From past to the future

Iron and steel industry is one of the basic industries of Ukraine.
Donetsk metallurgical plant is one of the oldest in southern Ukraine. Founded in 1872 by British industrialist John Hughes, he gave the name of the village, and then the city Yuzovka. And now the fate of the plant and the city are closely related.
Now a common problem for all the steel mills, that gave the life to the city in their time is not only the location in the heart of the city, but in the focus of its inhabitants also.
Local artists who decided to show the image of the city-worker at different stages of his life, began to draw it from factory chimneys — intensively smoking, they represented the peace labor and prosperity.
Hundreds of factors less prominent than factory chimneys , but with the same disastrous harmful emissions to human health and the nature around us were added in the process of industrialization of the city . These «competitors» have long bypassed the plant, leaving his share of eight per cent of harmful emissions.
But swallowing this «bouquet» of odors, Donetsk residents with hope and anxiety are looking in the direction of our plant in the first place . Their logical question: what steelmakers are taking to reduce emissions?
The level of production fell by more than 30% in Ukraine, in the 90 years .The general condition of the steel industry is estimated to be critical for the following reasons:
-steady aging of fixed assets;
-low efficiency of energy resources;
-hard ecological situation in large industrial centers.
All this fully applies to our factory.Therefore, since 2000 the company implemented a set of technical upgrading and strategic development of the plant, aimed at the introduction of resource saving technologies, the creation of cleaner production, and production of quality competitive products.
Identified two main stages:
modernization of blast furnaces;
modernization of steelmaking.
In April 2002, after overhaul of first rank, the company commissioned blast furnace number 2.The latest developments were implemented on the furnace , that match international standards and allowed not only increase the production of iron 1.2 times (20%), but also improve health indicators in the workplace significantly reduce emissions from the blast furnace into the atmosphere (at 110 tons / year).
Hiding places of iron and slag tapping was done during the overhaul , and flue gases were directed to the gas-cleaning bag filter. The dust concentration at the outlet of the chimney is 18-20 mg/m3, which corresponds to the highest international standards.
A similar overhaul of blast furnace number 1 was made In 2007.After overhaul BF № 2 and № 1 BF decreased) emissions: dust — to 224.85 tons per year of carbon dioxide — 60.8 tons per year of sulfur dioxide — 4.8 tons per year ( by two furnaces.Analysis of the results of the dispersion of pollutants from emission sources of the complex of blast furnaces has shown that the maximum ground level concentrations of dust of blast furnaces at the boundary of the sanitary protection zone is less than 0.3 percentage MPC.For the remaining ingredients, surface concentrations are very low and did not exceed 0.1 MPC. The impact of emissionson in the air from the complex ( after the blast furnace overhaul) should be seen as weak, and has no significant effect.
In order to increase the production of its own electricity, making fuller use of blast furnace gas and reduce emissions equipment of Power Plant was modernized for 25 mln grivnas. This allowed to use of blast furnace gas ,previously flared on the candle, more efficient .
The work carried out in the blast shop and Power plant, enabled factory services to initiate consideration of a number of projects as eligible to the Kyoto Protocol and leading to a reduction of environmental load.A work on obtaining a letter of approval in the State Agency of Environmental Investments is going at present, which confirms the serious attitude of the PrSC «Donetskstal» leaders" to the environment during production modernization.
Out of furnace steel processing plant («ladle furnace») was introduced in the open-hearth shop . It is equipped with modern gas cleaning system with bag filters. Residual dust content in flue gas is 20 mg/m3.Gas cleaning unit of «ladle -furnace» helps to reduce dust emissions from open-hearth production. The automatic control system of fuel supply to all open-hearth furnaces was developed and implemented .This action has reduced fuel consumption by approximately 10% and correspondingly reduce the amount of emitted pollutants into the atmosphere.
Analysis of the emission shows that today, at the factory main source of atmospheric pollution is the open-hearth production (about 70% of all emissions of the company).
A lot of options for the development of steelmaking metallurgical complex has been worked during 2006-2007.
Institute «Giprostal» developed key technical solutions and the construction project of a 150-ton arc furnace.
In 2008-2009.two open-hearth furnaces were shutdown for site preparation for construction of electric plant.After the introduction of electric furnace ,other four open-hearth furnaces will be stopped in operation .
Planned commissioning of the new mill is in May-June 2012. This will reduce the specific emissions of harmful substances into the atmosphere by 3.5 tons per year.
Phased reconstruction of heating furnaces of rolling mills is performed at the factory . After the reconstruction it is planned to decrease the consumption of fuel per ton of rolled products with a corresponding reduction in emissions of Donetsk.By the end of 2011 a new furnace of rolling mill «2300» will be put into operation, with the planned reductions in emissions to be 79.4 tons / year.
The reconstruction is carried out in the oxygen plant, and this is a construction of a new oxygen unit and a set of air compressors. It will reach the world’s best performance for the production of air separation products.This event also helps to reduce environmental burden in the region.
Our land is poor in fresh water, we do not have large rivers, and therefore the company’s development was made possible by the introduction of recycling schemes.Our company is one of the first on the way.
Now working cycle of the plant is closed 95% of water used, and only 5% of fresh tehnical water consumed to compensate for natural losses. The share of discharges into the external water accounts for 1%.
Water quality by the main indicators is practically no different from water of r.Donets. The company is mainly charging sulfates and chlorides in relieving water .Removal of salts requires considerable expenses, so the company has chosen to reduce the volume by more rational reuse of its own waste, reducing the number of annual discharges of water.
Another direction of the areas environmental activity is the management of waste in compliance with environmental laws and health regulations. The emphasis is on maximizing the use of waste and the introduction of low-waste technologies.
A large proportion of the waste is processed to produce the finished end product.
Granulated slag and sand ready rock-mix is obtained from blast furnace slags. A slag product of different fractions is obtained from steelmaking slag, with the extraction(also by fractions)of metal parts.
For these purposes, the company has a granulation plant for blast furnace slag, and crushing and screening plant by «AMKOM» for steel slag.
Generated large bulk of waste finds its application. It’s such a waste as flue dust, slag,scum from sludge tanks of rolling mills, spent refractories.
Wastes of 1 and 2 degree by hazard classes (waste mercury lamps, batteries, petroleum products) are sent to specialized companies with licenses for their disposal.
Disposal of waste to be reused in the future now is carried out on dumps. Processing plants (granulation plant by firm «AMKOM») is now on the territory of Polezhakovski dumps , finished products formed during processing is stored .
You can not ignore the fact ,that for the storage of waste at Polezhakovski dumps, the company pays an environmental tax, and not small. Thus, only in 2010 5.46 mln is directed in the state budget for waste disposal in the environment .
A briquette factory construction and obtaining of metal-products for reuse in production is planned for a more complete utilization of waste products and reduce the volume of raw materials consumed in the company .
Sanitary-protective zone of the dumps continues to equip to improve the ecological status of the territory of the dumps and the surrounding area .
Works are going constantly on landscaping of businesses and the surrounding areas.
50 to 70 mln grivnas are consumed annually for the maintenance of nature conservation and the implementation of environmental activities .
Smoking chimneys, symbolizing the stable operation of the plant inthe XX century in ,remained in the past.Our present is the modernization of steelmaking and the complete decommissioning of open-hearth furnaces by the Euro 2012, which is certainly a positive impact on the ecological state of the city and the region as a whole.A DMP will be one of the most environmentally friendly industrial enterprises in Ukraine.

2011-11-05 15:00