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ROMANIA

WASTE MINIMIZATION IMPACT PROGRAM

EVALUATION OF THE WASTE MINIMIZATIONPROGRAM

AT

SIDERMET S.A.

JUNE 16 - 18, 1997

USAIDIWEC COOPERATIVE AGREEMENTNO. ANE-0004-A-00-0048-00

World Environment Center419 Park Avenue South

New York, New York 10016

OCTOBER 1997

•WMIP PROGRAM - SIDERMET

REPORT DISTRIBUTION:

UNITED STATES AGENCY FOR INTERNATIONAL DEYELOPMENT

Melody BachaAlexandra BurkeAngela CrooksPatricia A. Swahn

Bureau for Europe and New Independent StatesBureau for Europe and New Independent StatesBureau for Europe and New Independent StatesDocument Acquisitions

USAID MISSION, BUCHAREST, ROMANIA

Peter B. LaperaRoberto Figueredo

USAID RepresentativeEnvironmental Director

POLLUTION PREVENTION CENTER

Vladimir Gheorghievici Director

•PROJECT CONSULTANTS

Louis GildeRobert Locke

WORLD ENVIRONMENT CENTER

Antony G. MarcilThomas J. McGrathRomuald MichalekBohdan AftanasValerie SepeErnest BolducRaymond L. FederP. Breese/File (2)

SIDERMET S.A.

•

Nicolae IvascuVictor Firescu

General DirectorTechnical Director

Project Description:

Project Type:

Country:

Industrial Sector:

Dates:

Funding Source:

Participants:

WMIP PROGRAM - SIDERMET

NIA

Waste Minimization Impact Program Assessment

Romania

Cast Iron

June 16 - 18, 1997

United States Agency for International Development

Sidermet Staff and WECIPPC Team •Project: NIA

Business Development: NIA

•

•Section

TABLE OF CONTENTS


Page

I. Introduction 1

II. Executive Summary 2

III. Findings 3 - 8

IV. Appendix I (Pollution Problems Highlighted by Plant) 9

Appendix II (Process Details From Plant) 10

Appendix III (Equipment Recommended by Cons~ltant) ll

Appendix IV (Business Cards of Contacts) 12~}

Appendix V (List of Material Forwarded to Sidermet) 13 - 14

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I. INTRODUCTION

Ajoint WEC/PPC team including Louis Gilde, Project Consultant, Robert Locke, ProjectConsultant, Vladimir Gheorghievici, Pollution Prevention Director, and Frank Szymborski,WEe Project Manager, visited Sidermet which had participated in the WEe Waste MinimizationSeminar.

The plant visit was to:

•

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Provide guidance and assistance in establishing an effective waste minimizationprogram; and

Ascertain the progress in the identification and implementation of the WMIP project.

During the discussions with the plant's technical staff, it became evident that Sidermet isinterested in developing a formal waste minimization program. However, due to a lack of funds,the plant proposed to concentrate their efforts on those projects that could contribute to reducingtheir production costs and/or improving product quality. In this regard, the plant requested WEeto provide additional expertise to improve manufacturing/process procedures.

WEe acknowledges the contribution made by the volunteer project consultants, Messrs. LouisGildc and Robert Locke, who gave freely of their time and energy in assisting WEC in its WasteMinimization Impact Program in Romania. •

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II. EXECUTIVE SUMMARY

The WEe team visited Sidermet S.A. on June 16, 17 & 18, 1997. The following report identifiespotential projects for improvements in the production of coke and pig iron. Problems are listedwith suggested solutions and benefits. Efforts to undertake solutions should reduce: operatingcosts, energy costs, employee exposure to toxic gases, air pollution, river pollution and groundwater pollution.

Sidermet management has expressed an interest in an improved waste management program asevidenced by requesting WEC to develop this plant visit. Sidermet already sells blast furnaceslag for highway construction. Water from the cooling tower is used for slag quenching purposesand other industrial water applications. Further water conservation measures are potentiallyavailable by investigations and a follow-up visit.

Although the major environmental impact is from water pollution, this should be resolved whenthe new air coke quenching system is activated. Air pollution matters concern worker exposurein addition to community effects.

The internal environmental management team must be reinforced with direction from topmanagement and strong leadership from the individual responsible for that position. It isexpected that WEC's 10 step waste minimization program, following receipt of this report, willprovide benefits. A follow-up visit to encourage and assist in furthering the plant'saccomplishment should be considered if results are to be optimized.

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III. FINDINGS

Introduction

We were impressed with the professionalism of the employees and management at SidermetS.A., Calan. It was obvious that the company's lack of financial resources limited what could beaccomplished. Many of the suggestions in this report were known to the staff of Sidermet, butfrequently the limitations of finances handicapped improvements in operations.

In addition to the suggestions below, the institution ofWEC's 10 step program of wasteminimization involving every worker in the factory will result in savings and strengthen theeconomics of Sidermet. The 10 step program only works if everyone from top management tothe lowest employee is totally dedicated to the effort in action and deeds.

This concept should not only be employed on existing operations, but should be incorporated inthe design and construction of the new continuous casting cast iron pipe project which isexpected to produce a major contribution to the income of the Sidermet factory.

The staff had given the visiting WEC team a general listing of some of their objectives toimprove factory efficiency and cost reductions. These are listed in the Addendum of this report.

Potential Projects

COKE OVENS

Problems:

1. Plant personnel are fully aware ofthe coke oven problem, but due to lack of money, thecondition has not been corrected. The coke oven doors do not provide a tight closure causingexcess fumes to escape into the atmosphere. This causes a ground level health and safetyproblems.

2. Water quenching of coke is used to prepare the coke for blast furnace. The water isgenerally discharged to the River Strei and has the potential of exceeding water quality standardsof the local equivalent EPA.

Solutions:

1. Currently, one coke oven battery is in the process of reconstruction. The plan is to holdthis completed unit in reserve pending failure of either of the currently used batteries. It isrecommended that the unit be placed into service and each used battery, in tum, be reconstructedusing the latest technology. The lifespan of a reconstructed battery with good maintenanceshould be approximately ten years.

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•WMIP PROGRAM - SIDERMET

2. Proceed with the completion of the current coke dry quenching project as quickly aspossible. Improvements in coke quality are recognized by factory personnel and the eliminationof a potential water pollution problem will be realized.

Benefits:

I. The appropriate rebuilding of the units with better gas connections will increase levels ofchemical concentrations thus improving the efficiency of coke oven batteries. This will have theadded benefit of reducing the volume of gas to be handled in the chemical plant and, at the sametime, increase the recovery of chemicals more efficiently.

The environmental benefit of these improvements will be a reduction in air emissions ofparticulates and chemicals. There will also be the corollary benefit of reducing worker exposureto these materials. By reducing ground level ambient air contaminants, the need for regularmonitoring of the atmosphere can thereby be reduced to occasional auditing of conditions.

The improved collection of coke oven gases reduces the volume of exhaust gas to becollected and treated for chemical recovery. By increasing the chemical plant efficiency, lessenergy will be needed to produce the same or greater amounts of chemicals.

2. Higher quality coke produced by dry quenching will reduce coke usage at the blastfurnace thus providing savings and eliminate water pollution and potential monetary penalties.

• Benefits:

I. The appropriate rebuilding of the units with better gas connections will increase levels ofchemical concentrations thus improving the efficiency of the coke oven batteries. This will havethe added benefit of reducing the volume of gas to be handled in the chemical plant and, at thesame time, increase the recovery of chemicals more efficiently.

The environmental benefit of these improvements will be a reduction in air emissions ofparticulates and chemicals. There will also be the corollary benefit of reducing worker exposureto these materials. By reducing ground level ambient air contaminants, the need for regularmonitoring of the atmosphere can thereby be reduced to occasional auditing of conditions.

The improved collection of coke oven gases reduces the volume of exhaust gas to becollected and treated for chemical recovery. By increasing the chemical plant efficiency, lessenergy will be needed to produce the same orgreater amounts of chemicals.

2. Higher quality coke produced by dry quenching will reduce coke usage at the blastfurnace thus providing savings and eliminate water pollution and potential monetary penalties.

•4


BLAST FURNACE

Problems:

1. Sludge resulting from air emissions wet scrubbing is not beneficially reused. Thismaterial is essentially 27% iron and the balance is ofminerals from the smelting processdischarged into the blast furnace flue gas. These particulates are collected in a dry cyclone andwet scrubber air emissions control train. The wet scrubber sludge is collected in aclarifier/settling basin. The sludge as removed is at 20% moisture. These solids are stored onsite causing loss of land and potential groundwater problems.

2. The dry cyclone rotary discharge valve discharges directly to an open railroad car. Thiscauses ground level air pollution problems in addition to loss of iron solids which could bereused.

3. Management has expressed concern about the weighing system used to prepare feed stockfor the blast furnace. Apparently, the lack of high quality iron ore adds to this difficulty andrequires an excess of coke to produce the pig iron product.

Solutions:

1. With approximately a 27% iron content, reclamation ofthis material from the wet •scrubber as a raw material feed stock for the blast furnace is recommended. To prepare thesludge for recycle, either a screw type centrifuge or belt press could be used to remove theresidual moisture. If a low cost binder, such as a starch, were to be added before the dewateringprocess, it is possible that the solids could be agglomerated to avoid losses from the blast furnacein the flue gas.

The on ground storage of blast furnace "sludge" is estimated to be 165,000+ tons. At thetime of this visit, the solids pile was dry. This suggests that recycle to the blast furnace could bepossible. There is a potential recovery of$3 million USD, based on the cost of raw iron ore.Recycle of this feed stock to the blast furnace is recommended.

2. Provide a sleeve from the rotary valve to the railroad car and use a temporary cover overthe open tailraces used for the recovery ofdry cyclone discharge. This cover will contain thefines as the valve discharges into the rail car.

3. Purchase ofhigher quality iron ore will have a multiplying affect. Besides reducing cokerequirements, there may be a reduction in the quantity of solids in the flue gas.

•5


Benefit:

• 1. Recovery of the blast furnace sludge as feed stock could supplant some iron orerequirements and improve cost efficiency of the factory. The estimated cost for iron ore is $18USD/ton. By reusing these solids as a feed stock, there is a projected savings of one millionUSD/year.

Unless higher quality iron ore is obtained on a continuing basis, improvements in thehandling of the sludge with a centrifuge for dewatering purposes will increase productivity of thefactory. Less equipment use and labor will be spent in handling the sludge at the clarifiers.

2. The dry cyclone discharge into the rail cars will reduce the loss of fines and eliminate aground level air pollution condition.

3. Weighing improvements can be achieved by using higher quality raw materials. Thisincludes iron ore and coke feed stock. If better raw materials are not obtained, then capitalexpenditure to provide for a new weighing system will be required.

General:

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Management has taken the position ofmaking area supervisors economically responsiblefor any events causing discharges to the River Strei: in excess of standard limitations. To be fairto area supervisors, management should provide adequate production facilities that operate withminimal pollution and proper end of pipe pollution treatment. Area supervisors are responsiblefor proper training of all employees. Management is encouraged to provide better equipment sothat unfair penalties are not assessed for no fault of the area supervisors.

Conservation ofnatural resources is expected to accrue from employing the abovesolutions. By collecting the blast furnace sludge through a dewatering system, the recoveredwater can be recycled or used as industrial water elsewhere in the factory. This reduces themakeup requirements ~rom the river and the pretreatment needs to make the water acceptable foruse.

Actions Required:

SIDERMET

1. Incorporate the attached "Boosting equipment reliability" guidelines, as an ongoingmanagement program of employee involvement in reducing operating costs. Minimizing lostproduction, improving profits and resulting waste minimization are expected to result.

2. Use the known technology currently available in Germany to recover the lost iron ore andsupplementary chemicals from the blast furnace flue gas as a raw material stock. The beginningphase is to recover a potential $3 million USD now in the sludge stockpile. This material isvirtually dry and should not result in any difficulty in handling.

6


3. Place the rebuilt coke oven batter. on line at completion of the reconstruction and beginrehabilitation of either of the two units currently in use. The upgrading of the coke ovens willimprove coke production, improve worker health and safety and increase chemical recovery.

4. Complete as quickly as possible the coke oven air quenching system. The drawback ofwater quenching of coke is the unreliability of avoiding contamination of the River Strei andconsequent monetary penalties.

5. If water quenching of coke is not eliminated, then management must seriously considerthe rehabilitation of the on site waste water pretreatment system.

WORLD ENVIRONMENT CENTER

1. Provide to management the latest technology of coke oven battery design and operatingpractices.

2. Provide the latest technology for raw material charging of blast furnaces.

Remarks:

Basically, management has not addressed the concept of waste minimization on theprecepts of the Pollution Prevention Center/WEC Program. The opportunities of wasteminimization are far out-weighed by concerns of maintaining market share and discovery ofways to improve the income of the company. We believe that pollution prevention is a moresignificant factor and we believe that the problems and solutions outlined above delineates theseconcerns. The concern of management is reflected in the many hours of interview afforded us.

By employing best management practices throughout the factory, adverse environmentalproblems can be lessened. By focusing on improvements in operations, higher job performancecan be expected. With concentration on production improvements, efficiency and productquality, the company should realize higher profits.

Addendum

The management team representing the company expressed concerns about theperformance of the company and the need to correct certain deficiencies. These are listed below.Our report touches on some of the issues with possible low cost solutions. Others may requiresome capital expenditure beyond the scope of the WE team to be able to address at this time.

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Blast Furnace

1. Due to raw material characteristics, the weighing equipment for charging is inappropriatefor this application.

2. Particulate in the flue gas are captured in a wet scrubber. Disposal of this sludge isbecoming a problem due to the quantities being amassed.

Coke Ovens

1. High leakage of the battery doors is effecting personnel with toxic gases.

2. Excess phone/ammonia in the coke quenching discharge water has resulted in monetarypenalties due to contamination of the River Stray.

8


APPENDIX I

(POLLUTION PROBLEMS HIGHLIGHTED BY PLANT)

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•Foundation

Pollution Prevention Center

Tel/fax: 40.1.2212050; 2211948; 2211899Email address:[email protected] ;Web site: www.cpp.ro

August 28, 1997

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Pollution Problems at the Company Sidermet S.A. Calan

1.1 Pollution Problems at the Sintering Plant

Following handling, crushing, screening, at the sintering plants results dust fromthe raw materials introduced into the batch and from the sintered iron.

Also, the intake· air from the exhaust fans is carrying dust particles andcombustion gases.

The pollutants are collected and introduced in cleaning facilities with bag filtersand electrostatic precipitators, but their construction and the high expensesnecessary for their operation and maintenance make that the exhaust air fromthese facilities to contain dust and chemical pollutants: CO, CO~ ,SO~, NOx.

Although, yearly, the quantity of dust retained in the dedusting facilities reaches495 tons/year, at the batching belt conveyors the dust concentration is 190400mg/m3

. The content of CO in the ambient atmosphere of the sintering plant is126 mg/m3

.

1.2 Pollution Problems at the Iron Making

The waters resulted from the liquid iron cooling at the belt casting machines atthe blast furnaces no. 1 and no. 2 have to be settled in one of the 2 containment's of the of the settling tanks belonging to the liquid iron casting machines.The waste water are discharged unsettled into the river due to the fact that theerection and commissioning of the settling and recirculation facility for thesprinkling water used at the liquid iron casting belt machine no. 1 is not finished.

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111 lIe s.ag c.ump which capacity is already completely used. During thegranulation process of the slag there are acid vapors emissions due to the sulfurcontent of the molten slag. The sludge resulted from the wet scmbbing of theblast furnace gas in the radial sc "ling tanks is evacuated in adhoc dumps whichdo not have anymore storage capacity. Although the sludge has an iron content(Fe) of 20-30%, there are not clients for it and its storage becomes impossible.At the time the monthly output of sludge is 500-600 tons and within thecompany's yard are stored more than 150,000-180,000 tons.

I .3 Pollution Problems at Coke Making Plant

At the coke plant (including the chemical facilities) the main pollutants are coaldust, gases and by-products.

The pollutants discharges are :

- permanent: waste gas stakes and aeration basins from the biological treatment- periodical: charging of the coal in the coking ovens, coke discharging and

quenching, the stack belonging to the adjusting station for thecoke gas outlet into the atmosphere, charging and discharging of

, the, utilized liquid chemical products and reactives (ingredients).- incidental : pipe ducts purging, hydraulic closing devices, accidental dis

charging from tanks, accidents at the equipment and facilities

In order to reduce the air pollution from the coke plant, strongly affected by theS02 and H2S emissions, is necessary to redesign and realize the coke gasdesulfurization and ammonia striping facilitiesAs these waters are corrosive, and the collecting and transport system for thewaste waters in that area is clogging, there is the danger to affect the grOlmdwater. It is necessary to remake the collection and transport system as for thestonn, sanitary and phenolic waters as for the coke gas condensate collectingsystem.The erection works for the biological treatment facility have been stopped in1990 due to the lack of financial resources. From the same financial reasons, thedesigning, erection, commissioning of the other works mentioned above aredeveloped, creating a potential risk for the sUITOlmding environment.

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APPENDIX II

(PROCESS DETAILS FROM PLANT)

10

•

•

Rl\'1ET S.A. CALAN.T.e. LABORATOARE

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•


APPENDIX III

(EQUIPMENT RECOMMENDED BY CONSULTANT)

11

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•l\

• • Compact 6' or 8' height fits into new orexisting structure

• Effluent polishing usually not required• Settled sludge mechanically thickened

-single discharge port• Capacities from 10 to 3000 gpm• Complete treatment systems available

-modular, shop assembled, low cost

Phone 630-543-9444 • http://www.gle.comFax 630-543-1169 • [email protected]

--...r-;]i GRFAT Il-1KES <2NVIRONM<2NrAL INC.... ""Jl1tRl NM CCMP,l.NY ...

• Waste Water Treafment • Vacuum Filter· Inclined Plate Clarifiers· OilJWater Separators

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Ul I JUv. l'C"clLWQ 111UUyC. d.J1U

temper control covers and rechargeable battery pack for 10hours of power. Sensidyne., Circle 192 on card.

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while maintaining a clean are:or venting a hazardous oneHEMCO. 2

Circle 193 on c rd ri.'

Circle 129 on card.BEST AVAILABLE COpy

APPENDIX IV

(BUSINESS CARDS OF CONTACTS)

12

~M-:

•

•

•~)09)L~_~\}~.Q~ C

l

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log. IVASCU NICOLAEDIRECTOR GENERAL

1

SIDERMETs.a.

2637 -CalanStr. FumaHsMui, or. 17Jud. HunedoRraROMANIA

TeL (54) 730.277730.560730.561730.303

Fax (54) 230.040730.341

Tlx 72.414

SIDERMET S.A. CALANFlU (54) 230.040

730.34JT1x. 72.414

TeL (54) 730.560in.. 102, J03

log. FUHRMANN FRANCISCSEF SECTIE COCSIFICARE

BIIIEIIIIIET,,;s.a.

Co 11.,):>11 (.·-nJ1I7'jAbV1iO't

Eng. MOROSANU VIRGIL&t:i:eratMaflagerc to f.( S I'Lt'6c:--r<

===============::=====================================2637 -CalanStr. J"umalistului, Dr. J7Jud. HunedoardROMANIA

In! Line 54 - 230040T,x 772414

2637 CalanSIr. Furnalistului Nr. 17Tel. 054·730303·18Fax 054-230040

Tel 54 - 730560730277

Fax 54 - 730341

Eng. BIIUA pmQDirector Tehnic Produc~ie

HtslJ IJ (,1= (1 0/11.11Y Ji&:n V/(~(!"

STOICOI MARIANA$EF SERVICIU CALITATE

2637 Calan, judo HunedoaraSIr. Bradului 10/45Tel. 004054·731567

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I '.D, ~ .;;l,s, ,A=, _k)E .i!;tUT

2637- UilanStr Furnaiistulul nr 17Jud HunedoaraRomania

•2637· CALANSir. Furnaliltulul; Nr.17Jud. Hun.doar.ROMANIA

Tel. (54) 730434 Fax: (54) 230040

730560 f'x: 7241 ..730561730303 Home Tel. (54)731078

SIIIEIIIIET5.8.

PROF. PETROl MIRONPUBLIC RELATIONS COUNSELLOR

•2637· CALA.NStr. Furnillillului; Nr 17Jucl. Hun.cloaraROMANIA.

Tel. (54) 730560..130110(Inl.561)

Fax(54) 730341

Inl.Line.: (1) 31231174

TIl( : 72414

HomeTeL: (54) 730953

REST.AVAILABLE COpy


APPENDIX V

(LIST OF MATERIAL FORWARDED TO SIDERMET)

13

•

•

•,

BROCHURES AND OTHER PERTINENT INFORMATION PREVIOUSLY

FORWARDED TO

SIDERMET

1.

2.

3.

4.

5.

6.

•

•

Bethlehem Steel - Waste Management

Coke Oven Door Liner

The Life of Coke Ovens and New Coking Processes Under Development

Coke Oven Exhaust System

Coke Plant Wastewater Biological Treatment Facility

Steelmaking Flow Lines

14

Documents

fN' - pdf.usaid.gov