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HELSINKI COMMISSION

HELCOM LAND 11/2006

Land-based Pollution Group Eleventh Meeting Sopot, Poland, 16-18 May 2006

Agenda Item 3

Information by the Contracting Parties, Observer Organizations and the Secretariat and matters related to cooperation with international organizations

Document code:

3/8

Date:

2.5.2006

Submitted by:

Poland

BACKGROUND DOCUMENT FOR CONSIDERATION OF ENVIRONMENTAL IMPACT OF THE JCP HOT SPOT NO. 88.8 – “PRZYJAZN” COKING PLANT IN DABROWA GORNICZA (KATOWICE)

One of the Polish industrial plants included in the list of hot-spots of Joint Comprehensive Environmental Action Programme is „Przyjazn” coking plant in Dabrowa Gornicza (No. of Hot-Spot: 88.8). The plant is located in the Katowice area in the west-southern part of Poland, in Silesia Province, hundreds kilometres from the Baltic Sea. In 2006, during the yearly investigation of hot-spots located in Poland by Chief Inspectorate for Environmental Protection the case of “Przyjazn” coking plant has been analysed. The investigation revealed very good performance of the plant, which achieves high environmental standards and applies Best Available Techniques with regard to both the process integrated measures and the end-of-pipe techniques. However, we have noticed that despite application of BAT to minimise the emission of particulate matter from coke pushing, which is reflected by >99% efficiency for dust collection, the emission of 5 kg particular matter/t coke, as recommended in Best Available Techniques Reference Document for coke oven plants is not being achieved. According to the plant experts judgement it is neither feasible or cost-efficient to further improve the de-dusting of coke-pushing. The existing technique represents BAT, enabling achieving very low concentration of particular matter about 5,4 mg/m3. Detailed description of the plant performance is presented below.

The Meeting is invited to consider the situation of the Hot Spot and give advice how to assess the plant against criteria for deletion of the Hot Spot from the Hot Spot List.

Note by Secretariat: FOR REASONS OF ECONOMY, THE DELEGATES ARE KINDLY REQUESTED TO BRING THEIR OWN COPIES OF THE DOCUMENTS TO THE MEETING

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HELCOM LAND 11/2006, Document 3/8

Detailed information on the Cokery “Przyjazn� in Dabrowa Gornicza Hot-spot No. 88.8 1. Reason for being the Hot-Spot: The reason for being on the JCP list was the environmental impact of the cokery resulting mainly from excessive emissions of gaseous and particulate pollutant to the air, especially from the coke oven batteries, as well as insufficient treated coking wastewater discharged to receiving water.

The coking plant has been included in the JCP list with the reservation of the completion of the coking batteries modernisation process and improvement of wastewater management.

2. Description of the enterprise and its production: The plant consists of four coking batteries with coke-charging cars, complex of objects to prepare blend of coal, installation for dry coke cooling, coke sorting plant, installation of coal recycling, waste water treatment plant as well as energetic and auxiliary objects. All together complex consists of 250 objects with the purpose of coal processing in the amount of 3.6 mln tonnes per year and coke production in the amount of about 2.5 mln tonnes per year.

The main product is stabilised blast furnace coke with graining: 80-25 mm and 80-30 mm.

The plant produces also nut coke II with graining 40-20 mm, pea coke with graining 40-20 mm, coke breeze and tiny coke with graining 10-0 and 3-0 mm, coke with mean calorific value 30 thousands kJ/kg.

Coke oven gas generated in the coking process is purified and at the same time the byproducts are recovered. The final products are: crude tar, crude benzol, ammonium sulphate, coke-oven gas. Coke-oven gas is applied in a technological process of the coking plant in order to underfire the batteries. It is also sold to the customers and fins application in metallurgical process. Benzol being a mixture of liquid hydrocarbons, mainly benzene, toluene and xylene, is used as a row material for production of e.g. some kinds of fuels or plastics. Crude tar is used in chemical plant as a row material. Ammonium sulphate is reused as a component of fertilisers.

The majority of the produced coke is exported mainly to such consignees as Germany, Czech Republic, Austria, Finland. In Poland the coke are delivered mainly to the iron and steel industry and chemical plants.

Two main production lines are operated in the plant: Department of Coke Production and Department of Coal Derivatives Products.

Table 1. Coke production capacity.

2001

2002

2003

2004

2005

Coke production [Mg]

2 267 315

2 242 219

2 468 709

2 425 601

2 264 989

Dry charge [Mg]

2 946 163

2 916 249

3 229 742

3 149 487

-

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HELCOM LAND 11/2006, Document 3/8

Table 2.Coal derivative products.

Production capacity

2004

2005

Crude tar [Mg]

110 800

100 165

Benzol [Mg]

33 296

31 111

Ammonium sulphate [Mg]

33 435

30 780

Coke-oven gas [1 000 m3]

1 123 751

1 018 426

2. Compliance with relevant HELCOM Recommendation 23/9 2.1.Wastewater Discharges The technological processes used in the cookery aiming at reduction of wastewater discharges are as follows: -

implementation of a system for gas purification from the process of coal coking with the removal of ammonia, hydrogen sulphide, benzol;

-

modernisation of the Department of Coal Products to implement a new method of sulphur removal from the coke-oven gas, catalytic method of ammonia decomposition and sulphur production with Clause method;

-

implementation of modern method of wastewater purification based on the twostage system of biological treatment, allowing to obtain the reduction in such compounds as: nitrate, phenols , cyanides, CID and PAHs emission;

-

implementation of the method allowing to collect, treat and reused the rainwaters.

The automatic methods of process control and monitoring of the wastewater quality allow to fully control the process of wastewater treatment. The plant’s WWTP is equipped with the system enabling to retain the rainwaters and industrial waters with the total capacity of 60 000 m3 and then retreat the waters. The retention system implemented in the WWTP allows proper operation of the plant in case of emergency. Moreover, sludge generated in the biological part of the WWTP is charged into coke ovens together with the coal. The specific discharges and concentration in run-off are presented in the table.

Table 3. Specific discharges values and annual concentrations in effluent in 2005 with comparison to the HELCOM Recommendation 23/9.

Reached by the WWTP

HELCOM requirements

N-tot

9.1 g/t of dry charge

-

COD- Cr

68.3 g/t of dry charge

100 g/t

Suspendable matters

7.9 g/t of dry charge

7 g/t

NH4-N

15 mg/l

25 mg/l

Phenol

0.04 mg/l

0.3 mg/l

CN VOL

0.05 mg/l

0.2 mg/l

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HELCOM LAND 11/2006, Document 3/8

Table 4. Specific discharges [g/Mg of dry charge] and annual concentrations [mg/l] in effluents before the WWTP modernisation.

2001

2002

2003

2004

N-tot

-

-

42

48

COD- Cr

-

107

76

73

Suspendable matters

-

21

19

19

NH4-N

59

73

51

54

Phenol

0.04

0.06

0.05

0.05

CN VOL

0.01

0.02

0.05

0.04

The WWTP performance is well in compliance with the relevant HELCOM Recommendation 23/9, with the exemption of one parameter which is very slightly exceeded. However, the further improvement in the WWTP operation is expected for 2006 due to the completion of the WWTP extension (see the point concerning investments).

Types of treated wastewater and mean wastewater amounts are as follows: -

process water 1 500 m3/day,

-

municipal wastewater 800 m3/day,

-

rainwaters 4 000 m3/day.

The two first groups of wastewater are directed to mechanical-biological WWTP. The rainwaters are treated separately with the use of mechanical-chemical methods. The technology used for wastewater treatment does not allow mixing or diluting of different wastewater, especially treated process waters with the cooling water and rain water with the aim to comply with required values.

2.2. Requirements concerning emissions to the air The following dedusting methods are used in the technological lines of coking plant: - electrofilters (3 pieces), each filter is able to dedust 400 000 m3 of process gas, - fabric filters (12 pieces), each filter is able to dedust 120 000 m3 of process gas, - cyclones (20 pieces), which are able to 162 000 m3 of process gas.

The cokery was the first plant in Poland, which according to HELCOM requirement, implemented the system enabling to avoid the fugitive emission from hard coal cokeries by enclosing the coke pushing operation as well as all transport lines and sorting plants. Dry quenching is used as a low emission coke cooling method, which fully complies with Recommendation 23/9; the coke is cooled in two installation of dry quenching (an installation per two batteries). Dust emission, after de-dusting with fabric filters, in the waste gas from dry quenching is lower then 10 mg/m3 (ndg) and does not exceeds the HELCOM requirements. Filling gases from the hard coal cokeries are reused as fuel gas. The great part of filling gases is directed to the hard coal batteries, after the process of the low pressure

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HELCOM LAND 11/2006, Document 3/8

treatment. Filling gases after high pressure treatment are sold to the external customers or reused as a fuel in the boiler.

The coke before the coke pushing is fully carbonised, according to HELCOM requirements.

Waste gases from the coke oven pushing are captured and directed to the installation of fabric filters. The mean efficiency of filter system is very high - more than 99,5% and this system allows to obtain very low emission - the particular matter concentration of about 5,4 mg/m3 as well as emission value about 0.43 kg/h. However, when expressed as emission factor in [g particulate matter/ kg coke] the value is about 10 and exceeds HELCOOM recommended limit 5. After investigating this situation, one can say that the emission after coke pushing is really low and according to the plant expert judgement its further reduction is not possible. Further extension of installation with new de-dusting sections would be not cost-efficient. The licence for the de-dusting system has been taken out from the Still Concern. Already now each battery is de-dusted by two newly modernised filters. Moreover, the plant emission complies with national requirements. The total emission, including fugitive emission is estimated on the basis of the indicators prepared for the cokery by the Institute of Base Environment Engineering, and further on balanced and reported.

3. Waste management Wastes generated in the coking plant are disposed of in the environmental friendly way.

Firstly, new technologies, minimising the waste amounts are implemented. Wastes, such as tar waste and sludge from WWTP, which are generated in the cokery, are in 80% rendered harmless in the coke batteries by using them as an addition to the coal mixture. A special charging installation is used to add the waste into the coal charge. Moreover, the rest part of the waste is disposed of on the plant’s landfill built with the European standards. Waste which have to be utilised are conveyed to the specialised receivers.

4. Best Available Techniques In the “Przyjazn” coking plant the following process integrated measures and end-of-pipe techniques are applied: •

Process integrated measures:

PI.1 Smooth and undisturbed operation of the coke oven plant PI.2 Maintenance of coke ovens PI.3 Improvement of oven door and frame seals PI.4 Cleaning of oven door and frame seals PI.5 Maintaining free gas flow in the coke oven PI.6 Emission reduction during coke oven firing PI.7 Coke dry quenching (CDQ) •

End-of-pipe techniques:

EP.1 Minimising over charging emission EP.2 Sealing of ascention pipes and charging holes EP.3 Minimising leakage between coke oven chamber and heating chamber

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HELCOM LAND 11/2006, Document 3/8

EP.4 De-dusting of coke oven pushing EP.7 Coke oven gas desulphurisation EP.8 Removing tar (and PAH) from the coal water EP.9 Ammonia stripper EP.10 Gas-tight operation of the gas treatment plant EP.11 Wastewater treatment plant 5. Investments Table. The investments aiming at the reduction of emission to the air within last years No. Investment years Ecological effect 1

Modernisation of 4 filter station

1991- 1993

Decrease in dust emission

2

Built of electrofilters with the aspirator unit

1991- 1993

Decrease in dust emission

3

Modernisation of de-dusting installation on the transport lines

1993-1994

Decrease in dust emission

4

Hermetisation of process of benzol loading to the tank

1992-1993

Decrease in fugitive emission of hydrocarbons (benzene)

5

Hermetisation of technological processes on the benzol unit

1993-1995

Decrease in fugitive emission of hydrocarbons (benzene)

6

Hermetisation of vacuum pomps

1995-1998

Decrease in fugitive emission of benzene

7

Modernisation of the sulfuric acid production line

1995-1999

Limitation of sulfuric acid emission

8

Hermetisiation and automatisation of the coke loading to the cars

1996-1997

Decrease in the dust emission

9

Modernisation of the boiler in the dry quenching installation unit

1997-1998

Decrease in emission to the air

10

Modernisation of the heating elements in waste-heat boilers

1997-1998

Increase in the efficiency of wasteheat boilers unit

11

Set up the monitoring of state of coke batteries

1997-1998

Decrease in emission to the air

12

Modernisation of ceramics in the chamber of dry quenching

1998-2001

Decrease in emission to the air

13

Modernisation of hydraulic seals on the riser tubes in the coke batteries

1998-2001

Decrease in emission to the air

14

Modernisation of ceramics in the coke batteries

2000-2001

Decrease in emission to the air

15

modernisation of electrofilters

2002-2005

Decrease in dust emission

16

Hermetisation of benzol loading unit 2004-2005

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Elimination of the fugitive emission of benzol while loading

HELCOM LAND 11/2006, Document 3/8

Within the years 1992-2001 programme of modernisation of the waste water treatment plant was carried out. The following activities were included in the programme: -

construction of the flotation installation based on the Flootek license,

-

construction of the new sludge cyclone station,

-

modernisation of the biological treatment unit.

In 2005 the further modernisation of WWTP was carried out, including: -

organic compounds removal,

-

nitrogen compounds removal (nitrification and denitrification processes),

-

implementation of the modern system of monitoring and control of the WWTP work.

Total investment expenditure on WWTP is estimated to be about 25 mln PLN (about 6,5 mln EUR).

For the next years the following investments are planned to be realised: -

Construction of a new coke battery with the aim to achieve the same production capacity level during the modernisation of the existing coke batteries.

-

Modernisation of the existing 4 coke batteries.

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