product →
regenerating resources” for materials flow, corresponding to the open (or one-way) model
“resources consuming → product → waste discharge” for materials flow in traditional economic activities. Technically, it is characterized as the reduction of resources consumption and re-utilization and regeneration of resources. It is centered on raising the utilization efficiency of resources.
The technical principal of circulating economy requires adding the feedback mechanism on the basis of linear technical model for traditional industrial economy. (1) Both coke ovens will adopt the dry coke quenching technology, to fully recover the heat produced in coke quenching, and the residual heat will be used to generate electrical power; all solid waste produced from the coke ovens will be mixed into the raw coal for coking, without discharging into the environment; the particles discharged from coking will be recovered by large ground dust collecting stations for use, and the recovered particles (coke dust) will be mixed into the raw coal for coking, not only reducing the emission of waste gas pollutant, but also effectively utilizing the heat in the particles. (2) In the project, only soft water and demineralized water are fresh water for production purpose, and makeup water for circulation cooling water is recycled water (from the general waste water treatment plant of Meishan Steel Company), therefore conforming to the principle requirements for recycling water and saving water. The water circulation rate of the project is 96.5%, fully embodying one of the technological and economic features of circulating economy “raising the utilization rate of resources and reducing the resources and energy consumption during production process”. (3) The enterprise will reduce pollutant emission by relevant treatment measures for the waste gas and solid wastes produced from processes. This embodies the second technological and economic feature of circulating economy “extending and widening the production technical chain, disposing the pollutants inside the production enterprises as far as possible and reducing pollutant emission from processes”.
Therefore, the implementation of this project conforms to the concept of circulating economy.
87
6 Investigation and assessment of regional pollution sources
Investigation was made into the atmospheric pollution sources and water pollution sources of the key enterprises in this assessment area. The intensity of each pollution source, pollution factors emitted and characteristic of the various pollution sources in the area of this project were verified and summarized based on the actual investigation and the drainage information of 2004. The “equivalent pollution load process” method was adopted for filtering the main pollution sources and main pollutants in the region.
6.1 Investigation and assessment of atmospheric pollution source situation
6.1.1 Investigation of atmospheric pollution source situation
According to the present situation investigation, the main atmospheric pollution sources in the assessment area are mainly from 9 enterprises. For the emission situation, see Table 6-1.
Table 6-1 Atmospheric pollution source emission situation in the assessment area
No. Enterprise name SO2
(t/a)
Fume (dust)
(t/a)
1 Meishan Iron and Steel Co., Ltd 17953.79 10762
2 Nanjing Titanium Dioxide Chemical Co., Ltd. 1146 246
3 Nanjing Jinjiang Concrete Plant 385 4
4 Nanjing Zhenghan Glass Co., Ltd. 222.12 5.82
5 Nanjing Tongrentang Pharmaceutical Co., Ltd. 157 4.92
6 Nanjing Banqiao Cement Co., Ltd. 129.1 23.24
7 Nanjing Banqiao Building Brick & Tile Co., Ltd. 50.87 48.98
8 Nanjing Golden Ballet Cosmetics Co., Ltd. 53.26 8.39
9 Huafa Company 50.0 9.0
Total 20147.14 11112.35
6.1.2 Assessment of regional atmospheric pollution sources
(1)Assessment method
Equivalent pollution load process and pollution load ratio process are adopted for comparison.
(a)Equivalent pollution load of certain pollutant in waste gas Pi
PQC
ii
i=
0
Where: Qi—Absolute emission quantity of certain pollutant in waste gas(t/a)
C0i—Assessment standard of certain pollutant(mg/m3)
88
(b)Equivalent pollution load of certain pollution source (factory): Pn
P Pn ii
j
==∑
1 (i=1,2,……,j)
(c)Total equivalent pollution load in the assessment area: P
P Pn
k
n==∑
1 (n=1,2,……,k)
(d)Pollution load ratio of certain pollutant in the pollution source or assessment area: Ki
KPP
ii
n= × 100%
(e)Pollution load ratio of certain pollutant in the assessment area: Kn
KPP
nn
= × 100 %
(2)Assessment items and assessment standard
The atmospheric pollution in the assessment area is mainly bituminous coal type. The assessment items selected by this report are SO2, fume. For the assessment standard, see Table 6-2.
Table 6-2 Assessment standard of main pollutants in waste gas
No. Pollutants Assessment standard (daily average)(mg/m3)
(1) SO2 0.15
(2) TSP 0.30
(3)Assessment result analysis
The equivalent pollution load and the pollution load ratio of the atmospheric pollution source in the assessment area are shown in Table 6-3.
Table 6-3 Equivalent pollution load and pollution load ratio of the atmospheric pollution source in the assessment area
No. Pollution sources PSO2 P 烟尘 ∑Pn Kn(%)
1 Meishan Iron and Steel Co., Ltd 119691.93 35873.33 155565.27 90.79
2 Nanjing Titanium Dioxide Chemical Co., Ltd. 7640.00 820.00 8460.00 4.94
3 Nanjing Jinjiang Cement Plant 2566.67 13.33 2580.00 1.51
4 Nanjing Shenghan Glass Co., Ltd. 1480.80 19.40 1500.20 0.88
5 Nanjing Tongrentang Pharmaceutical Co., Ltd. 1046.67 16.40 1063.07 0.62
6 Nanjing Banqiao Concrete Co., Ltd. 860.67 77.47 938.13 0.55
89
No. Pollution sources PSO2 P 烟尘 ∑Pn Kn(%)
7 Nanjing Banqiao Building Brick & Tile Co., Ltd. 339.13 163.27 502.40 0.29
8 Nanjing Golden Ballet Cosmetics Co., Ltd. 355.07 27.97 383.03 0.22
9 Huafa Company 333.33 30.00 363.33 0.21
∑Pi 134314.27 37041.17 171355.43 100.00
Ki(%) 78.38 21.62 100.00
According to Table 6-3, the main pollution source in the assessment area is Meishan Iron and Steel Co., Ltd , the pollution load ratio of this enterprise is 90.79%; main pollutant is SO2, with pollution load ratio of 78.38%.
6.2 Wastewater pollution source investigation and assessment
6.2.1 Present situation investigation of wastewater pollution source
According to the present situation investigation, the main industrial wastewater pollution sources in the assessment area are mainly from 10 enterprises; for their emission situation, see Table 6-4.
Table 6-4 Wastewater pollution source discharge amount in the region
No. Enterprise name
COD discharge amount
(t/a)
SS discharge amount
(t/a)
1 Meishan Iron and Steel Co., Ltd * 3871 4766
2 Nanjing Titanium Dioxide Chemical Co., Ltd. 298.87 365.56
3 Nanjing Jail, Jiangsu Province 37.3 37.3
4 Nanjing Fiberglass Research & Design Institute 30.94 34.92
5 No.3 Repair Shop, Public Traffic Company 7.83 37.6
6 China Animal Husbandry Industry Co., Nanjing
Spraying Equipment 18.43 27.89
7 Nanjing Tongrentang Pharmaceutical Co., Ltd. 26.44 14.3
8 Nanjing Banqiao Fire-fighting Equipment Plant 29.70 3.00
9 Nanjing Weida Clothing Co., Ltd. 11.4 14.1
10 Nanjing Compressor Co., Ltd. 5.36 13.72
Total 4337.27 5314.39
Note: Shanghai Meishan Iron and Steel Co., Ltd discharges separately to Yangtze River.
90
6.2.2 Regional wastewater pollution source assessment
(1)Assessment method
The equivalent pollution load process and the pollution load ratio process are used for comparison. The method is the same as that for atmospheric pollution source.
(2)Assessment items and assessment standard
For the assessment items and assessment standard, see Table 6-5.
Table 6-5 Assessment standard for main pollutants in wastewater
No. Hazardous substances Assessment standard (mg/l)
(1) CODcr 100
(2) SS 70
(3)Assessment result analysis
The equivalent pollution load and the pollution load ratio of the wastewater pollution source in the assessment area are as shown in Table 6-6.
Table 6-6 Equivalent pollution load and pollution load ratio of the wastewater pollution source in the assessment area
No. Pollution sources PCOD PSS ∑Pn Kn(%)
1 Meishan Iron and Steel Co., Ltd 38.71 68.09 106.80 89.53
2 Nanjing Titanium Dioxide Chemical Co., Ltd. 2.99 5.22 8.21 6.88
3 Nanjing Jail, Jiangsu Province 0.37 0.53 0.91 0.76
4 Nanjing Fiberglass Research & Design Institute 0.31 0.50 0.81 0.68
5 No.3 Repair Shop, Public Traffic Company 0.08 0.54 0.62 0.52
6 China Animal Husbandry Industry Co.,Nanjing Spraying Equipment
0.18 0.40 0.58 0.49
7 Nanjing Tongrentang Pharmaceutical Co., Ltd. 0.26 0.20 0.47 0.39
8 Nanjing Banqiao Fire-fighting Equipment Plant 0.30 0.04 0.34 0.28
9 Nanjing Weida Clothing Co., Ltd. 0.11 0.20 0.32 0.26
10 Nanjing Compressor Co., Ltd. 0.05 0.20 0.25 0.21
∑Pi 43.37 75.92 119.29 100.00
Ki(%) 36.36 63.64 100.00
According to Table 6-6, the main pollution source in the assessment area is Meishan Iron and Steel Co., Ltd, the pollution load ratio of this enterprise is 89.53%; main pollutant is SS, with pollution load ratio of 63.64%.
91
7 Investigation and assessment of environment quality present situation
7.1 Investigation and assessment of atmospheric environment quality present situation
7.1.1 Monitoring of atmospheric environment quality present situation
7.1.1.1 Monitoring scope and points
According to functional divisions of atmospheric environment, and following the principle of setting up equal points, 5 atmospheric monitoring points have been arranged within the assessment area, they are: 1. the living quarters of Meishan Iron and Steel Co., Ltd; 2. Sunjiacun Village; 3. Sanshancun Village; 4. Jiangning Town; and 5. north plant boundary; for directions of the monitoring points, see Table 7-1. For the detailed specific positions of the atmospheric monitoring points, see Fig. 7-1.
Table 7-1 Distance and direction of the monitoring points to the site of the project
Position to the project site No. Name of the monitoring point
Direction Distance (m)
1 Living quarters of Meishan Iron and Steel Co., Ltd East 1.3
2 Sunjiacun Village South 1.3
3 Sanshancun Village (Huangnitang) Northeast 1.7
4 Jiangning Town Southwest 3.0
5 North plant boundary Northeast 2.1
Note: The distance is from the existing No.2 BF as the original point.
7.1.1.2 Monitoring items
The monitoring items are: SO2, NO2, PM10, B[a]P, TSP, H2S. For items monitored at each monitoring point, see Table 7-2.
Table 7-2 Summary of items monitored at each monitoring point
No. Name of the monitoring point Monitoring items
1 Living quarters of Meishan Iron and Steel Co., Ltd SO2, NO2, PM10, TSP, BaP
2 Sunjiacun Village SO2, NO2, PM10, TSP
3 Sanshancun Village (Huangnitang) SO2,NO2, PM10, TSP, BaP
4 Jiangning Town SO2, NO2, PM10, TSP
5 North plant boundary BaP, TSP, H2S, NH3
92
7.1.1.3 Monitoring system and sampling method
(1)Monitoring time-interval and sampling
Nanjing Environment Monitoring Center carried on monitoring of the atmospheric situation for five days in succession April 12-16, 2005. The atmospheric sampling and analysis method followed the requirements and stipulations of “Technical specification for environment monitoring” and “Analysis method of air and waste gas monitoring” published by the State Environmental Protection Administration and “By-laws of atmospheric environment routine monitoring of Jiangsu Province” issued by Environment Monitoring Station of Jiangsu Province.
This assessment is based on the 5-day successive monitoring. SO2 and NO2 was monitored for 18 times a day at Jiangning Town, the monitoring time was between 07-24 hours; and 4 times a day at other monitoring points, the monitoring was at 02, 07, 14, and 19 hours. TSP and PM10 were monitored once every day for 12 hours in succession; BaP and H2S were monitored once every day for 3 days in succession.
(2)Sampling and analysis methods
Sampling and analysis methods follow the stipulations of “Technical specification for environment monitoring”(atmosphere part); refer to Table 7-3.
Table 7-3 Summary of sampling and analysis methods
Items Sampling methods Analysis methods
PM10 Filter diaphragm sampling Gravimetric method(GB/T15432-1995)
TSP Filter diaphragm sampling Gravimetric method(GB/T15432-1995)
SO2 Solution absorption method Formaldehyde absorption - vice-rose aniline spectrophotometric method(GB/T15262-94)
NO2 Solution absorption method Saltzman method(GB/T15435-1995)
B[a]P Filter diaphragm sampling Highly effective liquid phase chromatography
H2S Solution absorption method Methylene blue spectrophotometric method
NH3 Solution absorption method Nash reagent spectrophotometric method
According to the relevant technical specifications of the national central monitoring station and the provincial monitoring station, it had carried out the whole process quality control of the monitoring. The contents of the site sampling quality control are: The sampling instruments were calibrated by Grade 2 soap bubble flowmeter for flow and sampling time. The contents of laboratory quality control are: according to the requirement, 20% parallel samples and 10% additional standard sample were taken, implement the blank examination and standard working curve belt point control.
93
7.1.2 Assessment of atmospheric environment quality situation
7.1.2.1 Assessment standard
SO2, PM10, B[a]P and TSP are assessed by Class-2 standard of “Ambient air quality standard” (GB3095-1996); NO2 by the requirement of the revision notification of No. 1 document (2000) of the State Environmental Protection Administration concerning “Ambient air quality standard” (GB3095-1996); H2S and NH3 by maximal allowable atmospheric concentration of hazardous substance in the living areas stipulated in “Sanitary standard for the design of industrial enterprises” (TJ36-79). For the specific details, see Table 2-2.
7.1.2.2 Analysis of the monitoring results
The collected and sorted monitoring results of each monitoring item are summarized in Tables 7-4 to 7-11.
Table 7-4 Summary of SO2 monitoring result statistics
No. Monitoring points
1h concentration
mg/m3
1h concentration
exceeding standard rate(%)
Daily average concentration
mg/m3
Exceeding standard rate of daily average
concentration range(%)
1 Living quarter of
Meishan Iron and Steel Co., Ltd
0.008-0.171 0 0.059-0.077 0
2 Sunjiacun Village 0.003-0.038 0 0.004-0.036 0
3 Sanshancun Village
(Huangnitang) 0.003-0.037 0 0.003-0.035 0
4 Jiangning Town 0.010-0.108 0 0.024-0.059 0
Table 7-5 Summary of NO2 monitoring result statistics
No. Monitoring points 1h
concentration
mg/m3
1h concentration
exceeding standard rate(%)
Daily average concentration
mg/m3
Exceeding standard rate of daily average concentration range
(%)
1 Living quarter of Meishan Iron and
Steel Co., Ltd 0.011-0.098 0 0.043-0.063 0
2 Sunjiacun Village 0.006-0.037 0 0.010-0.029 0
3 Sanshancun Village
(Huangnitang) 0.006-0.032 0 0.011-0.023 0
4 Jiangning Town 0.006-0.079 0 0.022-0.049 0
94
Table 7- 6 Summary of PM10 monitoring result statistics
No. Monitoring points
Daily average concentration range
mg/m3
Exceeding standard rate of daily average concentration range
(%)
1 Living quarters of Meishan
Iron and Steel Co., Ltd 0.088-0.177 60
2 Sunjiacun Village 0.216-0.439 100
3 Sanshancun Village
(Huangnitang) 0.213-0.345 100
4 Jiangning Town 0.086-0.197 40
Table 7-7 Summary of TSP monitoring result statistics
No. Monitoring points
Daily average concentration range
mg/m3
Exceeding standard rate of daily average concentration range
(%)
1 Living quarters of Meishan
Iron and Steel Co., Ltd 0.217-0.384 40
2 Sunjiacun Village 0.310-0.872 100
3 Sanshancun Village
(Huangnitang) 0.284-0.794 80
4 Jiangning Town 0.177-0.364 40
5 North plant boundary 0.215-0.534 60
Table 7-8 Summary of B[a]P monitoring result statistics
No. Monitoring points
Daily average concentration
μg/m3
Exceeding standard rate of daily average concentration range
(%)
1 Living quarters of Meishan
Iron and Steel Co., Ltd 0.0011-0.0045 0
3 Sanshancun Village
(Huangnitang) 0.0059-0.0090 0
5 North plant boundary 0.0018-0.0066 0
95
Table 7-9 Summary of H2S monitoring result statistics
No. Monitoring point 1 time concentration
(mg/m3)
Exceeding standard rate of 1 time concentration(%)
5 North plant boundary 0.001-0.001 0
Table 7-10 Summary of NH3 monitoring result statistics
No. Monitoring point 1 time concentration
(mg/m3)
Exceeding standard rate of 1 time concentration(%)
5 North plant boundary 0.01-0.01 0
Through statistical analysis of the monitoring results, we can come to know the pollution situation of various pollutants in the atmospheric environment of the assessment area. They are described item by item as follows:
SO2 1h concentration value range was 0.003-0.171mg/m3, and average daily concentration value range 0.003-0.077mg/m3; the 1h concentration value and the average daily concentration value at each monitoring point did not exceed the standard.
NO2 1h concentration value range was 0.006-0.098mg/m3, and average daily concentration value range 0.010-0.063mg/m3; the 1h concentration value and the average daily concentration value at each monitoring point did not exceed the standard.
PM10 average daily concentration value range was 0.086-0.439mg/m3; the average daily concentration value at each monitoring point in the assessment area all exceeded the standard.
TSP average daily concentration value range was 0.177-0.872mg/m3; the average daily concentration value at each monitoring point in the assessment area all exceeded the standard.
B[a]P average daily concentration value range was 0.0011-0.0090μg/m3; the average daily concentration value at each monitoring point in the assessment area did not exceed the standard.
H2S 1 time concentration value range was 0.001-0.001mg/m3; the 1 time concentration value at each monitoring point did not exceed the standard.
NH3 1 time concentration value range was 0.01-0.01mg/m3; the1 time concentration value at each monitoring point did not exceed the standard.
7.1.2.3 Assessment of atmospheric environment quality situation
(1)Assessment factors
The assessment factors of this assessment are: SO2, NO2, PM10, TSP, B[a]P, H2S, NH3
(2)Assessment methods
96
The assessment of atmospheric quality situation uses single item standard index method, namely:
Iij= Cij / Csi
Where: Iij— the ith type pollutant, the index at the jth monitoring point
Cij—the ith type pollutant, the monitoring average value at the jth monitoring point(mg/m3)
Csi—the ith type pollutant assessment standard(mg/m3)
(3)Assessment results
For calculation of single factor pollutant index, see Tables 7-11 and 7-12.
Table 7-11 Pollutant indexes of conventional pollutants
Value I No. Monitoring points
SO2 NO2 PM10 TSP
1# Living quarters of Meishan
Iron and Steel Co., Ltd 0.51 0.53 1.18 1.28
2# Sunjiacun Village 0.24 0.24 2.93 2.91
3# Sanshancun Village
(Huangnitang) 0.23 0.19 2.30 2.65
4# Jiangnining Town 0.39 0.41 1.31 1.21
5# North plant boundary — — — 1.78
Table 7-12 Pollutant indexes of characteristic pollutants
Value I No. Monitoring points
B[a]P H2S NH3
1# Living quarters of Meishan Iron and Steel Co., Ltd
0.45 — —
3# Sanshancun Village (Huangnitang)
0.90 — —
4# Jiangnining Town — — —
5# North plant boundary 0.66 0.10 0.05
Through calculation of each assessment factor value I in the assessment area, we may further learn about the atmospheric environment quality situation in the assessment area. The conventional pollutant value I in the assessment area from smaller to bigger are: ISO2 < INo2
<IPM10 <ITSP; and the characteristic pollutant value I from smaller to bigger are: INH3 <IH2S <IB[a]P.
97
The assessment of the atmospheric environment quality situation in the assessment area showed that there was quite serious dust pollution in the atmospheric environment quality in the assessment area. The main causes of some pollutants exceeding the standard at some monitoring points in the assessment area are:
(1)The Banqiao industrial area and the Yuhua economic development zone around the assessment area are in a full swing of development, the projects of road building and land leveling produce fly dust, causing serious dust pollution during certain periods of time;
(2)The monitoring time was just at the time changing from spring to summer, there were more sunny days than rainy days, which caused dust flying from the ground seriously.
7.2 Investigation and assessment of surface water environment quality situation
7.2.1 Monitoring of surface water environment situation
7.2.1.1 General information on water system in the assessment area
The surface water system nearby the planned project area has Nanjing Banqiao section of the Yangtze River, the Banqiao River and Jiangning River; the waste water of Meishan Iron and Steel Co., Ltd discharges into the Yangtze River by way of the open canal close to the Jiangning Rivert through the main plant’s west outlet.
The Yangtze River is the longest river in China, as long as about 6300km, with a total drainage area of 1,800,000km2, the runoff resources account for 37.8% of the national total; the water is abundant, the annual mean water volume into the sea measures 960 billion cubic meters, with maximum flow 92600m3/s, mean flow 28500m3/s, minimum daily mean flow 5970m3/s, and minimum monthly mean flow 6940m3/s.
The Yangtze River of Nanjing Banqiao section is a tidal river reach, tide rising and ebbing two times a day, the tide rising lasting approximately 3 hours, tide ebbing lasting approximately 9 hours, with average tidal range of 0.57m, and maximum tidal range difference 1.56m. The River water in its high water period has only setup amplitude but no backflow; during the dry season it has alternating current; and the flood season is from May to October every year. Annual mean flow is approx. 28600m3/s, the maximum peak flow amounts to 92,000m3/s; the minimum flow in winter is over 8000m3/s. The flow in dry season compared to the rest of the year is 0.89: 1; in the high water period the maximum velocity is 3.39m3/s; during the normal water season velocity is 1.0m3/s, with mean velocity of 1.1-1.4m3/s. When in high water period, the water surface gradient is 0.2/10000; when in low water period, it is 0.3/10000; the highest water level is 10.22m, and the lowest water level 1.5m; the water level at Sanshanying nearby the Banqiao is 8.7m; the water temperature changes between 6.0-30.5. In the area south of the Yangtze River there are mainly the Jiangning River, the Banqiao River and the New Qinhuai River. Downstream the Sanshan Crag, from the Fengxiang Port to the mouth of the New Qinhuai River, there is a deepwater waterfront of 5km, with perennial water depth of approx. 20m.
In the Yangtze River of Nanjing Banqiao section there are many boats and ships anchoring at the wharfs of the southern bank; the main wharfs are: the wharf of Meishan Iron and Steel Co., Ltd, the Yunxiang wharf of Meishan Mining Industry Company, the Fenxiang wharf, and the Banqiao vehicle ferry wharf.
98
Both the Banqiao River and the Jiangning River originate in the neighboring hilly areas. The Banqiao River has a catchment area of approx. 100km2, flowing into the Yangtze River at Dashengguan through Guli, Banqiao and running through the Banqiao Town. The Jianging River is approx. 13.5km long, with a catchment area of approx. 200km2, which originates in Anhui Province, flowing into the Yangtze River at the place of 2km upstream from the Sanshan Crag after flowing through the three towns of Lulang, Guli and Jiangning in the Jiangning District. The River is 15-25m wide, with a mean depth of 1.7m; because of the effect of rising and ebbing tide of the Yangtze River, there are changes in the river water quality and flow direction, but the river water flows northward perennially. To meet the need of diverting the flood, the Gongnong canal was dug to the south of Meishan Iron and Steel Co., Ltd area in the 1970's, which has a catchment area of nearby 8km2, diverting water of 40-50m3/s; the Gongnong canal converges with the Yangtze River nearby the mouth of the Jiangning River.
7.2.1.2 Monitoring cross-section and points
Three monitoring cross-sections are set in the Yangtze River of Nanjing Banqiao section in the assessment area, with each cross-section set with three perpendicular lines, away from the shore at 30m, 80m, and 250m respectively; for the monitoring cross-sections, monitoring items and sampling frequency, refer to Table 7-14 and Figure 7-1 (analysis made after mixing the 3 samples taken at the three monitoring cross-sections at the same time).
Table 7-14 Specific position of water quality monitoring section
No. Water area Position Distance Monitoring
items Monitoring frequency
1 SectionⅠ
2500m upstream from Meishan Iron and Steel Co., Ltd north drainage
into the Yangtze River(water catchment)
2 SectionⅡ
100m downstream from Meishan Iron and Steel Co., Ltd north
drainage into the Yangtze River (Banqiao vehicle ferry)
3
Yangtze River, Nanjing Banqiao Section
Section Ⅲ
3300m downstream from Meishan Iron and Steel Co., Ltd north
drainage into the Yangtze River (No.3 Yangtze River Bridge)
PH, CODcr, SS, CN-, volatile phenol,
ammonia nitrogen, petroleum
Sample for 3 days, 1 for spring tide
and 1 for ebb tide
7.2.1.3 Monitoring and analysis methods
The monitoring method follows “Technical specification for environment monitoring” (environment part of surface water) issued by the State Environmental Protection Administration. Sampling and analysis methods follow the related national standard and the
99
related code and standard of the State Environmental Protection Administration.
7.2.1.4 Monitoring time interval and sampling frequency
The Nanjing Environment Monitoring Central Station took samples at each monitoring cross-section continually for three days on April 5-7, 2005, two times a day, one at tide rising, and one at tide ebbing.
7.2.1.5 Monitoring results of water quality
For monitoring results of water quality of the assessment water body, refer to Table 7-15.
Table 7-15 Monitoring results of water quality for assessing water body
(Unit: mg/l)
Water body
Cross section
Items PH CODcr SS Cyanide Volatile phenol
Ammonia nitrogen
Petroleum
Maximum value
8.12 10 18 Not found Not found 0.255 Not found
Minimum value
7.92 <10 12 Not found Not found 0.126 Not foundSection
Ⅰ
Average value
8.05 <10 15 Not found Not found 0.199 Not found
Maximum value
8.13 15 21 Not found Not found 0.208 Not found
Minimum value
7.94 <10 12 Not found Not found 0.125 Not foundSection
Ⅱ
Average value
8.06 <10 16 Not found Not found 0.170 Not found
Maximum value
8.12 10 18 Not found 0.002 0.210 Not found
Minimum value
7.93 <10 13 Not found Not found 0.148 Not found
Yangtze River,
Nanjing Banqiao Section
Section Ⅲ
Average value
8.06 <10 15 Not found Not found 0.173 Not found
Detection limit - 10 - 0.004 0.002 - 0.05
Assessment standard Type Ⅱ 6-9 15 25 0.05 0.002 0.5 0.05
Note: PH dimensionless; SS follows the standard of Ministry of Water Resources.
100
7.2.2 Assessment of surface water environment situation
7.2.2.1 Assessment methods
Single factor standard index method was used to assess the surface water environment quality situation. The single factor standard index calculation formula is:
i
ij c
cS0
=
Where: Si- the standard index of the ith type pollutant;
ci- the monitoring average value of the ith type pollutant (mg/L);
c0i- the assessment standard of the ith type pollutant (mg/L).
The pH standard index calculation formula is:
Sp Hp Hp H J
J
s d,
..
=−−
7 07 0
p H J ≤ 7 0.
Sp Hp Hp H
J
s U
=−−
7 07 0..
0.7>JpH
Where: pHi- the monitoring average value at the jth point;
pHsd- the lower limit stipulated by water quality standard;
pHsu- the upper limit stipulated by water quality standard.
7.2.2.2 Assessment results
For the assessment results of water quality situation, refer to Table 7-17.
Table 7-17 Calculation result 1 of each factor standard index (Pij)
Sections PH CODcr SS Cyanide Volatile phenol
Ammonia nitrogen
Petroleum
Section Ⅰ 0.53 <0.67 0.60 0.00 0.00 0.40 0.00
Section Ⅱ 0.53 <0.67 0.64 0.00 0.00 0.34 0.00
Section Ⅲ 0.53 <0.67 0.60 - - 0.35 0.00
From Table 7-17, we may see that PH, CODcr, SS, CN, volatile phenol, ammonia nitrogen, and petroleum at each monitoring cross-section in the Yangtze River of Nanjing Banqiao section all reached the limit value of Grade II of “Environmental quality standard for surface water” (GB3838-2002). From the above analysis, we can see that the water quality at each monitoring cross-section in the Yangtze River of Nanjing Banqiao section is quite good, which can meet the requirement of GradeⅡ standard of “Environmental quality standard for surface water” (GB3838-2002).
101
7.3 Investigation and assessment of acoustic environment quality situation
7.3.1 Investigation of acoustic environment situation in the project location
Shanghai Meishan Steel Co., Ltd. is located at Banqiao Town of Yuhua District, Nanjing, outside the Zhonghua Gate of Nanjing, approx. 20km to the center of Nanjing; the company now covers an area of approx. 4.2km2. The plant area is close to the Yangtze River in the north, meeting the Nanjing-Wuhu highway and Nanjing-Wuhu railway in the south; the transportation is very convenient.
Around the Meishan Iron and Steel Co., Ltd are a marine auxiliary equipment factory, Jiantong Building Material Plant, Jiangning Insecticide Factory, Jiangning Cement Plant, and the People's Liberation Army Institute of International Relations. For the construction of the planned project, some local residents will have to be relocated, yet there will still be some sensitive objectives like the residences in the peripheral area of the plant boundary; the closest residences are the Lijiabian Village, which is only 50m away from the plant boundary. Such are the main sensitive objectives of noise in the project construction. Table 7-18 shows the main sensitive points and their scale around the plant area.
Table 7-18 Main sensitive objectives around the plant area
Sensitive objectives Direction Distance (m) Population or
household
Living quarter of Meishan Iron and Steel Co., Ltd
East 150 Approx. 5000 households
Residential area of Huangnitang Village Northeast 290 100 households
Residential area of Sunjiacun Village South 380 50 households
Residential area of Gujiabian South west 100 30 households
Residential area of Lijiabian West 50 25 households
Residential area of Caocun Village West 100 30 households
In Nanjing acoustic environment functional divisions, the area in which the Meishan Iron and Steel Co., Ltd located is Grade III environment noise functional area; the noise at plant boundary follows Grade III of the standard for noise at boundary of industrial enterprises; but the local government has determined the residential area around the plant boundary as Grade II acoustic protection area for protecting the living environment; therefore, the sensitive objectives in this assessment area follows the acoustic environment standard of Grade II area.
As a large-scale integrated iron and steel works, Meishan Iron and Steel Co., Ltd has a large number of high noise equipment; and all the workshops have high noise equipment. Table 7-19 shows the main high noise equipment of the Steelworks, which were obtained through on-the-spot monitoring and measuring of the existing production equipment.
102
Table 7-19 Existing main noise source and the sound level of Meishan Iron and Steel Co., Ltd Company dB(A)
No. Name of noise equipment Noise value
dB(A) number measures
1 Coke oven coke pusher(at 3m, is pushing) 85.4 3 —
2 Sintering plant vertical crusher fan (at
3m) 81.0 1
Building sound insulation
3 Sintering machine(at 5m outside ground) 76.8 2 —
4 Sintering machine main exhaust fan 97 3
5 Sintering machine ignition furnace
blower 98 3
6 Sintering machine circle cooling fan 100 3
7 Sintering machine dust removal system
fan 97 5
8 Coal preparation dust removal fan 80-100 1
Select low noise type product,
provide with muffler
9 Coal preparation vibration screen 80-85 1 Provide with seal cover to insulate
sound
10 Air compressor station air compressor 90-95 8 Sound insulation
plus muffler
11 Blast furnace hot blast stove fan 100 3 Silencing, insulating
and absorbing
12 Blast furnace hot blast stove blower
(outdoor 3m, is running) 85.0 3
Building sound insulation
13 Comprehensive noise of BF cast house
platform (before tapping) 76.3 3
Building sound insulation
14 Blast furnace dust removal system fan 98 4 Provide with
muffler, absorb
15 Blast furnace fan snort valve 120 3 Provide with muffler
16 Furnace top pressure relief valve 115 3 Provide with muffler
17 Excess pressure power generation unit 100 3 Sound insulation,
absorption
18 Various circulating water pump 90 12 Sound insulation,
absorption
103
No. Name of noise equipment Noise value
dB(A) number measures
19 Active lime kiln gas compressor 80-100 2
20 Active lime kiln blower 80-90 4
Silencing, insulating and absorbing
21 Active lime kiln dust removal fan 80-100 2
22 Active lime kiln ventilator 80-90 2
Provide with muffler, insulate and
absorb
23 Active lime kiln vibration screen 80-85 2 Provide with seal cover to insulate
sound
24 Dust removal fan for stock storage and
transportation facilities 100 2 Sound insulation
25 Comprehensive noise of steelmaking
plant 76.4 —
Building sound insulation
26 Converter of steelmaking plant (at 12m,
indoor) 99.8 2
Building sound insulation
27 Comprehensive noise of continuous
casting plant 78.8 —
Building sound insulation
28 Continuous casting machine(at 5m,
indoor) 89.5 1
Building sound insulation
29 Hot-rolling heater fan (at 2m) 93.0 2 Building sound
insulation
30 Hot continuous rolling machine (at 5m) 100.1 7 Building sound
insulation
31 Train 105 —
32 Steam turbine generator set 101 2 Sound insulation and vibration reduction
33 Steam bleeder valve 115 2 Muffler
7.3.2 Monitoring of environment noise situation
To understand the effect of production noise of Meishan Iron and Steel Co., Ltd on the environment outside the plant boundary, to grasp completely the present environmental noise level around the old and new plant areas, 20 monitoring points for present plant boundary noise were arranged along the new and old plant boundaries of Meishan Iron and Steel Co., Ltd, they are arranged in principle of quasi-uniform arrangement, but the monitoring points are dense at the plant boundary nearby high noise equipment. In addition, 4 environmental
104
noise monitoring point were arranged in Huangnitang, Meishan No.3 Middle School, new developed area of Shangyiyicun and Sunjiacun Village. For details of the noise monitoring points at plant boundary and the environmental noise monitoring points, refer to Fig. 7-2. Each noise monitoring point is monitored for two days, once for every day and night.
According to the stipulations of the Environmental Protection Department of Jiangsu Province, the noise monitoring work of Meishan Iron and Steel Co., Ltd was completed on April 6 and 7, 2005 by Nanjing Environmental Monitoring Central Station; the measuring instrument used was AWA5611 type integrating sound level meter made by Aihua, Zhejiang; the measurement was made by following closely “Measurement method for environment noises in urban areas” and “Measurement method for environment noises at boundary of industrial enterprises” . The noise level obtained from the measurement was the equivalent sound level after being processed by sound level meter; during the measurement, the environment and main noise pollution sources surrounding the measuring points were also recorded. For the specific measurement results, see Table 7-20. On April 13, 2005, the environment assessment unit made inspective measurement at each noise monitoring point for the reliability of the data; and the inspective measurement results were told to the monitoring unit. The monitoring unit re-measured the noises at Monitoring points 7, 8, 11, 12, 14 and 15 on April 15, 2005. Therefore, there is only the measurement data measured of the last day in Table 7-20, but the measurement data measured on the previous two days were not used. As a whole, the measurement data of environment noise in this assessment are quite credible.
Table 7-20 Statistics of monitoring results of present noise situation [Leq(A)]
April 6 April 7 Average of two days No. Measuring position
Day Night Day Night Day Night
Main noise source
Environmental function
1 Gate of Meishan
Iron and Steel Co., Ltd
66.5 54.5 69.5 56.8 68.0 55.7 Traffic, society
2 Outside the old
cold drink workshop
59.6 57.2 59.6 52.8 59.6 55.0 Traffic
3 Outside the
command building of switchyard
57.1 55.3 51.0 43.8 54.1 49.6 Train blow
4 Change line 60.8 49.4 57.5 49.1 59.2 49.3 Train
whistling, production
Plant boundary
105
April 6 April 7 Average of two days No. Measuring position
Day Night Day Night Day Night
Main noise source
Environmental function
5
Gate of Refrigeration
Equipment Service Center
53.5 54.0 61.5 48.3 57.5 51.2 Traffic, society,
production
6★ 2# gate of Meishan Iron and Steel Co.,
Ltd Branch 52.4 51.6 52.4 51.6
Production, motor
7★ South boundary of
coke plant 58.5 51.9 52.3 51.2 55.4 51.6 Production
8 East boundary of
coke plant 57.6 49.4 49.6 45.9 53.6 47.7 Production
9 North boundary of
coke plant 54.6 52.9 60.1 50.2 57.4 51.6
10 North boundary of
stock plant 54.6 52.9 60.1 50.2 57.4 51.6
Traffic, production
11★ West boundary of
stock plant 63.1 63.9 63.1 63.9
Traffic, belt conveying
12★ 9# gate of Meishan Iron and Steel Co.,
Ltd 61.4 59.9 61.4 59.9
Traffic, belt driven motor
13 Gate of Scrap Steel
Plant 63.1 54.5 58.6 51.3 60.9 52.9
Traffic, production
14★ North boundary of
Scrap Steel Workshop
55.4 53.3 55.4 53.3 Production
15★ West boundary of
lime kiln 53.2 57.0 53.2 57.0 Production
16 West boundary of
hot rolling 48.8 46.1 51.5 47.7 50.2 46.9
Society, traffic
17 Southwest
boundary of hot rolling
47.5 43.1 46.8 42.5 47.2 42.8 Society
18 Southeast of the
project 52.4 44.7 50.9 46.6 51.7 45.7
Production, construction
106
April 6 April 7 Average of two days No. Measuring position
Day Night Day Night Day Night
Main noise source
Environmental function
19 East of
compression station
58.9 59.4 60.7 58.5 59.8 59.0 Gas station
20 South gate of power plant
60.1 54.3 56.8 55.1 58.5 54.7 Traffic, power plant cooling
tower
Average noise level at plant boundary
57.3 53.5 56.2 50.0 56.8 52.6
21 Huangnitang 55.7 47.4 55.6 49.8 55.7 48.6
22 Meishan No.3 Middle School
52.6 45.9 55.7 48.2 54.2 47.1
23 New developed
area of Shangyiyicun
56.2 47.3 52.3 48.1 54.3 47.7
24 Sunjiacun Village 54.9 45.9 51.8 49.4 53.4 47.7
Traffic, society noise in day time, production
noise at night
Average noise level at sensitive point 54.9 46.6 53.9 48.9 54.4 47.8
Residential area
Average 56.9 52.4 55.7 49.7 56.3 51.1
7.3.3 Acoustic environment quality situation assessment
According to the acoustic environment situation monitoring results, the noise level at plant boundary of Meishan Iron and Steel Co., Ltd is between 46.8—69.5 dB(A) at day time, and 42.5—63.9 dB(A) at night, the average noise at the plant boundary is 56.8dB(A) at day time, 52.6 dB(A) at night. Seeing from the average noise sound level at the plant boundary, the noise level at the plant boundary of Meishan Iron and Steel Co., Ltd at day time and night can meet the standard for noise level at plant boundary of Grade III area. The environmental noise monitoring results of the 4 sensitive points show that the sound levels of the 4 monitoring points at day and night time are all lower than the standard for environmental noise of grade II area, the average noise level at day time and night of all the measurements of the sensitive points was 54.4dB(A) and 47.8 dB(A) respectively. For the analysis results of the present noise at the plant boundary and the environmental noise, see Table 7-21.
107
Table 7-21 Analysis of present noise situation
Classification of environmental divisions
Plant boundary Environmental sensitive points like residential area, school
Day Night Day Night
Sound level range 46.8—69.5 42.5—63.9 51.8—56.2 45.9—49.8
Average sound level [dB(A)] 56.8 52.6 54.4 47.8
Excessive amount [dB(A)] / / / /
Measurements of exceeding standard
2 9 0 0
Exceeding standard rate % 6 26 0 0
According to the present noise situation analysis results, the average noise at day and night in old plant area of Meishan Iron and Steel Co., Ltd can all meet the standard, but there were 2 measurements in daytime exceeding the standard, 9 measurements at night, with the exceeding standard rate reaching 6% and 26% respectively. According to the on-the-spot survey of the plant boundary environment made by the assessment unit and the main noise pollution source of each measurement point recorded by the monitoring unit, analysis for the cause of exceeding standard of these measurements exceeding standard has been made. For details, see Table 7-22.
Table 7-22 Causes of exceeding standard measured Measuring
points Time Measured
sound level dB(A)
Cause analysis
1 Day 66.5, 69.5 1 56.8
This point is at the plant gate, mainly affected by traffic noise
2 57.2 3
55.3
Mainly affected by traffic and train coming and going, the plant boundary noise is quite low when no such effect. The sound level
at the two sites does not exceed the standard on another day. 11 63.9 12
59.9
Both points are at the roadside, affected by vehicle running and running noise of stock plant belt conveyer. The proposed sheet
metal project shall pay attention to this problem, striving to solve the old problem by the new.
15 57.0
The noise at this point in day time is lower than that at night, indicating the night measurement may be affected by accidental
causes 19
57.0,58,5 Affected by noise from the gas compression station, the proposed
sheet metal project should be able to solve this problem. 20
Night
55.1 Exceeding the standard slightly, mainly affected by traffic noise.
The measured sound level at this point is 52.5 dB (A) measured by the assessment unit when no vehicle passing by.
108
It can be seen through the above analysis that, although there were some measuring points exceeding the standard for the day and night noise in plant boundary of Meishan Iron and Steel Co., Ltd, yet only 1 measuring point, No.11, exceeded the standard that was caused by production noise of Meishan Coke Plant, and the exceeding was quite slight. If technological innovation project is made by taking proper noise control measures on the basis of improving the old by the new, the day and night noise in plant boundary at this measuring point will be able to be up to standard. The exceeding standard problem of other measuring points will be solved by the proposed project “Technical transformation project of product structure adjustment and process equipment upgrading of Meishan Iron and Steel Co., Ltd, Bao Steel Co., Ltd.” (the existing sheet metal project) by improving the old through the new.
The environmental noise at day and night at the 4 sensitive points were lower than the standard of grade II area, none of them exceeding the standard. In general, the plant boundary noise and its surrounding acoustic environment of Meishan Iron and Steel Co., Ltd are quite good at present.
109
8 Prediction and assessment of environmental impact
8.1 Atmospheric environmental impact assessment
8.1.1 Pollution meteorological characteristics survey
In this assessment, an analysis of pollution meteorological characteristics will be made based on ground meteorological data and space observation obtained by Nanjing Meteorological Station in recent years.
8.1.1.1 Routine ground meteorological characteristics analysis (omitted)
8.1.2 Prediction mode
Because this construction project only has a little scale atmospheric environmental impact which is a problem of local air pollution diffusion, and the terrain in the prediction area is relatively flat, Gaussian air quality model is utilized for this assessment in accordance with Technical Guideline of Environmental Impact Assessment (HJ/T2.2—93). This model not only applies to the problem of air pollutants diffusion and transport, but has the advantage of high resolution and high calculation efficiency, etc.
(1) Diffusion mode for non-point source under wind condition (omitted)
(2) Diffusion mode for non-point source under little wind and calm wind (omitted)
8.1.3 Environmental impact prediction
The calculation of impact of H2S on plant boundary and environmentally sensitive points is done under the condition of different stability degrees and on the basis of non-point diffusion mode. For the impact of H2S with average wind velocity in prevailing wind direction (2.5m/s), refer to Table 8-1. And for the impact of H2S under little wind condition, refer to Table 8-2.
Table 8-1 Prediction of H2S Impact under Different Stability Degrees with Average Wind Velocity (mg/m3)
Stability degree A-B C D E-F
East 0.0004 0.0003 0.0002 0.0001
South 0.0002 0.0001 0.0001 0.0000
West 0.0004 0.0003 0.0002 0.0001 Plant boundary
North 0.0025 0.0018 0.0012 0.0008
Standard GB14554-93 0.06 0.06 0.06 0.06
Living district of Meishan Iron and Steel Co
0.0004 0.0003 0.0002 0.0001 Environmentally sensitive point
Sanshan Village 0.0003 0.0002 0.0001 0.0001
Standard TJ36-79 0.01 0.01 0.01 0.01
110
Table 8-2 Prediction of H2S Impact under different stability degrees with little wind (mg/m3)
Stability degree A-B C D E-F
East 0.0006 0.0005 0.0004 0.0002
South 0.0004 0.0003 0.0002 0.0001
West 0.0006 0.0005 0.0004 0.0003 Plant boundary
North 0.0030 0.0025 0.0021 0.0015
Standard GB14554-93 0.06 0.06 0.06 0.06
Living district of Meishan Iron and Steel Co
0.0006 0.0005 0.0004 0.0003 Environmentally sensitive point
Sanshan Village 0.0005 0.0004 0.0003 0.0002
Standard TJ36-79 0.01 0.01 0.01 0.01
From Table 8-1 and Table 8-2 we can see that under the condition of average wind velocity (2.5m/s)and little wind, the contribution values of H2S to the concentration at plant boundary and environmentally sensitive points are all below those specified in the corresponding assessment standard.
For the adding result of present value (maximum value) of pollutants concentration at plant boundary and environmentally sensitive points and impact value of this project under the condition of atmospheric stability degree D after this project is put into operation, refer to Table 8-3(B[a]P is daily average value).
Table 8-3 Adding of Calculation Value
B[a]P(μg/m3) H2S(mg/m3) Pollution factor
Plant boundary Present value
Impact value
Adding value
Present value
Impact value
Adding value
North part of plant boundary
0.0066 0.0001 0.0067 0.001 0.0021 0.0031
Living district of Meishan Iron and Steel Co.
0.0045 0.00004 0.00454 - - -
Sanshan Village 0.0090 0.00003 0.00903 - - -
Assessment standard
(GB14554-93) 0.01 0.01
111
From Table 8-3 we can see that B[a]P and the adding value of the present value and impact value of H2S boundary and environmentally sensitive points don’t exceed the standard after this project is put into operation.
After this project begins to operate, the emission amount of SO2 and dust (powder) all decrease compared with the situation before operation of this project with the implementation of “new promotes old” measures. Therefore, the atmospheric environmental quality in the company area will improve after the operation of this project.
8.1.4 Exhaust stake height argumentation
The exhaust stake height setting in this project should be in accordance with exhaust stake height requirement specified in Integrated Emission Standard of Air Pollutants (GB16297-96). For the exhaust stake height in this construction project, refer to Table 3-21. The atmospheric pollutants after emission from the exhaust stake are up to the standard. With the implementation of the “new promotes new” measures, emission of atmospheric pollutants decreases and the atmospheric environmental quality in ambient area improves. Therefore, the height setting for the exhaust stake in this project is rational.
8.1.5 Advice on rationalization of land use
Meishan Iron and Steel Co. is a large iron & steel complex, and the atmospheric pollutants it discharges have an obvious impact on the ambient atmospheric environmental quality. Advice on rationalization of land use in the assessment area is made from the point of atmospheric environmental impact and based on the atmospheric environmental impact assessment for this project and the layout of Banqiao New City where it locates.
(1) According to the layout of Banqiao New City, it’s rational to arrange east city cluster (residential land) of Banqiao New City to the east of Meishan cluster (industrial land). From the point of atmospheric environmental impact, such arrangement makes the residential land in the upwind direction of Meishan Iron and Steel Co. so as to avoid the impact of atmospheric pollutants from the company on the residential area in planning.
(2) Protective green block should be set for the industrial land and residential land in planning to reduce the impact of atmospheric pollutants on the residential area.
(3) Progressive relocation of large and small residential areas around Meishan Iron and Steel Co. in a planned way to gradually improve the situation of close distance between and intersection of the company production area and residential areaes.
8.2 Analysis on environmental impact of surface water
Because no new employees are hired in this project, no new sewage is produced. Waste water from this project only includes cooling water for equipment and steam condensate and is discharged to Changjiang through the north discharge outlet of Meishan Iron and Steel Co.. After completion of this project, the amount of water pollutant decreases comparatively and only has a little impact on the water quality of Changjiang at BanQiao, Nanjing section.
112
8.3 Environmental noise impact assessment
8.3.1 Prediction contents
Equivalent sound level at all prediction points.
8.3.2 Noise pollution source strength analysis for this project
The system project of moving #1 and #2 coke ovens of Shanghai Meishan Iron & Steel Co., Ltd to another place for overhaul locates in the new plant (to the north of the original Coking Plant) of Meishan Iron& Steel Co. with an area of 200000m2. The construction project includes coal mixing plant, coking plant, coke dry quenching unit, gas purification plant and public and auxiliary facilities. These production facilities and main high-noise equipment in the production workshops are as listed in Table 8-4. For the location of main production workshops in plant area, refer to plane layout of the construction project. Sound source equipment in every workshop are located near the workshop.
Table 8-4 Main Noise Pollution Source in the Construction Project
Workshop Description of
noise equipment
Measuring distance(m)
Sound pressure dB(A)
Measures Treatment
effects
Coal cracking
room cracker 2 88-97
Coke screening equipment
2 92-99
Sound insulation and vibration damping
Gas fan 2 91-96 Silencer Coking plant
Coke pusher 3 86 Silencing and sound
insulation
Air compressor 1 90-100 Sound insulation ,
vibration damping and silencer
Water pump 1 85-96 Sound insulation and
vibration damping
Dedusting fan 2 97 Silencer
Generator 1 92 Sound insulation and vibration damping of
the plant
Public and auxiliary facilities
Cooling tower 1 80 Reasonable layout
Up to the standard at the plant boundary
113
8.3.3 Prediction mode
The industrial enterprise noise prediction mode recommended in “Environmental Impact Assessment Technical Guideline –Sound Environment”(HJ/T2.4-1995)will be adopted in environmental noise impact prediction and assessment.
(1) for outdoor sound source, the sound attenuation mode is as follows:
LA(r)=LA(r0)-20lg(r/r0)-ΔLA
Where:
LA(r) is predicted sound pressure which the point source exerts on a prediction point r m away from it,
LA(r0) is dB(A) at places r0 m way from the point sound source,
ΔLA is attenuation caused by different factors (including attenuation by sound barrier, obstacling objects, air absorption, and ground effect, etc. See below for the calculation formula of sound barrier and air absorption).
If sound power level of the sound source is known and sound source locate on the ground, then
LA(r0)=LWA(r0)-20lgr0-8
For indoor sound source, first to calculate dB (A) of a point sound source exerting on a point near some guarding structure.
LA1(i)=10lg(Q/4πr12+4/R)
Where:
LA1(i) is dB(A) a certain point source exerting on the indoor prediction points
Q is directivity of the sound source
r1 is the distance of the sound source from indoor prediction points
R is a constant for the room. R=Sa/(1-a), S is the room area and a is the average sound absorption coefficient.
LA1(T) is the total sound level all indoor sound sources exerting on a certain indoor prediction point
LA1(T)=10lg[∑100.1LA1(i)]
LA2(T) is dB(A) received at outdoors from indoor noise transmission
LA2(T)=LA1(T)-(TL+6)
TL is sound insulation amount of this guarding structure, and its experience formula is
TL=18lgm+8 (m>100kg/m2)
=13.5lgm+13 (m<100kg/m2)
114
To convert outdoor sound level and sound transmission area into sound power level LWA of equivalent outdoor sound source.
LWA=LA2(T)+10lgS
S is sound transmission area. Then to calculate according to outdoor sound source formula.
(3) Total sound level of prediction point
Supposing the sound impact level No. i sound source exerting on prediction point j is LA j i, the total impact value of prediction point j is:
LA j=10lg[∑100.1LA j i]
LA j i also includes background noise.
(4) Other sound attenuation factors
Attenuation caused by sound barrier
Abar=10lg(3+20N)
N=2δ/λ
δ=SO+OP-SP δ is acoustic-path difference(see diagram)
λ is sound wave length.
Sound attenuation caused by air absorption
Aatm=a(r-r0)/100
The above prediction mode can be used for prediction and calculation for the environmental noise during day and night.
8.3.4 Predictive result assessment
Environmental noise impact assessment in coking plant of Meishan Iron&Steel Co. mainly conducts prediction and assessment on the outside environment of plant boundary. Therefore, sound prediction points are all set along plant boundary with total number of 20. See noise prediction point arrangement diagram for details. The shortest distance between the construction project and noise sensitive points along the plant boundary is over 1000 m and the project is unlikely to have an impact on them, therefore, no prediction and assessment will be made for them. Table 8-5 is noise predictive result at plant boundary.
Ｐ
0
S
Sound barrier attenuation
115
Table 8-5 Noise Predictive Result for Outside Environment at Plant Bounday (dB(A))
Day Night
No. Location of prediction
point
Contribution of this project
Background Superposed
with this project
Contribution of this project
Background Superposed
with this project
1
Gate of Meishan
Iron&Steel Co.
19.0 68.0 68.0 19.0 55.7 55.7
2 Outside of the old cold drink
plant 23.4 59.6 59.6 23.4 55.0 55.0
3
Outside of marshalling station and command building
23.5 54.1 54.1 23.5 49.6 49.6
4 Transshipment
Track 22.8 59.2 59.2 22.8 49.3 49.3
5
Refrigeration equipment
service center gate
30.2 57.5 57.5 30.2 51.2 51.2
6
Gate 2# of Meishan
Iron&Steel Co.
46.9 52.4 53.5 46.9 51.6 52.9
7
South boundary of
coking branch plant
28.7 55.4 55.4 28.7 51.6 51.6
8 East boundary
of coking branch plant
29.5 53.6 53.6 29.5 47.7 47.8
9
North boundary of
coking branch plant
33.4 57.4 57.8 33.4 51.6 52.0
116
Day Night
No. Location of prediction
point
Contribution of this project
Background Superposed
with this project
Contribution of this project
Background Superposed
with this project
10
North boundary of
Materials branch plant
33.0 57.4 57.4 33.0 51.6 51.7
11 West boundary
of Materials branch plant
31.8 63.1 63.1 31.8 63.9 63.9
12
Gate 9# of Meishan
Iron&Steel Co.
27.9 61.4 61.4 27.9 59.9 60.0
13
Gate of abandoned
steel section plant
23.5 60.9 60.9 23.5 52.9 52.9
14
North boundary of steel scrap workshop
18.5 55.4 55.5 18.5 53.3 53.4
15 West boundary
of lime kiln 17.4 53.2 54.4 17.4 57.0 57.6
16 West boundary of hot rolling
15.6 50.2 50.4 15.6 46.9 47.2
17 Southwest
boundary of hot rolling
14.1 47.2 47.5 14.1 42.8 43.5
18 Southeast
corner of this project
15.9 51.7 53.0 15.9 45.7 49.4
19
East of converter gas storage and distribution
station
17.8 59.8 59.9 17.8 59.0 59.1
20 South gate of power plant
19.0 58.5 58.8 19.0 54.7 55.3
Average value of noise at plant
boundary 25.2 56.8 57.1 25.2 52.6 53.0
117
From the predictive calcuation result of environmental noise we can see that after the project is put into operation, the noise level at plant boundary of Meishan Iron&Steel Co. is between 47.5-68dB(A) in the day and 43.5-60.0dB(A)at night, which is almost the same with present sound environmental level. After the project begins to operate, disqualification ratio of plant boundary noise is still the same with present situation with 1 prediction point exceeding the standard during the day and 6 at night, i.e. respective disqualification ratio of 5% and 30%. But the prediction points which exceed the standard are caused by present production equipment noise and have nothing to do with this project. This project and the project of product structure adjustment and process equipment updating & technology reforming in Meishan steel plant of Baoshan Iron & Steel Co., Ltd(the original thin sheet project) in planning should adopt proper noise control measures in the construction process to make the prediction points that exceed the standard be up to standard during day and night at plant boundary in accordance with the principle of “new promotes old”(this project shall adopt proper noise control measures to make No.11 prediction point be up to standard during day and night at the plant boundary in accordance with the principle of “new promotes old”). The noise sensitive points outside Meishan Steel Plant boundary have a distance of over 1000 m from this project which will have no adverse impact on these sensitive objects. 8.4 Analysis on environmental impact of solid waste 8.4.1 Disposal situation of solid waste For the generation amount of solid waste in this construction project and the treatment and disposal situation, refer to Table 8-6.
Table 8-6 Generation Amount of Solid Waste in This Construction Project and the Disposal Measures
No. Description of solid
waste Code
Generation amount(t/a)
Disposal measure
1 Dust(coal dust) 84 10310 Transport to coal yard for coal blending by
truck after moistening
2 Coke dry quenching
dust (coke dust) 84 5000 For mine blending
3 Coke dust 11 612 Tar tank
4 Bitumen residue 11 30 Coal blending
6 Dry sluge 11 210 Coal blending
7 Tar slag 11 1269 Coal blending
Gas Purification is done in Chemical
Company of Baoshan Iron and Steel Group
8.4.2 Analysis on environmental impact of solid waste According to The National Catalogue of Hazardous Wastes, crude benzene slag, bitumen residue, dry sludge and tar slag belong to hazardous wastes.
All solid waste in this project will ultimately be disposed in a proper way with zero discharge. Solid waste has little impact on environment.
118
9. Total amount control analysis for pollutant emission
9.1 Purpose of total amount control
To implement total amount control, an enterprise is required to advance the pollution control and rectification and technical upgrading and transformation of existing projects through the implementation of technical transformation projects, to carry out the principle of “bringing up the old by the new and reduce the current pollutant emission level, so that the overall pollution emission of the enterprise is controlled within the limit of total amount control as verified by the environmental protection authority, to achieve organic unification of economic, environmental and social efficiencies.
In the total amount control of pollutant emission, the principle of clean production is carried out based on the result of engineering analysis, environmental protection control and rectification measures and prediction and analysis of environmental impact. The balance plan for total amount control of emission of waste gas, waste water and solid wastes from the project is analyzed and determined according to the principle of total amount control of pollutant emission, to provide a basis for supervision and management by the environmental protection authority.
9.2 Determination of total amount control factors
The control indicators for pollutant emission are verified according to the advanced level in the industry or at the level that can be attained using the optimum practice technologies for pollutant prevention and control. According to the requirements in document “Total amount control plan for main pollutant emission in Jiangsu Province during the ‘Nineth Five-year Plan’” [Su Huan Ji (1997) No. 51] and in conjunction with the pollutant emission characteristics of the technical transformation project, the total amount control factors were determined as follows:
(1) Waste gas: SO2 and smoke (power) dust;
(2) Waste water: CODcr and SS;
(3) Solid waste: emission of solid waste.
9.3 Pollutant emission from project
It can be seen from the engineering analysis results of the project that all pollutant will be emitted by the project after meeting the standards, and the emission amount is as shown in Table 9-1. Mitigation from “bringing up the old by the new” in the project is as shown in Table 9-2.
119
Table 9-1 Summary of pollutant emission amount of the project (t/a)
Category Emission method
Description of pollutant
Output Mitigation Emission amount
Powder dust 3985.5 3811.5 174
Smoke dust 15 (Baosteel
Chemical 1.0) -
15 (Baosteel Chemical 1.0)
Organized emission
SO2 86.9 (Baosteel Chemical 4.3)
- 86.9 (Baosteel Chemical 4.3)
Powder dust 50 - 50 Non-organized emission SO2 20 - 20
Smoke and powder dust
4050.5 3811.5 239
Waste gas
Total SO2 106.9 - 106.9
Waste water
Continuous COD 39.4 (Baosteel Chemical 21.7)
- 39.4 (Baosteel Chemical 21.7)
Solid waste
- - - - 0
Table 9-2 Mitigation from “bringing up the old by the new” for the project (t/a)
Description Smoke and powder dust SO2 COD SS
Mitigation 4428.4 2469.7 1180.6 418.5
9.4 Change in total pollutant emission amount after the implementation of the project
Change in total pollutant emission amount after the implementation of the project is as shown in Table 9-3.
9.5 Analysis and balance plan for total amount control on pollutant emission for project
The total amount control quotas for pollutants given by Nanjing Municipal Environmental Protection Bureau to Shanghai Meishan Co., Ltd. are mainly smoke (powder) dust, SO2, COD and SS. The total amount quotas for pollutant emission and the pollutant emission amount after transformation and expansion are as shown in Table 9-4.
It is shown in the total amount control analysis that, after the project is put into operation, by conscientiously carrying out various measures of pollution control and rectification and replacing the old with the new, and the principles of “increasing the output without increasing pollution” and “bringing up the old by the new”, the emission of pollutants COD, SS, smoke (powder) dust and SO2 will be substantially reduced from the current level, the total amount of emission can be controlled within the quotas given by Nanjing Municipal Environmental Protection Bureau to Shanghai Meishan Co., Ltd. and the pollutant emission from the project can conform to the requirements of total amount control.
120
Tabl
e 9-
3 C
hang
es in
pol
luta
nt e
mis
sion
am
ount
from
Sha
ngha
i Mei
shan
Co.
, Ltd
. bef
ore
and
afte
r th
e co
mpl
etio
n of
the
proj
ect (
t/a)
Cat
egor
y Po
lluta
nt
Emis
sion
from
ex
istin
g pr
ojec
t Th
is p
roje
ct
Miti
gatio
n of
this
pr
ojec
t thr
ough
“b
ringi
ng u
p th
e ol
d by
th
e ne
w”
Cha
nge
(+ -)
be
fore
and
afte
r the
co
mpl
etio
n of
this
pr
ojec
t
Fina
l em
issi
on
amou
nt o
f Sh
angh
ai M
eish
an
Co.
, Ltd
.
Cha
nge
(+ -)
in S
hang
hai
Mei
shan
Co.
, Ltd
. bef
ore
and
afte
r the
com
plet
ion
of th
is p
roje
ct
Smok
e an
d po
wde
r dus
t 10
689
239.
0 44
28.4
-4
189.
4 64
99.6
-4
189.
4 W
aste
gas
SO
2 18
568
106.
9 24
69.7
-2
362.
8 16
205.
2 -2
362.
8
CO
D
4012
.8
39.4
11
80.6
-1
141
2872
-1
141
Was
te w
ater
SS
41
35.7
-
418.
5 -4
18.5
37
17.2
-4
18.5
Solid
was
te
Solid
was
te
0 0
0 0
0 0
Not
e: th
e ex
istin
g am
ount
of w
aste
wat
er is
the
tota
l dis
char
ge a
mou
nt o
f wes
t dis
char
ge p
ort a
nd n
orth
dis
char
ge p
ort.
Ta
ble
9-4
Tot
al a
mou
nt q
uota
s and
pol
luta
nt e
mis
sion
am
ount
aft
er th
e tr
ansf
orm
atio
n an
d ex
pans
ion
(t/a
)
Des
crip
tion
of
pollu
tant
Tota
l am
ount
quo
tas g
iven
by
Nan
jing
Mun
icip
al E
nviro
nmen
tal P
rote
ctio
n B
urea
u to
Sha
ngha
i Mei
shan
Co.
, Ltd
.
Emis
sion
from
ex
istin
g pr
ojec
t
Cha
nge
(+ -)
bef
ore
and
afte
r the
co
mpl
etio
n of
this
pr
ojec
t
Emis
sion
am
ount
of
Shan
ghai
Mei
shan
Co.
, Lt
d. a
fter t
rans
form
atio
n an
d ex
pans
ion
Surp
lus o
f tot
al
amou
nt q
uota
s
Smok
e an
d po
wde
r dus
t 10
600
1068
9 -4
189.
4 64
99.6
41
00.4
SO2
1900
0 18
568
-236
2.8
1620
5.2
2794
.8
CO
D
5400
40
12.8
-1
141
2872
25
28
SS
1050
0 41
35.7
-4
18.5
37
17.2
67
82.8
Solid
was
te
0 0
0 0
0
121
10 Analysis of environmental impact during construction period
The construction project consists of ground leveling of the plant area, road and plant house building, laying of feed and drain water pipe network, equipment installation etc. During construction period, various construction activities will inevitably destroy and influence the surrounding environment. Main impacts include impacts on the surrounding environment by waste gas and dust, noise, solid waste, waste sewage etc, among which dust and construction noise are especially obvious. Analysis and corresponding prevention measures of above pollution and their environmental impact are as follows:
10.1 Analysis of atmospheric environmental impact during construction period
When building plant house etc of the construction project, main atmospheric pollutants include:
(1)Waste Gas
Waste gas during construction period mainly comes from exhaust gas emitted by construction machinery and transport vehicle.
(2)Dust and raised dust
During construction period, dust pollution mainly comes from:
①Building material such as cement, white lime, sand etc will generate pollution by raising dust with wind in loading/unloading, transporting and stacking process.
②The come-and-go of transport vehicle will cause raised dust above the ground;
③Construction waste will raise dust while being piled and cleared.
Waste gas, dust (raised dust) generated in above construction process will pollute surrounding atmospheric environment, and the damage caused by dust is more serious. Reasonable and feasible measures must be taken to reduce its pollution and influencing range. Major solutions that shall be taken are as follows:
(1) The construction site shall be managed scientifically. Sandstone shall be centralized piled, cement shall be piled in dedicated warehouse, and its transporting links shall be minimized, do be careful and gentle when lifting and lowering the material to avoid the breakage of packing bag;
(2) Carry out adequate water spray to the working face while excavating pipelines to maintain certain humidity. At the same time, setting-up fence or partial fence so as to reduce diffusing range and amount of raised dust in construction. Building material and waste shall be moved away in a timely manner.
(3) Guard against overloading transport vehicle, take sealing and covering measures to reduce material falling down on the way, promptly clear the soil and dust fallen down to the road, flush tyres, spray water regularly to lower dust so as to reduce raised dust in transportation.
(4) In case of strong wind, stop construction and cover piled materials such as sandstone etc.
122
10.2 Analysis of construction acoustic environmental impact
Running of all kinds of construction machinery and transport vehicle during construction will inevitably generate noise pollution. Transport vehicle and construction machinery etc. used during construction are noise pollution sources. According to respective documents, noise generated by major construction machinery is listed in table 10-1:
Table 10-1 Noise generated by construction machinery
Description of construction equipment Average sound level A at a distance of 10m from the
equipment dB(A)
excavator 82
bulldozer 76
concrete mixer 84
electric cutter 88
road roller 82
dump truck loader 82
From table 10-1, it is found that construction equipment at construction site can generate very high noise. In actual construction, all kinds of machineries often operate simultaneously, noise generated by various sources mixes, causing higher noise level and bigger radiation area.
Besides, transportation of building material entering into the plant area increases flowing noise source on the road at construction site, and will cause noise pollution on both sides of the locality along the road.
To reduce acoustic environmental impact during construction period of the project, following measures can be taken:
(1)Setting-up barriers around the construction site of the project to reduce impact;
(2) Put the construction machinery in places where causes the least impact on the plant boundary as much as possible. Replace pneumatic tool with hydraulic tool. Set sound barrier around high-noise equipment.
(3)The amount of vehicle and driving density at construction site shall be minimized, and whistle of vehicle shall be controlled.
(4)Arrange construction working time in a reasonable way. High-noise construction at nighttime is forbidden. Avoid demolishing as far as possible while dismantling.
10.3 Analysis of water environmental impact during construction period
Waste water produced in construction mainly includes:
(1) production waster water including slurry water produced by excavation and drilling, cooling and cleaning water produced by various construction mechanical equipment in
123
running. The former contains large amount of silt, and the latter may have a certain amount of oil contamination. At the same time, a certain amount of oily waste water will be produced while commissioning and cleaning equipment during installation.
(2) Sanitary sewage
It produced by living activities of the construction group, including water from canteen, waste water after cleaning and flushing water of the toilet. Sanitary sewage contains large amount of bacterium and pathogen.
(3) Waste water after cleaning at construction site
Although it does not contain large amount of toxic and harmful pollutants, it may has a lot of soil, sandstone and a certain amount of oil containment and chemicals.
(4) Waste water produced by flushing vehicle
During construction period, flushing transport vehicle will produce waste water which contains large amount of silt and a certain amount of oil.
The amount of above waste water during construction period is not very big. However, it will be harmful to the environment if not handled or not properly handled. It should be noted that waste water during construction period shall not be drained directly and arbitrarily. During construction period, loss, missing, overflow of material shall be minimized if the pollutants discharge system is not perfect. Water treatment buildings and structures such as water collecting basin, sediment basin and drainage ditch must be built at construction site. Waste sewage during construction period shall be colleted after classification according to its nature. It shall enter into sewage treatment plant for treatment so as to reach the standard before being drained.
10.4 Analysis of environmental impact of construction waste
Construction wastes are mainly from the building wastes in construction and living wastes produced by construction personnel. There are also a certain amount of building materials abandoned such as sandstone, lime, concrete, waste bricks as well as earth and stone. Since working capacity of the project is large, there will inevitably be many construction personnel who will produce a certain amount of living wastes. Building waste in construction process shall be cleared and moved away in a timely manner or be recycled to avoid forming of raised dust due to long-term stacking. If living waste is not cleared and moved away in time, it will rot and deteriorate, thereby breeding mosquito and insect, emitting offensive smell, propagating disease, bringing harm to surrounding environment and construction personnel. Therefore, it shall be cleared and disposed.
10.5 Environment management during construction period
The construction unit shall prepare detailed construction organization plan and establish environment management system before construction. There shall be specialized person in charge of environmental protection during construction period. Prevention measure and treatment procedure shall be taken for “the three wastes” (waste water, waste gas and industrial residual) produced in construction. National environmental protection laws and
124
regulations as well as standards shall be implemented, and environmental protection management system shall be established. Carry out scientific management following the rules.
10.6 Construction Schedule
The project started from civil works construction in November, 2005. It is expected to be officially put into production by November, 2007.
125
11 Public Poll
11.1 Purpose and function of public poll
Public poll is an important part of environmental influence evaluation and the purpose and function of the public poll mainly is:
(1) To let the public know and fully understand the project so as to bring the environmental and social benefit into full play.
(2) Public poll is an important means to coordinate project construction and social influence. It is through this method of public poll to ensure that important environmental problems which have been aroused or may probably be aroused have already been analyzed and proofed in the environmental influence evaluation.
(3) To put forward different views and suggestions of the public about the project and take into full consideration the public demand when adopting environmental protection measures.
(4) To coordinate relations between the enterprise and masses through digestion of the public suggestions and demands towards the construction project to improve social stability and unity.
11.2 Investigation method, items and the people to be visited
11.2.1 Method of public poll
To find out the suggestions and demands of the public of this area about the project and surrounding environment the method adopted in this environmental evaluation is to request the people visited to fill in Form of Public Opinion on Environmental Protection for Construction Items of Jiangsu Province to solicit their comments and suggestions on the project. Evaluating department issued and collected the investigation forms on April 29 and 30, 2005. Sample survey method is adopted and investigation scope is as follows:
(1) Inhabitants nearby the construction project site (several natural villages under the jurisdiction of Sanshan administrative village of Banqiao Town, Yuhua District);
(2) Staff and workers of the enterprises nearby the construction project site.
The investigation work was carried out in the following steps: firstly, give the public the presentation of environmental protection situation after the project is put into construction; secondly, exchange, communicate and answer the questions concerned environmental protection; thirdly, request the public to fill in “Form of Public Opinion on Environmental Protection for Construction Items of Jiangsu Province” after they have got full information on the construction project to widely solicit the suggestions.
100 copies of “Form of Public Opinion on Environmental Protection for Construction Items of Jiangsu Province” were issued for public poll and recovered 100%.
11.2.2 Investigation items of public poll
(1) Is the public satisfied with the present environment quality (including atmospheric environment, water environment and sound environment etc.) of the construction project site?
126
(2) Public′s awareness of the construction project and their reactions.
(3) What is the public views on the environmental influence of pollutant which the project may discharge after they are aware of the construction project.
(4) What is the public suggestion and demand on treatment of pollution and approval of the environmental protection department for this project
See Table 1 for the concrete investigation item.
11.2.3 Composition of the public poll
The investigated people are 100 of which 52 are male and 48 female. According to their cultural level there are 60 people of high middle school education (including secondary specialized school), 25 of junior middle school education, 14 of primary school education and 1 semi-illiterate. Viewing from their occupation 61 people are staff and workers (including engineers) of enterprises, 32 peasants, 1 teacher and 6 jobless. According to their ages 15 people are 18-34 years old, 65 people 35-55 years old and 20 people above 55 years.
The investigated people are mainly inhabitants of Sanshan living quarters, Huangnitang Group and Meishan living quarters of Sanshan village, Banqiao Town.
11.3 Result of the public poll
11.3.1 Statistic result of the public poll
(1) With the present environmental quality of the project site, very satisfied: 5 people; fairly satisfied: 62; not satisfied: 16 and quite unsatisfied: 17;
(2) For the project to be built, be unaware of: 2; knowing a little: 80 and knowing quite well: 18;
(3) The public who consider that the project shall exert serious hazard or influence on the environmental quality after completion of the project: 15 people; considerably serious: 25; ordinary: 57; less: 1 and not clear:2;
(4) The public firmly supporting this project: 20 people; conditionally supporting: 77; not care: 1 and objecting:2. The people who conditionally support this project demand that the “3 wastes” must be treated up to standard for discharge.
11.3.2 The public suggestions and demands
According to the views of investigated people and inquiry form the suggestions and demands on environmental protection of this project are summarized as follows.
The summany of the public suggestions and demands includes:
(1) Most of the investigated people are for this project and this shows that the masses around the project site support the project to be constructed considering from the view point of environmental protection.
(2) They request to learn from Baoshan Iron and Steel Works to enhance treatment of waste water, waste gas and noise and solid wastes so as to ensure that the pollutant is to be treated up to standard for discharge and minimize influence upon the environment. At the same time
127
do a good job for those affected whose houses are pulled down and its occupants moved elsewhere.
(3) The masses request that measures for environmental protection shall be adopted to avoid dust, garbage and noise pollution and minimize influence upon the environment during construction of the project.
(4) It is hoped that the environmental protection department shall strictly apply law of environmental protection and the related regulations and standards for environmental protection.
11.3.3 A return visit to the opposed and analysis
There are 2 persons holding an attitude against this project in the public poll. The evaluating department paid a return visit to them on May 10,2005. The principal reason for their being against this project is that they are not satisfied with the status quo of the environmental quality and in their point of view the existing coking plant produced serious atmospheric pollution that hazard health of the nearby inhabitants and they are afraid of still serious influence upon the environment exerted by the project. This worry is normal. One of them suggested that the inhabitants must firstly be moved elsewhere before any expansion start up. This shows that these two people are not firmly against this project, so long as the project owner makes good arrangement for those whose houses are pulled down and occupants moved elsewhere they shall not be against this construction project. The project owner shall also do as more as possible work of propaganda and explanation to dispel misgivings of the masses so that they shall support this project.
128
Table 1 Inquiry form of the public poll for environmental protection of construction project
The investigated Age Occupation
The investigated unit
Sex Cultural level Tel. Residence Address of the unit
Are you satisfied with present environmental quality?(if not please give reasons) very satisfied fairly satisfied unsatisfied quite unsatisfied
Do you know/be aware of the project to be built in this area? not a little quite clear
Do you think that the hazard/influence this project shall exert is serious considerably serious ordinary less not clear
What attitude do you adopt to this project? firmly support be conditionally for not care oppose
What suggestions and demands do you have about the environmental protection for this project? Signature (sealed) Briefing of the project In recent years, iron and steel industry has rapid development and coke is short of supplies with its price rising steadily; at the same time the international market is dependent more and more upon Chinese coke, therefore, Shanghai Meishan Iron and Steel Co. Ltd. has decided, based on the market demands and development planning, to remove the existing 3 old 65-ports coke ovens and build 2 new JN60-6 type coke ovens with production capacity of 1 million tons dry full coke. This project is located at the area from Huangnitang to Yanjiawei Village, north of the existing coking district. South of the site is new coal yard, north adjoins the land for development, east is wasteland and west connects the road leading from Meishan Iron and Steel Works to quay. Now the site is uncultivated land and the area for the project is about 200000m2
｡ Dry coke cooling method shall be adopted for this project thus avoiding atmospheric pollution produced by wet coke cooling and preventing coke cooling waste water so that greatly reduce discharge of various pollutants and at the same time save the water and recycle energy so the environmental benefits is quite obvious. The atmospheric pollutant produced in this project is mainly particles, SO2 and few H2S. After treatment the discharge shall meet the standard class III of “Overall Standard for Discharge of Atmospheric Pollutant” Table 2, standard class III for newly built mechanized coke oven of “Standard for Discharge of Atmospheric Pollutant of Coke Oven ” and newly revised standard class III of “Standard for Discharge of Smelly Pollutant ”. Quality of discharged waste water (condensate) shall be treated up to class I discharge standard of coking industry specified in Table 3 of “Standard for Discharge of Waste Water of Iron and Steel Industry” and penetration proof measures shall be reliable and underground water shall not be contaminated. Slag shall be treated properly and integratedly used that meet the requirement of the related regulations for treatment of slag. Noise pollution shall be under effective control and treatment. Noise within battery limit of the plant site shall be up to class III standard of “Standard for Noise of Battery Limit of Industrial Enterprises”. Through forecast the pollutant discharged from the construction project shall have minor influence upon the environment.
129
12 Analysis of reasonability of the project site selection
12.1 Analysis of conformability of the project site selection with the planning
According to “The Overall Planning of Nanjing City” (1991-2010) function orientation of the new Banqiao Town(location of the project to be built) is that it shall be an integrated industrial town of the municipal development area and its industry shall be orientated to encourage development of metallurgical, mechanical and trade industry but prohibit construction of project seriously contaminating the water body.
“Essential of the Overall Planning of New Banqiao Town” pointed out that: in the near future relying upon Banqiao Neighborhood and Shanghai Co. Ltd. of Baogang Group to develop the area from west of Nanjing-Wuhu Highway to north of Meishan Co. Ltd. and gradually develop from north to south and from west to east in the far future. With Nanjing-Wuhu transportation corridor, the special railway of Meishan Co. Ltd. and natural terrain as battery limit new Banqiao town is divided into three functional group, namely: Yuhua Economical and Technical Development Zone Group (north-west group, land for industrial purpose), Meishan Group (south-west group, land for industrial purpose) and East Town Group(residential land). North-west group is processing industrial park mainly for industry, storage and municipal works, south-west group is mainly used for metallurgical and extended processing industry of Meishan Co. Ltd. and east town group is used for living quarters.
In “Overall Planning of Development along the Yangtze River of Nanjing” the industrial development target is: to achieve obvious results in adjustment of industrial internationalization and modernization and in adjustment of its scale; to greatly strengthen competitive power of industry and to form an overall frame of advanced manufacturing industry base of the world. To further improve concentration of industry and establish the industrial competitive superiority in Jiangsu province and Yangtze River Delta. Sale revenues of the five major industry ,namely: petrol-chemical, electronic information, automobile, iron and steel and power industry in 2010 shall be four times that of 2002 reaching ¥500 billion. Total investment of 2003-2010 shall reach ¥300 billion.
Persist in the policy of placing industry at foremost, take the road of new industrialization, push forward construction of industrial group along the Yangtze River and promote and enhance the five major industry---petrochemical, electronic information, automobile, iron and steel and power industry. Iron and steel industry shall give full play to superiority of the golden waterway of Yangtze River and make full use of existing industrial base to accelerate adjustment in enlargement, internationalization and modernization of iron and steel industry so as to bring it up into pillar industry of Nanjing. Adjust product structure, improve product grade, form product series and put emphasis on development of wide middle thick plate, hot (cold) rolled stainless steel plate (roll) and plate with corrosion resistant coating.
The construction project is iron and steel industry project locating at the scope of Meishan group (land for industry purpose) in new Banqiao town in the Overall Planning of Nanjing. It conforms the Overall Planning of Nanjing and the Overall Planning of New Banqiao Town and meet the requirement of encouraging development of metallurgical industry within Meishan group.
130
It is auxiliary item of “adjustment of product structure and innovation of technological equipment project of Meishan Co. Ltd.” in conformity with new round of development strategy of Baogang Group and industrial development target of Nanjing overall planning along the Yangtze River.
To sum up, the project to be built conforms to the Overall Planning of Nanjing, the Overall Planning of New Banqiao Town, Nanjing Overall Planning of Development along the Yangtze River and new round of development strategy of Baogang Group.
12.2 Analysis of compatibility of the project with environmental planning
“Nanjing environmental protection planning of development along the river” pointed out that industry with serious water pollution shall be arranged down stream of the city and water resources and industry with air pollution shall be arranged down wind of the city.
Follow recycle economy mode, encourage development of industry of pollution-free or minor pollution and with high added value. While rapid growth of economy is maintained, zero increase and even minus increase of total quantity of pollution shall be realized. Strictly implement system of environmental influence evaluation and “three concurrence”, strengthen control of total quantity of pollutant and treatment of pollution, adopt hi and new technique to reform chemical and metallurgical industry and practice cleaning production technique and push forward confirmation of ISO14000 environmental management standards.
The project is metallurgical and rolling industry, an item with comparatively serious air pollution. Banqiao area where the project is located is at down wind of Nanjing conforming the principle of Nanjing environmental protection planning of development along the river, i.e. to arrange industry with serious air pollution down wind the city as far as possible.
Three old type coke ovens will be removed and two new type ovens which is in conformity with the national industry policy be built and a series of technical reform measures, including gas purification technique (adoption of FRC method of desulphurization and decyanation to produce sulphuric acid ), shall be adopted so that the waste water produced from coking shall be treated (carried out in Baoshan chemical corporation) up to standard to be entirely used for flushing of furnace and inorganic discharge of waste gas shall be greatly reduced thus it shall conform with the spirit of realization of zero or even minus increase of total pollution and strengthening control of total pollutant quantity and enhancing treatment of pollution to reform chemical and metallurgical industry with hi and new technique.
12.3 Analysis of conditions of site selection
Meishan Iron and Steel Works (Meigang) is an old factory, locating at Meishan Group Industry Park of new Banqiao Town in Nanjing City, gathering around it are branches of Shanghai Meishan Co. Ltd. of Baogang Group, Nanjing Beibao New Type Building Materials Co. Ltd., Meishan Branch of Baohua Co., Jiantong Building Material Factory, Jiangning Agriculture Chemical Factory, Jiangning Cement Factory and Ship Auxiliary Factory etc. Its north is neighboring with Sanshan Village Industry Park of Banqiao Neighborhood, Yuhua District and Yuhua Economical and Technical Development Zone, which is an important industrial base of Nanjing.
131
Meigang, bordering on the Yangtze River, is convenient in communication and transportation and it can use the natural golden waterway for big transportation saving transportation cost. Meigang is located in the Yangtze River Delta where steel consumption is considerably great and there is a special railway leading straight to the factory from Nanjing-Wuhu railway line thus its raw material and products can be transported through the railway. In addition, there are several high grade highways nearby Meigang, such as Nanjing-Ma’anshan Express, Nanjing belt highway etc. to further guarantee the transportation. So it is special superiority for Meigang to be built here. 12.4 Analysis of health protection distance The environment sensitive points around the project is International Relationship Collage of PLA, Banqiao Town, residential land of east town group of Banqiao Town, living quarters of Meishan Co., Huangnitang Village residential area, Sunjia Village residential area, Gujiabian residential area, Lijiabian residential area and Caocun residential area,etc. The distance from the project site to environment sensitive points is beyond 1000m (Health protection distance of project is 1000m) with exception of part of Huangnitang residential area, inhabitants of which have already moved elsewhere in “the project of product structure adjustment and technical innovation of technological equipment of Meigang Co.” Meigang Co. is a large scale incorporated iron and steel enterprise and the atmospheric pollutant it discharged has a certain influence upon the surrounding atmosphere environment. According to the evaluation on atmospheric environmental influence the project exerts and Nanjing Overall Planning of Development along the River and Overall Planning of New Banqiao Town, and from the view point of atmospheric environmental influence it is suggested to move part of inhabitants of Huangnitang Village within the health protection distance gradually, at the right moment and in a planned way and to establish shelterbelt between the factory and residential area so as to reduce influence of atmospheric pollutant upon the living quarters and gradually to change the status of short distance between production area and living area and crisscross with each other. 12.5 Influence on the surrounding environment quality after completion of the project Three old type coke ovens will be removed and two new type ovens which is in conformity with the national industry policy be built and a series of technical reform measures shall be adopted so that the waste water produced from coking shall be treated up to standard to be entirely used for flushing of furnace and inorganic discharge of waste gas shall be greatly reduced, therefore, after the project is completed it shall have minor influence upon the atmosphere, water and sound environment and improve the status quo of the local environment. To sum up, selection of the project being to be built in production area of Shanghai Meishan Iron and Steel Co. Ltd. (Banqiao Town,Yuhuatai District, Nanjing) is in line with the Overall Planning of Nanjing, the Overall Planning of New Banqiao Town, Nanjing Overall Planning of Development along the River and Nanjing Environmental Protection Planning of Development along the River. The local environment status quo shall be improved after the project is completed. In a word the project site selection is feasible.
132
13. Environmental Risk Evaluation
Risk evaluation is often referred to as accidental risk evaluation, in which abrupt disastrous accidents are mainly taken into account during the progress of construction projects. Although there is little probability of disastrous accidents, their effect usually can be very great. Environmental risk evaluation has become an important and indispensable component part in the environmental influence evaluation on the construction project that has potential risks. The emphasis of environmental risk analysis in this evaluation is laid on the projects of coking products.
Since many products and byproducts made by coking industries are dangerous substances that are inflammable, explosive and poisonous, the possibilities and results of the latent accidental risks shall be reflected in the environmental risk evaluation for coking construction projects in which accidental risks may exist.
13.1 Accidental Pollution Analysis
Accidents are often the first cause of serious contamination accidents. In view of various disastrous types and different leaking forms of poisonous and harmful substances in the same type of accident, representative types are adopted as the examples in this evaluation. The discharge amount of pollutants shall be estimated for the possible accidents that may cause serious pollution to the environment.
(1) Raw Gas: The way of making coke and gas is to confine fine washed coal in carbonization chamber of coke oven to make dry distillation and generate raw gas. In case that the inside of oven is in a state of high temperature and positive pressure, raw gas shall be led out; otherwise the pressure inside the oven may rise rapidly and raw gas escape from the oven in large quantities, resulting in serious pollution accidents. Thus, the gas shall be discharged through bleeders in a certain order. The main reason for gas discharge is the stoppage of gas blowers and HP ammonia circulating pumps.
There are two states for discharge of raw gas: one is direct discharge without burning (discharging directly from coke oven or discharging through bleeders in case of malfunction of ignition devices), the other is raw gas discharge after burning. Generally, both states last for less than 10 minutes. For the analysis results of possibility statistics of discharge accidents related with engineering coke ovens, please refer to Table 13-1.
Generally speaking, there is greater possibility of accidents of power failure, which may cause more serious pollution. The survey statistics for many inland cokeoven plants shows that power failure accidents last an average of 6~8 minutes (from detecting power failure to putting emergency power supply into service), and they last no more than 10 minutes each time. If the most unfavorable case is taken into account, that is, 10 minutes in this evaluation, the pollutant discharge in raw gas discharge accidents (unlit) can be referred to Table 13-2.
133
Table 13-1 Reasons for and Possibilities of Raw Gas Discharge
Reasons Accident Reasons Accident TypesAccident Frequency
(times/10 years) Duration
(minutes/each time)
Delay operation in starting emergency plant
Minor ≤1 3~5
Instrument malfunction, misoperation
Medium ≤2 4~6 Interior
Accidental overload tripping
Medium ≤2 4~6
Exterior Power Failure Major ≤3 5~10
Table 13-2 Pollutant Discharge in Accidents of Raw Gas Release
S/N Projects Release Amount Discharge Source
Intensity Ratio of Source
Intensity to benzene
1 Release amount of raw gas 7768m3/each time 13.94m3/s -
2 H2S 36.4kg/each time 60.7g/s 17.00%
3 Dust 144kg/each time 240g/s 67.23%
4 Benzene 214.3kg/each time 357g/s 100%
5 Ammonia 44.6kg/each time 74.3g/s 20.81%
6 Hydrogen cyanide 7.9kg/each time 13.2g/s 3.70%
7 Benzopyrene 0.042kg/each time 0.07g/s 1.96×10-4
8 Naphthalene 58.7kg/each time 97.8g/s 27.39%
In normal conditions, raw gas discharged in accidents is ignited and released. After burning, all the main pollutants in raw gas turn to CO2, H2O and SO2 discharging into the air. For discharge of atmospheric pollutant, refer to Table 13-3.
Table 13-3 Discharge Amount of Air Pollutants after the Burning of Raw Gas
Projects Release Amount Discharge Source Intensity
Discharge amount of exhaust gas 52430 m3/each time 87.4m3/s
SO2 129.4kg/each time 1294g/s
134
(2) Pollutants such as benzene, ammonia, H2S and gas: gas leak occurs in accidents related with gas tanks and pipelines; benzene leak often relates with accidents of benzol washers and scrubbers as well as pipelines; ammonia leak usually results from accidents of ammonia tanks and ammonia stills; and H2S leak may happen in thionizer accidents.
In addition to the equipment mentioned above, leak of noxious and harmful gas also occurs due to seal failure or other faults of valves, pumps, flanges as well as tubes connected with it. In a gas tank mostly is the clean gas, in which the content of pollutants is only 0.2~0.5% of that in raw gas. The essential ingredient of clean gas is hydrogen. In case of slight leakage, there will be little serious pollution affecting the environment to a large extent. So, no estimation shall be made here in respect of gas tanks and gas conduits. The discharge amount of pollutants, such as benzene, ammonia, H2S and gas shall be estimated for the possible accidents that may cause serious pollution to the environment. Pollutant discharge amount shall be calculated by 10 minutes when an accident occurs. Table 13-4 shows the discharge amount of main pollutants brought about by individual plant in a state of possible accident.
Table 13-4 Discharge Amount of Partial Pollutants in a State of Possible Accident
No. Typical Damage Types of
Plant Typical Damage Levels of
Plant Main
Pollutants Leakage of Pollutants
1 Leakage and breakage of benzol washers
Calculated by 100% effective volume of the washers
Benzene 12m3,16000g/s
2 Leakage and breakage of benzol scrubbers
Calculated by 100% effective volume of the scrubbers
Benzene 6m3,8000g/s
3 Leakage and breakage of crude benzol tanks
Calculated by 100% effective volume of the tanks
Benzene 100m3
4 Leakage and breakage of thionizers
Calculated by 100% effective volume of the thionizers
H2S 114m3,0.76g/s
5 Leakage and breakage of ammonia stills
Calculated by 100% effective volume of the stills
Ammonia 7m3,8.8g/s
6 Leakage and breakage of ammonia tanks
Calculated by 100% effective volume of the tanks
Ammonia 100m3,6.4g/s
(2) Pollutants such as benzene, ammonia, H2S and gas: gas leak occurs in accidents related with gas tanks and pipelines; benzene leak often relates with accidents of benzol washers and scrubbers as well as pipelines; ammonia leak usually results from accidents of ammonia tanks and ammonia stills; and H2S leak may happen in thionizer accidents.
In addition to the equipment mentioned above, leak of noxious and harmful gas also occurs due to seal failure or other faults of valves, pumps, flanges as well as tubes connected with it. In a gas tank mostly is the clean gas, in which the content of pollutants is only 0.2~0.5% of that in raw gas. The essential ingredient of clean gas is hydrogen. In case of slight leakage, there will be little serious pollution affecting the environment to a large extent.
135
13.2 Accidental Risk Evaluation
13.2.1 Calculation Modes (Omitted)
13.2.2 Concentration Estimation and Risk Analysis in Accidental Discharge
Accidental discharge is an instant discharge in special conditions, which is usually caused by many factors such as ill management, misoperation, particular operating conditions, unexpected accidents, natural disaster, or ageing equipment. Therefore, three typical air speeds, i.e. 0.2m/s,1.0m/s and 2.0m/s shall be used as the estimated speeds in the accidental discharge; it’s very favorable to pollutant diffusing when air speed is more than 0.2m/s and the pollution source has a relatively less effect on close range, and the influence on distant range is not obvious with the diluting and scattering effect of the wind. The actual calculation shows that there little changed in terms of maximum ground concentration and distance within the period of 10 minutes, mostly centralizing near the pollution source; after 30 minutes, with the influence of such factors as wind speed and run, the maximum ground concentration is far away from the source in breeze and the concentration is relatively low; if the wind speed is high, the ground concentration is relatively low as a result of diluting and scattering. Thus, 10, 15 and 30 minutes shall be taken as the duration periods. Estimation project is benzene that is discharged in large quantities. For the concentration of benzene in accidental discharge, refer to Table 13-5.
Table 13-5 Estimation on the Concentration of Benzene in Accidental Discharge
Types of stability Projects
A—B C D E—F
Concentration beyond the level after accidents
Beyond 2km Beyond 2km Beyond 2km Beyond 2km
Max. Ground Concentration(mg/m3)
76.9 171 297 567
Multiples of Max. Concentration beyond Levels
32.0 71.3 123.8 236.3
Influence of Max. Concentration Serious
intoxicationSerious
intoxicationSerious
intoxication Serious
intoxication
t=10min
Distance of Max. Concentration 100m 100m 100m 100m
Concentration beyond the level after accidents
Beyond 4km Beyond 4km Beyond 4km Beyond 4km
Max. Ground Concentration(mg/m3)
76.9 171 297 567
Multiples of Max. Concentration beyond Levels
32.0 71.3 123.8 236.3
Influence of Max. Concentration Serious
intoxicationSerious
intoxicationSerious
intoxication Serious
intoxication
t=15min
Distance of Max. Concentration 100m 100m 100m 100m
136
Types of stability Projects
A—B C D E—F
Concentration beyond the level after accidents
Beyond 8km Beyond 8km Beyond 8km Beyond 8km
Max. Ground Concentration(mg/m3)
76.9 171 297 567
Multiples of Max. Concentration beyond Levels
32.0 71.3 123.8 236.3
Influence of Max. Concentration Serious
intoxicationSerious
intoxicationSerious
intoxication Serious
intoxication
t=30min
Distance of Max. Concentration 100m 100m 100m 100m
(1) In coke oven accidents of raw gas release, the gas isn’t discharged from bleeders due to failures of power or plant etc., but released directly from coke ovens:
Since H2S, ammonia, hydrogen cyanide, naphthalene, benzopyrene and dust are all gaseous pollutants compared with benzene; in course of calculation, except the only difference in source intensity, they have the same parameters. So, only the greatest amount pollutant of benzene shall be taken into account in this estimation, other pollutants may be made an analogy analysis compared with benzene: they have the same max. ground distances; compared with benzene, values of the max. ground concentrations and the concentrations at various distances are equal to the ratio of their source intensity to that of benzene.
(2) In coke oven accidents of raw gas release, the gas is discharged from bleeders in case of the failure of flame igniters:
Compared with the last section, the only difference is discharge through bleeders instead of direct discharge from coke ovens. However, calculations can also be made taking pollutant of benzene as an example while analogy analysis can be made for other pollutants.
(3) Abnormal discharge of SO2 after burning of raw gas:
In this case, there is the single pollutant of SO2, allowing an easy calculation.
(4) Leakage of tanks such as benzol washers and scrubbers:
It's also simple with calculations on pollutants in accidental discharges related with benzol washers, scrubbers, benzene tanks, thionizers, ammonia still and ammonia tanks.
The results of calculation prove that there are large differences in terms of max. ground concentrations due to various source intensities in accidental and abnormal discharge. However, there are also similarities: that is, in breeze or calm wind, pollution in close range is serious and pollutants of high concentration accumulate near the pollution source, which makes it very difficult for troubleshooting and maintenance of plant; pollution in far range is
137
relatively slight. In case of high wind speed, pollution near the source is relatively slight because of air blowing, which gives the advantage to maintenance operation. However, this may cause a remote pollution and influence a larger area. Therefore, during the operation period of project, accidents shall be prevented to the full extent, and pollutant discharge shall be strictly controlled, with an effort to bring down source intensity and reduce discharge time; meanwhile, importance also shall be put on emergency treatment and countermeasures.
13.3 Relief Solutions and Emergency Preventions for Environment Risk Accidents
It shall be considered in two respects for prevention and control of harmful substances resulting from projects to be started. First of all, control the pollutant source by using advanced manufacturing techniques and equipment so that no such substances or little of them shall be discharged to achieve the end of reducing harmful substances at the workplace; secondly, actions of high efficiency at home and abroad shall be taken for inevitable harmful substances, and relevant protective measures shall be adopted for operating personnel so as to their risk to a minimum extent.
To prevent accidents and reduce disasters, prevention measures and emergency plans shall be made against risk accidents.
13.3.1 Prevention Measures for Risk Accidents
Prevention measures for risk accidents are the main content in project risk evaluation. To prevent the occurrence of accidents, the following prevention measures are proposed in environmental risk evaluation for projects to be launched with respect to management, safety design, fire control, gas defense etc.
13.3.1.1 Prevention Measures for Risk Accidents in Manufacturing Process
(1) Full consideration shall be taken for safe velocity of flow in conveying of combustible liquid, all the process units inside the devices collecting static electricity shall be grounded, and all piping flanges shall be bridged against static electricity. Anti static grounding shall be made in accordance with the standard made by former Ministry of Chemical Industry (HGJ28-90). Electric installation of explosion proof type shall be used for that inside the production plant, whose design shall be in concordance with the rule of GB50058-92. In production process, inflammable and explosive substances as well as combustible materials shall be kept in sealed plant and pipes under operation conditions, and reliable sealing shall be applied to each connection. In process control system, limit alarm system as well as interlock self-insurance system shall be set up to ensure a safe control of dangerous materials in case of misoperation and abnormal conditions.
(2) As for leakage accidents caused by poor tightness or accidental damages of plant, piping and valves of production system, regular inspection and maintenance is necessary and faulty components shall be replaced in time.
(3) As for unexpected mistakes made in operation, prevention measures shall be taken according to human-centered principle, and relevant working system shall be established so that operating personnel can start their work after training and those with related certificates shall be assigned to important posts; operation shall be made according to procedures in a
138
strict manner, misoperation shall be prevented and individuals be provided with preventive items. (4) Units shall be designed as a closed system; poisonous materials shall be used in a closed state and contact no operating persons in production to ensure that no harm shall be done to the workers. Detectors for combustible gas shall be installed in places where leakage of gas and oil may be possible so that timely alarm shall be given whenever any leakage accidents take place, allowing operating personnel to take countermeasures as soon as possible. Strict safety education shall be provided to operating personnel: no smoking in areas of plants and warehouses, items such matches shall not be brought in plant area, shoes with spikes are forbidden, putting on or off clothes is not allowed in warehouse area or workplaces to avoid producing of static electricity. In normal operation or maintenance, knocking or striking equipment with ironware is forbidden against any sparkles produced. Those at their posts shall observe the regulation of patrol inspection so that any potential accidents can be detected in time.
13.3.1.2 Preventions against Risk Accidents in Course of Material Storage
(1) Take comprehensive measures with respect of technique, process and management to prevent any unexpected accidents of poisonous substance leakage. For risk accidents in course of material storage, risk separation shall be made in general layout, separating and isolating different risk units and confining risks within a minimum range to avoid any chain or mutual reactions in case of a single risk. Reinforce design work of fire and explosion prevention; jobs in workshops shall be done strictly according to related regulations. There shall be a reasonable layout of plant area with storage tanks sitting in downwind direction of the plant area and keeping an enough distance from other facilities. They shall be far away from site office buildings.
(2) Pay attention to sunlight prevention and shockproof partition in handling and transporting of materials, and load and unload with care. Transportation lines shall be chosen as far as possible from residential areas and densely inhabited districts and no stay shall be allowed in such places. National regulations concerned with inflammable, explosive and poisonous substances shall be performed in the design and construction of plant buildings. Qualified level meters and alarm systems for high levels shall be installed in storage tanks; systems that are advanced in the world for prevention of lightning and static electricity shall be used, and maintenance shall be stressed for such systems; also, anti seepage treatment shall be made for the ground.
(3) Hydrants shall be provided around plant and tank areas, CO2 extinguishers and powder extinguishers shall be provided in areas of production plant; in tank areas, spray cooling headers shall be installed on the top of tanks in addition to hydrants, to bring down temperatures by sprinkling when necessary.
13.3.2 Emergency Plan for Risk Accidents
The purpose for preparing the emergency plan is to obtain the greatest efficiency at fastest speed when an accident occurs, to take actions for an orderly rescue, and to control the development of the status in the shortest period of time to reduce the harm and damages
139
caused by accidents.
The basic requirements of emergency plan for risk accidents include: scientificalness, practicability and authority. Emergency rescue in risk accidents is a work of science, which requires scientific analysis and reasoning as well as an emergency plan that is strict, unified and integrated; the plan shall meet the objective conditions of the project, with characteristics that are practical, simple and easy to understand and carry out; clear rules shall be made in terms of responsibilities, entitlements, tasks, working standards, rewards and punishments, and such rules shall become a system of enterprise, and the authority of which shall be assured of.
A complete chart of treatment procedure shall be prepared for dealing with project risk accidents. Once an emergency occurs, actions shall be taken according to such a chart. Fig. 13-1 is a basic frame diagram of emergency organization system for risk accidents, and enterprises shall make it suitable to their own practical situations.
Fig. 13-1 A Basic Frame Diagram of Emergency Organization System for Risk Accidents
13.3.3 Treatment of Risk Accidents To make an efficient treatment of risk accidents, feasible disposals shall be available. Emergency treatment for a project risk accident includes such systems set up for equipment, accident site commanding, rescuing, and communication as well as shall site emergency disposal plans, monitoring team for accidental disasters, site evacuation and aftermath disposals, etc.
13.3.4 Emergency Plan for Risk Accidents
Enterprise Center of Emergency Rescue
Site Emergency Headquarters
Expert Commission of Emergency Treatment
Community Center of Emergency Rescue
Safety Supervision
Production
Safety
Conservation of Environment
Voluntary Fire Fighting
Communication
Maintenance
Supplies
Environment Monitoring
Professional Fire Control
Public Health, Medical Service
Safeguard and Security
Information Communication
Materials Supply
Traffic Transportation
Maintenance
Accident Site
Branch Factory, W
orkshop, Device,
Departm
ent
Discipline D
epartment of E
nterprise
140
Emergency disposals shall be prepared for projects to be launched on a usual basis to cope with possible accidents so that emergency actions can be taken with sufficient preparations whenever a accident occurs.
An emergency plan for risk accidents consists of types of emergency status, emergency planned areas, accident grades, emergency protection and medical treatment.
13.3.4.1 Contingency Plan for Sudden Accidents
A contingency plan for sudden accidents is a set of work programs and specific measures prepared in advance with definite purposes. It provides persons on site with clear directives for actions so that they will not be in dismay after the occurrence of any serious and tremendous accidents, and no hasty discussion is required to make countermeasures. In this way, actions can be taken without hurry or bustle and accidents can be properly dealt with immediately, thus casualties and property loss can be reduced to a minimum extent.
Before a project being put into service, relevant and effective action proposals for disasters caused by sudden accidents shall be made by enterprises depending on the individual flow of manufacturing technique. The proposals shall be approved by the departments concerned; proper cooperation and interaction among plants, local governments and different service sectors shall be necessary. The contingency plan is prepared for serious risk accidents, the content of which shall meet the following requirements:
a. Means of site emergency alarm;
b. Evacuate site personnel in safety;
c. Rescue and arrange the injured and dead;
d. Prevent further development of the event; reduce property and environmental loss to the maximum extent;
e. Restore areas affected to normal safety status as soon as possible;
The contingency plan shall be implemented in case of any serious risk events happened or to be happened;
13.3.4.2 Emergency Measures for Sudden Accidents
Prevention is a radical measure for accidents; however, emergency measures are also necessary. Whenever an accident occurs, different actions shall lead to different extents and losses related with the accident. Emergency measures are treating programs based on the determination of risk loss, the aim of which is to completely restore in the shortest period of time the production process interrupted by any serious risk events, reduce further loss and bring down their influence to the minimum extent. In an emergency plan, not only shall countermeasures be provided, but also corresponding responsibilities be prescribed for different departments.
Once an unexpected environmental accident occurs due to various mistakes or troubles, emergency measures shall be carried out immediately depending on its nature and cause, and the range and extent affected by the accident shall be taken under control. The key of dealing
141
with accidents is timely warning, correct decision and prompt rescue. Adequate measures shall be necessary for efficient actions.
For the environmental risks mentioned above, emergency measures are as follows:
a. For accidents of 冲 料 and leakage resulting from any equipment failure or misoperation,close valves and stop feeding immediately. Clean up the overspill in no time and put them into containers and dispose them properly. Never discharge them with wastes or sewage to prevent any environmental pollution.
b. Leak stoppage shall be made at sight in case of leakage accidents caused by mechanical damage, etc. in the process of warehousing and transportation of materials. Collect the spilled materials in airtight containers as much as possible, absorb any residue with sand or inert absorbent, remove them to a safe place, and never dispose them at discretion. c. Some of the materials and products used in this project are inflammable, explosive and corrosive, so fire is likely to break out in a sudden accident, to which great importance shall be attached. Once a fire occurs, fire extinguishers of dry powder or CO2 can be used to stifle the fire. In case of big fire, call the fire brigade immediately and connect hydrants at the same time. Disperse inflammable steam with spray water, and extinguish the fire with CO2
extinguishers or sand soil.
d. Corresponding measures shall be taken for other types of accidents.
e. For procedures of emergency measures, refer to Fig.12-1.
13.4 Accidental Discharge and Countermeasures
13.4.1. Failure of Wastewater Treatment Facilities and Countermeasures
(1) Failure of Wastewater Treatment Facilities
In service of the sewage treatment plant, once failures occur due to operational accidents or other causes, efficiency of sewage treatment may come down or lose completely, resulting in adverse effect on the equipment and bringing pollution to the environment.
(2) Main Prevention Countermeasures for Failure of wastewater Treatment Facilities
① Pre-job training shall be strengthened for the staff of wastewater treatment station to enhance their professional proficiency and to keep working instructions being stuck to;
② Strengthen regular management and maintenance of wastewater treatment facilities;
③ To prevent wastewater treatment station from discharging off-standard water due to an operational failure, underproduction or even off production is proposed for measures to be take after the sudden accident. Buffer pools shall be provided for phenol-cyanogen or Acid-alkali wastewater treatment stations, the whole section in which wastewater is produced shall be stopped if the failure lasts more than 4 hours.
13.4.2. Accidental Gas Exhausting and Countermeasures
The failure of facilities for exhaust gas treatment is that, in the operation of electrical precipitators or bag-type dust collectors, the efficiency of dust removal comes down or loses
142
completely due to operational accidents, bag damage, power failure or other causes so that pollutant concentration in exhaust gas increases to a great extent, resulting in environmental pollution.
Dust collectors for proposed projects shall be provided with online monitors. Once an off-standard discharge occurs due to plant damage, corresponding measures shall be taken to suspend production for trouble shooting without allowing a long time off-standard discharge.
Main Prevention Countermeasures for Failure of Exhaust Gas Treatment Facilities
① Pre-job training shall be strengthened for the staff of exhaust gas treatment station to enhance their professional proficiency and to keep working instructions being stuck to;
② Strengthen routine management and maintenance of the equipment such as electrical precipitators and bag-type dust collectors; make a regular maintenance and replacement of components.
③ Durable new type fiber materials shall be used for bag-type dust collectors to prolong their service time.
④ To prevent off-standard discharge of exhaust gas caused by operation failure of dust removal facilities, sudden accidents shall be controlled immediately, otherwise, underproduction or even off production shall be regarded as measures against such a problem.
13.5 Integrated Measures against Environmental Risks
In a word, the key to preventing the occurrence of tremendous accidents lies in strengthening education on risk and environment consciousness to all leaders and employees of the plant, enhancing their safety and environmental protection consciousness. Therefore, it is suggested that:
(1) Strengthen system of personal responsibility; rigorously enforce each operational rule and reward and punishment system. In addition to establishing of specialized agency for environmental protection, an individual shall be designated by each production section to take charge of affairs concerned with safety and environmental protection; frequent inspections shall be made for the components that are subject to causing accidents so that potential dangers could be prevented; any problems discovered shall be reported to the departments concerned in no time;
(2) Regular emergency exercises shall be performed by the staff of a plant under conditions of an assumed accident so that they can be well prepared for all contingencies with no fear or fuss.
(3) Make it well prepared for safety and firefighting equipment, strengthen the building of safety and firefighting teams, and improve their abilities of dealing with an emergency.
(4) Reinforce the maintenance and management of the equipment, prepare strict operational rules and emergency plans; strengthen the management of dangerous articles and establish a complete set of rules and regulations on the whole process of the storage, transportation and usage of such articles.
143
In summary, with efficient preventive measures, a risk accident occurred can be limited within the production site and brought quickly under the efficient control, without causing great losses for the production, personnel and properties, or affecting the neighbors outside the plant, either.
144
14 Environmental monitoring and EP Management plan
14.1 Environmental monitoring
For the purpose of real information on the waste discharges from the enterprise and the environmental status quo so that the pollutant discharge/emission from the enterprise are curbed within the limits set by the State and a sustainable development can be assured for the enterprise and good health be assured for the workers and employees as well the discharge ports of all the different workshops in the enterprise must be brought under testing and monitoring,
Based on different pollutants factors, the items and frequency proposed for monitoring are shown in detail in the Table 14.1
Table 14-1 Monitoring plan of pollution source type of
pollution sources
Monitoring factors
Monitoring frequency
Monitoring place and unit Remarks
Fume and dust,SO2
Once a week Within factory, quality
control center of Meigang Waste gas
苯并比, BSO, H2S, NH3
H2S: once a week
Rest: twice/a Battery limit, quality
control center of Meigang
Twice per year by environment
monitoring center of Nanjing
noise
Equipment: sound level
Battery limit: equivalent
continuous sound level A
Equipment: twice/a battery
limit: once/quarter
Quality control center of Meigang
-
Waste water from north
outlet
As the project has minor discharge of waste water and the north outlet is mainly used for discharge of waste water from Meishan Baohua Co. so the routine monitoring and
management of this outlet is put under the control of Meishan Baohua Co.
14.2 Environmental management system and monitoring instrument
14.2.1 Environmental management system
Security and environment branch is environmental management organ of coking factory of Shanghai Meishan Iron and Steel Co. Ltd. It is the Co.’s functional department having 19 people for environmental protection management and monitoring (Quality control center is charge of environmental monitoring). Meanwhile, every factory of the Co. has its own organization for environment management in charge of environmental protection. SE branch of the Co. is responsible for routine environment management and for supervision and control over the Co.’s development planning and environmental protection measures of all new, expanding and reforming projects and technical innovation items as well as for EP statistics and construction of environmental protection infrastructure.
145
There are 14 people for environmental monitoring and they are divided into 3 groups, namely: sampling group, analysis group and quality control group with capability of atmospheric quality monitoring, fume testing, waste water monitoring and noise testing etc. They are responsible for routine monitoring and analysis of pollution sources of factories and living areas of the whole corporation and for technical supervision over effect of all purification equipment so as to provide technical support for information of environment quality and change trend, treatment of pollution, protection and improvement of environment.
Monitoring of pollutant shall still be under the responsibility of the technique and quality department of the corporation after the project is put into service.
General Manager shall be responsible for EP work of Meishan Branch of Baohua Co. and Deputy General Manager in charge of it while the Security and EP Branch (SEP) shall carry out implementation. Its duty is to carry out environmental protection policy, work out and implement work plan and planning of environmental protection, review and supervise “three concurrence” of the construction project, organize implementation, acceptance and examination of environmental protection of the whole factory, supervise qualified discharge of “three wastes” and labor protection of work site, direct and organize environment monitoring, be in charge of investigation, analysis and handling of accident and draw up EP statistics and write report of EP examination etc. Part-time EP personnel of each workshop shall be in charge of EP management of its own department. Sludge produced from sewage disposal plant and other solid wastes shall be storied in the designated place and under the charge of appointed personnel.
Meishan Branch of Baohua Co. shall be staffed with 50 full-time EP personnel, 6 of them are managers with 44 people at sewage disposal plant. Each workshop section shall be provided with 10 part-time EP personnel.
14.2.2 Provision of environment monitoring instrument
See table 14-2 for environment monitoring instrument.
Table 14-2 EP monitoring instrument Description Model and size Qty Price (10000 Yuan)
Spectrophotometer 722 grating,7210 3 0.9 Atom absorber AA-650 1 20.0
Infrared spectro oil meter 红外分光测油仪 JDS-100 1 5.0 Burning rate meter 燃烧效率测定仪 DH9003 1 0.1
Smoke SO2 analyzer TH-990S 1 3.0 On-line COD analyzer — 2 22.0
Chimney gas monitoring vehicle Toyota 1 50.0 Smoke and dust sampler 300H+ 2 4.0
Acidimeter — 3 0.3 Sound level meter HS5633 HS6220 2 0.5
Total 20 235.9
146
14.3 Suggestions for environmental management system
SEP Branch of Shanghai Meishan Iron and Steel Co. Ltd., through many years efforts, has pushed EP work onto the road of systemization, standardization and scientific management and worked out a complete set of EP management systems and consistently has made them revised and improved through practice. The main management systems are as follows:
1. EP management method of Shanghai Meishan Co. Ltd.;
2. Implementation method of EP responsibility system of Shanghai Meishan Co.Ltd.;
3. Regulations of management of EP facility of Shanghai Meishan Co. Ltd.;
4. Environmental monitoring management system of Shanghai Meishan Co. Ltd.;
5.EP management details of project of Shanghai Meishan Co. Ltd.(for trial implementation);
6. Management method of industrial solid wastes Shanghai Meishan Co. Ltd. (for trial implementation);
7. Management method of automatic monitoring system for industrial pollution sources of Shanghai Meishan Co. Ltd. (for trial implementation);
After completion of the project environmental management shall be strengthened according to the requirement of the provincial and municipal EP Bureau and EP supervision and management systems be established and perfected. Leading carders of the Co. shall attach importance to EP work and draw up environment policy, environmental management manual and a series of operating instructions for the whole corporation so as to improve EP work and to make the work standardized and systemized and shall put forward continuous improvement measures through identification of important environment factors to minimize influence on environment. According to the requirement of work it is suggested to draw up the following regulations and systems of EP work:
1. Regulation of EP duty management.
2. Management system of “three concurrence” of project.
3. System of pollutant discharge report
4. EP education system.
5. System of handling of pollution accident.
6. Management system of routine operation of sewage disposal plant.
7. Management system of sewage discharge.
8. Management system of underground drainage pipes and networks.
9. Management and disposal system of solid wastes.
147
15. Analysis of economic profit and loss of environment
15.1 Analysis of economic benefit
The total investment in this project is RMB¥ 1300.5 million. After the project is put into operation, it is estimated that the annual sales income will amount to RMB¥ 1704.28 million, the annual profit after tax RMB¥_____.The recovery period of investment for the project is 7.26 years. See Table 15-1.
Table 15-1 Financial evaluation of the project
No. Description Unit Qty.
1 Total investment of the project 10000 Yuan 130050
2 Annual sale income 10000 Yuan 170428
3 Annual sale tax and addition 10000 Yuan 13083
4 Annual total cost 10000 Yuan 119034
5 Annual total profit 10000 Yuan 36736
6 Annual income taxation 10000 Yuan 12123
7 Annual profit after taxation 10000 Yuan 24613
8 Profit ratio of investment % 25.99
9 Profit tax ratio of investment % 33.80
10 Financial internal rate of income of total investment
(before taxation) % 24.56
11 Financial internal rate of income of total investment
(after taxation) % 19.30
12 Financial internal rate of income of self-owned fund % 24.62
13 The recovery period of investment Year 7.26
From the above financial index we can see that after the project is completed its economic benefit is fairly good. Financial internal rate of income of total investment (after taxation) is greater than the basic internal rate of income of trade (7%) and the recovery period of investment is smaller than the basic recovery period of trade. This indicates that the project is feasible in finance and has comparatively strong capability against risk.
Besides, dry cooling has a better increment result. Dry cooling is a technique with advanced technology and having remarkable environmental and energy-saving benefit. This method can not only recover heat energy from red coke to produce steam and generate electricity having direct economic benefit but also raise strength of coke and increase its wearability so that the coke briquette has even grade with less coke powder and water content. All these factors shall be benefit to reducing coke rate of iron manufacture and smooth operation of furnace so as to
148
increase production capacity of furnace. Through financial measure and calculation the annual increment benefit of dry cooling is RMB¥ 20.08 million.
15.2 Analysis of social benefit
Coke is the major raw material and fuel for metallurgical, mechanical and chemical industry among which furnace iron manufacture consumes the maximum part of coke. It is predicted that in the future 20-30 years the iron and steel of the world shall still be mainly produced by furnace. With aging of coke ovens of western industrial countries the production capacity of coke is reducing gradually. As the western countries strengthen their EP laws and regulations day by day building new coke ovens and expanding and reforming the old ones is constrained thus forcing these countries to find out supply of coke throughout the world. China is the biggest manufacturing and exporting country of coke at present and with implementation of strict constraint over indigenous coke production in China short of coke supply may appear throughout the world in the future.
Shanghai Meishan Iron and Steel Co. Ltd., based on the above mentioned situation and development requirement, for the purpose of meeting its own demand for coke and achieving better economic benefit and meeting the requirement of EP and management, has decided to reform in changed place the 3 existing 65-hole coke ovens. Advanced, proven, reliable and reasonable processing flow shall be adopted in this project. Coal preparation workshop section shall employ technology of supplying coal before pulverizing which has advantage of short flow and saving investment. Coking workshop section shall use JN60-6 dual-heat (复热式) coke oven which is advanced in equipment and reliable in technique and in addition environment control measures shall be taken. Coke cooling system shall employ the advanced dry cooling technique, by doing so coke quality is raised and energy recycled and environment is protected. EP measures adopted for this project has not only taken into consideration the adaptability with the level of the factory’s equipment but also made the treatment result meeting the requirement of the national standard so that the target of high output and low energy consumption and less pollution is fulfilled; environment is protected and energy consumption saved under the pre-condition of development of production thus embarking on the road of harmonious development of production and environment. So its social benefit is remarkable.
15.3 Analysis of profit and loss of environmental influence
According to analysis of the project and environmental influence the “three wastes” produced from the project has minor influence on environment after it is completed. Based on the estimation of EP measures to be adopted the investment required for EP of this project shall be about RMB¥160 million accounting to 12.3% of the total investment of the Co.
The Co. shall use 12.3% of the total investment to control pollution sources and afforest factory area so as to achieve the aim of pollution control and environmental protection.
149
16 Conclusion and suggestion
16.1 Conclusion
16.1.1 Conformity with industrial policy
Technically advanced, proven, reliable and reasonable processing flow is adopted for this project being in conformity with the following industrial policies of the country:
(1) This project is within the item No. 47 of Environmental Protection and Integrated Use of Resources, category III of “Guide (catalogue) to Key Field of Hi-tech Industrialization to be Developed Currently and Preferentially ” issued by State Planning Commission and Ministry of Science and Technology , namely: Industrialization of dry cooling plant of big and middle scale coking factory;
(2) The following technology of metallurgical industry of “Guide (catalogue) to Cleaning Production Technology of State” (first lot and second lot) issued by State Economic and Trade Commission:
The first lot of technology of metallurgical industry: 1.dry cooling technology;
The second lot of technology of metallurgical industry: 9.purification technique of smoke of coke oven;
(3) The following technology of the 14th category iron and steel of “Catalogue of Industry, Product and Technology Currently Encouraged to Develop (revised in 2000)” issued by State Economic and Trade Commission:
(4) coking coal wetting, distributed coal coking, tamping coking and dry coke quenching technology. (炼焦煤调湿､配型煤炼焦､捣固炼焦､干法熄焦)
(5) Product, production scale, production technology and equipment used for the project is not within the scope of being inhibited and constrained by “Notice of Further Strengthening Coordination of Industrial Policy and Credit Policy to Control Credit Risk”(FGCY[2004]No.746). Production capacity, technology and product are not within the scope of “Catalogue of Production Capacity, Technology and Product Limited and Eliminated by Industry and Trade of Jiangsu Province” (2005).
(6) The project is conformity with the related specification of Appendix III “Admitted Condition for Coking Industry” of “Announcement No.76 of 2004”issued by State Development and Reform Commission(including the related requirement for desulphurization of gas. See 2.3.4 on p15-p23)
16.1.2 Conformity with the local overall planning and environment planning
The project shall be built in the existing factory area of Shanghai Meishan Co. Ltd., which conforms to the requirement of the overall planning of Nanjing and the overall planning of the new Banqiao Town as for development of metallurgical industry within Meishan Group area.
Banqiao area where the project is located is at down wind of Nanjing conforming the principle of Nanjing environmental protection planning of development along the river, i.e. to
150
arrange industry with serious air pollution down wind the city as far as possible.
Through removal of three old type coke ovens and construction of two new type ovens which is in conformity with the national industry policy and a series of technical reform measures, including gas purification technique (adoption of FRC method of desulphurization and decyanation to produce sulphuric acid ), the project shall have the waste water produced from coking be treated (carried out in Baoshan chemical corporation) up to standard to be entirely used for flushing of furnace and inorganized discharge of waste gas shall be greatly reduced thus it shall conform with the spirit of realization of zero or even minus increase of total pollution and strengthening control of total pollutant quantity and enhancing treatment of pollution to reform chemical and metallurgical industry with hi and new technique.
16.1.3 Conformity with the principle of cleaning production
Technically advanced, proven, reliable and reasonable processing flow shall be adopted in this project. Coal preparation workshop section shall employ technology of supplying coal before pulverizing which has advantage of short flow and saving investment. Coking workshop section shall use JN60-6 dual-heat (复热式) coke oven which is advanced in equipment and reliable in technique and in addition environment control measures shall be taken. Coke cooling system shall employ the advanced dry cooling technique, by doing so coke quality is raised and energy recycled and environment is protected. FRC desulphurization and decyanation method shall be used for gas purification to produce sulphuric acid (The project using this method can make desulphurization degree of coke gas over 96 %.). Desulphurization and reproduction is comparatively reliable. Desulphurization is arranged before deamidization and debenzolization and direct final cooling (直接终冷)can be entirely closed thus reducing corrosion to equipment. Reproduced air is less and directly added into post tower gas (塔后煤气)eliminating second pollution. This method can not only eliminate pollution by ammonia sulfate gas but also reduce greatly pollution by unorganized discharged SO2. Adoption of PHOSAM method to produce waterless ammonia is advanced technology in the world having advantages of simple technology, high quality and high value of product and better economic benefit.
The project is in conformity with the principle of cleaning production.
16.1.4 Realization of up-to-standard drainage
During implementation of the project the target of up-to-standard drainage of pollutant is achieved through all kinds of pollution prevention measures.
All pollution treatment measures of this project shall be taken in synchronization with the project.
16.1.5 Fulfillment of total quantity control requirement
The principle of “up-to-standard drainage”, “cleaning production” and “the new bring along the old” shall be implemented in the project. After the project is completed the discharged pollutant shall be reduced greatly and the final drainage quantity of pollutant can be balanced within Shanghai Meishan Co. Ltd. to meet the requirement for total quantity control.
151
16.1.6 No degradation of local environmental quality
Evaluation of status quo of the environmental quality shows that the surface water and sound environmental quality within the evaluated scope can meet the requirement of environment function and dust pollution of atmospheric environment is comparatively serious. The main cause is as follows:
(1) The concentrated industrial zone of Banqiao and Yuhua economical and technical development zone are now being under the stage of vigorous development and the road maintenance and ground leveling result in serious dust pollution in local construction stage within the evaluated area;
(2) The monitoring period is just at the transition of spring and summer of Nanjing and many days are fine and cloudless thus resulting in serious dust raising.
Analysis of environment influence forecast shows that after the project is put into implementation the environment status value of B[a]P､H2S battery limit and sensitive points added with influence value does not exceed the standard. Drainage of smoke (powder) and dust and SO2 etc. is decreased greatly and the atmospheric environment quality of the area the Co. located shall be improved. Construction of this project shall not change the present function requirement for water and sound environment of the area. The project shall not have any disadvantageous influence upon noise sensitive targets.
16.1.7 Conclusion of public poll
(1) The public firmly supporting this project: 2 people; conditionally supporting: 47; not care: 1 and objecting:2. The people who conditionally support this project demand that the “3 wastes” must be treated up to standard for discharge. A return visit to 2 persons holding an attitude against this project shows that the principal reason for their being against this project is that they are not satisfied with the status quo of the environmental quality and in their point of view the existing coking plant produced serious atmospheric pollution that hazard health of the nearby inhabitants and they are afraid of still serious influence upon the environment exerted by the project. This worry is normal. One of them suggested that the inhabitants must firstly be moved elsewhere before any expansion start up. This shows that these two people are not firmly against this project, so long as the project owner makes good arrangement for those whose houses are pulled down and occupants moved elsewhere they shall not be against this construction project. The project owner shall also do as more as possible work of propaganda and explanation to dispel misgivings of the masses so that they shall support this project.
(2) The public request that the project shall learn from Baogang to strengthen the treatment of waste water, waste gas, noise and solid wastes and ensure up-to-standard discharge of wastes to minimize influence upon the surrounding environment. They also request that the affected inhabitants to be well arranged to remove elsewhere.
(3) The masses request the project management to take EP measures during construction and pay attention to prevention against dust, rubbish and noise pollution and minimize influence upon the surrounding environment.
152
(4) They hope that EP department shall strictly follow law of environmental protection and related EP regulations and standard in management of the project.
16.1.8 General conclusion
To sum up, from the point of view of environmental protection, the project is feasible under the condition of seriously implementing all kinds of EP measures.
16.2 Suggestions
(1) Strengthen EP management, enhance EP consciousness and the project owner must implement all treatment measures for this project and strengthen the operation management of EP facilities to prevent accident drainage.
(2) Strengthen environmental management during construction and operation stages of the project and increase necessary measures to avoid harmful influence upon the environment by abnormal and accident drainage.