ABSTRACT THE TABLE OF CONTENTS Intriduction 1. Literature review on the topic of master's work 2. Analysis of structural and technological scheme of "Yenakiieve Iron and Steel Works" as a source of waste generation and emission of pollutants 3. Evaluation of the implementation of the company environmental program 4. Technical and technological solutions to reduce the negative impact of "Yenakiieve Iron and Steel Works" Summary References Intriduction Yenakiieve Iron and Steel Works is one of the oldest industrial assets of Ukraine. It produces iron back in 1897. JSC "Yenakiieve Iron and Steel Works" manufactures various billets and mills, that comply with the requirements of world standards. It's a fully integrated pig iron, agglomerate and end-product producer. Now YENAKIIEVE STEEL produces abt. 7% of national total iron output. The plant "productes" many different pollutants, which enter to atmosphere and water, like any metallurgical factories. And also it is a "producer" of large waste such as sludge and slag of blast furnace and BOF, the waste of molding sands, scrap and ferrous metals. Relevance is determined by the integrated approach to reduce the negative impact of YENAKIIEVE STEEL on the environment. The aim of research is the analysis of the enterprise and the development of technical and technological solutions to the most pressing environmental problems connected with the works. Scientific contribution is to amend the existing technological schemes of a number of subdivisions of YENAKIIEVE IRON AND STEEL WORKS (sinter plant, water treatment systems) that reduce the amount of pollution and to introduce energy saving technologies, as well as optimization of existing methods of waste management. Goals and objectives 1. Study of metallurgical factories in Ukraine and in the world as a source of waste generation and discharge of pollutants; as well as experience with them to reduce environmental risks. 2.Study of existing technology with the establishment of places of waste and discharge of pollutants, identifying the most problematic points in terms of impact on the environment. 3. To offer technology solutions and measures to reduce the possible negative effects of the plant's work (with the world experiense as a base): – modernization of the technological scheme for the sinter plant to reduce dust emissions into the air; – development of water treatment process scheme with the possibility of impaired water quality; – technical solutions for the optimization of systems for solid waste and sludge; – development and implementation of environmental management system as an instrument of improving the environmental performance of plant. 1. Literature review on the topic of master's work Metallurgical industry of Ukraine in terms of production is the seventh largest in the world. The development of attractive pricing environment for foreign steel markets promotes this situation. Industrial potential of the mining and metallurgical complex of Ukraine in recent years is a foundation element of economy.Mining and smelting complex is the major contributor to the budget, providing more than 40% of the proceeds of currency. Part of the gross domestic product is more thans 30% [1]. Today there are three main metal smelting technologies: blast furnace, BOF-technology and metal smelting in electric furnaces. Currently, more than half of the world's metal melted in converters [2]. The basic of process is oxidant treatment of raw materials with no additional heat input from the outside. The difference in the charge material, requirements for the final product led to the large number of varieties of BOF's process. For example, depending on the gas raw materials there are next types of smelting: in air, oxygen and mixed blast. By way of gas supplies are three groups of methods - from the top (through a water-cooled lance), with the bottom through the bottom (with the help of special devices) and with combined blowing (simultaneous gases supplies from the top and bottom). The most effective method for metal's pouring is billet conticaster (BC), which receives pre-alloyed and refined product. Getting assortment is carried out in rolling mills. In addition to the main process chain companies of metallurgical industry include additional departments for making the necessary raw materials (production of lime, preparing molding compounds) and energy (TEP-SAS). In the field of environmental management is illustrative of metallurgical enterprises of several countries of Western Europe, for example, in Finland. A leading manufacturer of metal in this country is considered to be the corporation Ruukki, which owns several plants in the south-western Finland, and the largest metallurgical plant in Raahe in the north. The company is located near the center of a small town with a population of 22.4 thousand people in the international sea port. The best illustration of a high level of ecological safety of manufacturing is the juxtaposition of industrial sites combine housing and social infrastructure (clubs, restaurants). This example is not an isolated incident, but a widespread practice in most European Steel Works [3]. Directions of development of metallurgical industry is the use of recycled material and energy resources [4,5], switching to energy-saving technologies for the reason to the lack of quality of traditional raw materials, a substantial rise in energy prices, environmental concerns regional perspective. For the majority of metallurgical enterprises in Russia and Ukraine the most significant environmental problems (requiring urgent solutions) are related to the operation of obsolete equipment and tecnological theme of process, failure technical requirements and modes of operation of equipment, raw materials and non-conformity of normative and technical documents. As noted in [3, 6] is faced with problems of reduce the amount of gas and dust emissions sintering, the decrease in water intake, slags and sludge utilization . 2. Analysis of structural and technological scheme of "Yenakiieve Iron and Steel Works" as a source of waste generation and emission of pollutants The company has a complete production cycle, from making the sinter production and befor rolled products of various grades of steel. Figure 2.1 shows the general scheme of "YISW". The Company manufactures conticast billet being one of the world leaders in the field, as well as various long products (beams, channels, angles bars, etc) of carbon, structural, and low-carbon and low-alloyed steel grades. Figure 2.1 – Structural and technological scheme of "Yenakiieve Iron and Steel Works" The production facilities of Yenakiieve Steel consist of three blast furnaces, BOF steelmaking plant (three BOF’s, two ladle furnaces, each with a six-strand billet conticaster) and four rolling mills. In conjunction with the production process of "Yenakiieve Iron and Steel Works" is set LLC "Metalen". In the process of sintering a composition of fine-grained ores and concentrates, metallurgical wastes from pulverized solid fuel it produced agglomerate. The main departure is the dust emissions from raw material storage, the waste of handling, crushing raw material, sludge lime and solid fuels, carbon dioxide, sulfur dioxide and nitrogen oxides. On average, the sinter produced about 12 000 tonnes/year of various waste of dust and about 45 tons/year of sludge. Currently, the process flow as dust collectors provides battery cyclones, but this system does not provide the required degree of purification. Sinter charge (a composition of sinter, fluxes and fuel) and various additives (converter and weld slag, scrap, metal shavings and the like) is sent to the blast furnace. The temperature in the furnace is about (1900 – 2050) °C. It's regulating the supply of combined blast. As a result of recovery and oxidation processes formed iron, slag and blast furnace gas. The gas contain carbon dioxide, nitrogen oxides and sulfur oxides, particulate matter. His temperature should not exceed 1500 °C. The slags is supplied to the department of slag utilization. Also when cleaning the top gas it's formed iron sludge sent to sludge. The blast furnace includes the following subsidiary objects: the three filling machines and office preparation of mortar, making separation of refractory masses, office cleaning pig iron ladles; site relining pig iron ladles. The end product is a liquid steelmaking iron for the BOF's department, and the filling machines - iron trade. Further technological chain includes processing of iron. In BOFs melted boiling, quiet and low-alloy steel. System traffic BOF's consists of the following lines: delivery and pouring molten iron, scrap supply and load, feed, feeding and loading of bulk slag-forming materials, the oxygen supply, dosing and delivery of ferroalloys in the ladle, the reception, transportation and casting of steel; slag removal. Liquid iron from storage tanks (mixers), scrap, ferroalloys and deoxidizers, alyumokremnievy flux fed into a BOF. The downloaded material is purged of oxygen purity of at least 99.5%. After purging download slag and metal is sent to furnace treatment in ladle furnaces and later in continuous casting machines. Low heat, depending on the steel in the range (1535 – 1575) °C. The biggest waste generated in the BOF are slags and sludges. In recent years, an average of about 70% of them recycled at the works, the rest is stored on the slag heaps and sludge. In addition, the BOF produced the following waste: scrap refractories, ferroalloys and slag's dust, gas treatment of ladle furnaces, used molds. The resulting ingots are sent to the Rolling Mill to get rolling. The lagest waste of this stage is to scrap and ferrous metal scraps, scale. Process water supply is organized by the reverse pattern. Currently, the plant operated by six local cycles of water recycling and one offsite cycle through the cooling pond. Fresh water is supplied to the technical to compensate for losses in the systems of water recycling. In addition to his own use, the company partially transmits the resource subsubscriber. The total deadweight loss in water supply systems of the factory 1233.5 m3. Currently, compensation is due to channel resources Donets-Donbass and Volyntsevskogo reservoir. One of the most effective ways to reduce water consumption and better use of natural resources is a departure from the existing water treatment system according to the scheme of lime-lighting, filtration, two-stage Na-cation exchange. 3. Evaluation of the implementation of the company environmental program Currently, the company has a "Program of Environmental Action JSC "Yenakiieve Iron and Steel Works" in 2008 – 2015 years." (Hereinafter – the Program). The most significant project to help reduce air emissions is the construction of a new sinter plant, which will significantly reduce dust emissions, besides the installation of filtration equipment effectively at all stages of production. In line with impact assessment of the plant facilities on the environment, the risk of environmental impact, the technical condition of equipment, regulations and guidelines controlling environmental organizations, the program outlines measures to protect surface water and groundwater in key areas: waste water discharged into water bodies; reuse of treated wastewater into recycled water supply systems, development of local water recycling systems, the introduction of advanced methods of water purification systems, local water recycling, reduction of anthropogenic impact on groundwater and surface water, control of exposure. One of the primary tasks of the enterprise is to maximize recycling, and reducing their number at the sites for the storage reserves are almost exhausted. In this regard, developed effective technology utilization and waste disposal. Also being sought markets as secondary raw materials. The implementation of several activities of the Programme has been delayed because of the economic crisis in previos years. Every environmental action (activity) is considered under the scheme (Fig. 3.1): Рисунок 3.1 – The general scheme of environmental activities Now most capital-intensive projects (construction of a new sinter plant, upgrading of water recycling and water treatment systems, end repair slurry tank) just enter a period of development. However, despite the time shift timing of events, the plant's management plan to carry out all planned Programme of action to reduce the negative impact on the enterprise environment. 4. Technical and technological solutions to reduce the negative impact of "Yenakiieve Iron and Steel Works" As noted earlier, one of the most problematic sites of the "Yenakiieve Iron and Steel Works" from an environmental point of view is the sinter plant, emitted into the atmosphere huge amounts of dust, which is not only an air pollutant, but also contains valuable components to be recycled at the plant. By 2015, the planned construction of a new sinter plant with the introduction of new filter systems. At the metallurgical enterprises of Ukraine and neighboring countries have a positive experience introducing new technologies. Thus, in Ilyich Iron and Steel Works electric filter is successfully, and in Dnepropetrovsk and in the JSC "Chusovsky Iron and Steel Works" embedded system with bag filters for cleaning gases [7]. In the master's work by the development of the technological scheme, which includes one of this methods. In addition, the development is planned to replace the existing newer models of exhauster. Another pressing problem is the large intake of fresh water due to the obsolescence of equipment and processes, the imperfection of his control. In [8-10] discussed the possibility of using water quality impaired for drinking and industrial water. Studies [8, 9] allow us to talk about whether the transfer of water treatment system on a new raw material – water closed the mine shaft "Red October". It should be noted that this event requires a reorganization of technology with the introduction of a new wastewater treatment system. In the master's work highlights two possible workarounds: use of reverse osmosis or ion exchange counter equipment. Examples of technical design of these systems are shown in Fig. 4.1., 4.2. Рисунок 4.1 – High-performance industrial reverse osmosis system Рисунок 4.2 – Countercurrent desalting plant water Sredneuralskaya WPP On the basis of theoretical research carried out is selected and the optimal technological solution is developed on the basis of its modernized system of water treatment company. Most of the waste of «Yenakiieve Iron and Steel Works» being recycled production that is recycled at the Works. Not found solutions to the full use of metallurgical slag, spent molding sand, and some other (scrap refractories, refractory waste mass). One of the objectives of the search for ways to put optimizing waste management systems. Effective element of environmental management of any enterprise is an environmental management system (EMS). The basis of EMS is the international standard ISO 14001:2004 «Environmental Management System. Requirements and application guide». Operation of the system is aimed at identifying environmental aspects. Aspect - element of the activities or products, or services to the organization that can interact with the environment. With such a large scale production of both "Yenakiieve Iron and Steel Works" is no doubt the extent of its impact on all elements of natural systems. Currently, the company has not been certified according to international standard ISO 14001:2004. Harmonization of standards with EU norms enterprise – another step to enhance competitiveness in the global market. Summary So, it should be noted that the current state of "Yenakiieve Iron and Steel Works" requires solving a large number of environmental problems. Considered in this paper are the most relevant questions and require immediate solutions. Most of the complex activities required - long-term perspective. P> Implementation of the proposed technical and technological methods will significantly reduce the negative impact of the plant on the environment, and further implement and its recovery. 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Final completion: December 2011. Full text and materials on the topic can be obtained from the author or his scientific supervisor after this date.