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Avdeevskiy coke - processing works

ACPW today

       The construction of the Works lasted for 20 years, while the general layout having been significantly changed. In 1993 the Works turned into Open Joint Stock Company "Avdeevskiy Coke-processing Works" according to the decision of Ukrainian Government. In 1996 the shareholders of ACPW approved the organization and technical upgrade program aimed at Works steady operation and technical-economic indices significant improvement.

        The program included not only reconstruction and modernization of manufacturing facilities but also upgrade of inner Works' management system and presupposed further development of repair and auxiliary shops of ACPW. Four new special repair shops, communication and technology automation shop were founded within the frames of this program. At the present moment ACPW comprises nine coke oven batteries designed by GIPROKOKS with PVR system and bottom gas heating, gas exhausting system, the overall annual design output amounting to 6870 thousand tpy. Four coke oven batteries comprising 77 coke ovens each are 5 meters high whose coke oven volume is equal to 30 m3; two coke oven batteries comprise 65 coke ovens each are 5,5 meters high with coke oven volume amounting to 30,3 m3 whose overall annual output is 690 thousand tpy; three coke oven batteries comprise 65 coke ovens each with 7 meters height, whose coke oven volume amounts to 41,3-41,6 м3 and total annual output capacity amounts to 910 thousand tpy per each. All the coke oven batteries are equipped with Dry Quenching Plants where approximately 60% of coke manufactured at the Works is processed, also six coke oven batteries are equipped with Wet Quenching Plants.

        The core strategy of the Works steady operation caused the constant productivity and employees' salary increase, enhancement of technical-economic and financial indices of ACPW.

        Today the industrial giant ACPW comprises: - territory over 340 hectares; - 84 km of inner Works' railroads; - over 15 km of inner and 30 km of outer automobile roads; -13 basic and 30 auxiliary shops and service structural departments; - ACPW is a leading manufacturer of over 30 commercial products, this amounting to 25% of overall annual output manufactured in Ukraine; - the Works is a warrantor of social stability protection for 7 300 employees. - the Works offers best-in-class communal-general services to citizens of Avdeevka.

Industrial Innovations

        Since the very commissioning of ACPW its most peculiar trend is appliance of the advanced sophisticated technical decisions in all the design projects for Basic and Detail Engineering. During the previous decade the employees of the Works offered over 3 thousand design innovation projects, 26 technical upgrade proposals 15 of which were successfully implemented at the Works.

        Avdeevskiy Coke-processing Works was many times chosen the scientific testing center for implementation of the new invented chemical technological processes' enhancement. For example, the Works was the first to have implemented the most sophisticated technology of two-stage gas primary cooling, ammonia sulfate manufacturing without saturators, distant gas transportation technology, the manufacturing of phthalic anhydride and enriched anthracene from coke raw materials (naphthalene and raw anthracene).

        The coke oven batteries No. 1,2,3 were commissioned after the reconstruction.

        The most peculiar feature of these coke oven batteries is the appliance of door extracting machines with dedusting hoods, due to which it became possible to two times decrease the gas emission during coke pushing process. Special entrainment traps were installed to exclude the gas emissions. To totally avoid gas evacuation the specially designed gas-tight covers of standpipes and flares are used on the battery top. The improved design of the coke oven battery refractory lining and gas heating system allowed to 90% decrease the gas evacuation from doors, to significantly enhance the refractory lining life and to improve the working conditions for the workers.

       ACPW was the first in Ukraine to construct covered warehouses comprising 32 silo hoppers with 2,5 thousand tons capacity each to store coal. The automatic dosing modules, pneumatic coal hulling system installed at the warehouses ensured them to be applied as weighing system. Three special defrosting garages were constructed to accelerate coal discharging from cargoes in winter.

       In September 1998 two flotation tailings settling and concentrate non-moistering plants made by "Allied Colloids Manufacturing GMbH" (Germany) were commissioned. In April 2003 we commissioned coarsegrained slum enrichment plant with hydrosizers made by "Gramtech Associates LTD" (England).

        Blast furnace coke, coke nut, coke breeze, raw benzol, ammonia sulphate, phthalic anhydride, pitch coke, coal-tar oils are exported to domestic and overseas market segments we serve: Russia, Belorus, Moldova, Giorgia, Turkey, Poland, Chechia and Slovakia, Romania, Iran etc. The commercial products manufactured by ACPW amount to the tenth part of the overall export volume confirming the best-in-class quality.

Environment protection

        The recycling of wastes has been always within the scope of the Works' most profound attention. The specialists of the Works found new technical solutions to recycle the chemical wastes in the technological process of ACPW. They are applied for the production of road cementitious additive and additives for cement and concrete. The floatation tailings are enriched and used as additives for charge.

       The problem of dust exhaustion being the third part of all the emission Works' volume is under the thorough control by ACPW's management. The sample industrial small-size flat bag filter, the first ever applied in the coke processing segment has been recently commissioned in coke-processing shop No. 4 at ACPW. This filter ensures the high efficiency of dust exhaustion. The positive effect of this filter appliance gave us ground to conclude the contract with Ukrainian Scientific center of Technical ecology for design and construction of industrial dust exhausting plants to be installed at coke-sorting mill No. 4 which is the largest fume and dust evacuating source. The installation of this plant will allow to decrease the dust emissions by 3 thousand tons/hour.

        The water mechanical purification was commissioned at non-site clearing plants, the aerated purified water is directed to storage pond thus effecting the sewage purification by 25%. Due to the appliance of purified sewage for recycling the Works managed to decrease the consumption of raw water by 3 times.

       The appliance of secondary heat generating the steam with the same technical specifications as steam generated by power boilers of heat Power Plant has caused the generation of steam in excess. Now the Works generates over 50 MWt/year meeting all the needs of ACPW while the excess is transferred to "Donbasenergo" Company to be used for the needs of the region.

       Having passed the main entrance of the Works it's hard not noticing the large pigeonloft and picturesque animal department where various animals and birds feel themselves at home - such as pheasants, peacocks, parrots and other exotic birds. The birds are the so called barometer stridly reflecting the real ecological conditions of the Works' operation.

        Some years ago it was hard to believe that the green grass can grow near the coke-processing and desulphurization shops. Now everybody has accustomed to see the green lawns with trees and bushes. Practically each shop territory abounds in flower-beds


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