EnvironmentalAssessment/Analysis __
Reports____ ___
Report E0040
China -Liaoning EnvironmentalPro ectEA Category B
Environmental Assessment10 of 12September 1993
This report has been prepared by the Borrower or its Consultant
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JUN 0 S 1994
SZ40FCE:-XP^ECSr OLIXM
* ~ ~.. : ASSE3S S EI REPRT
x -- ArIc PR
* ~(Coal-loiad irag Arid Unloading Proesses
in NO- 31-4 Ovens )
Beijing Environment Assessment Corporation
Oct. 1992 Beijing
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The preparation work of this EA report for " Benxi Smoke-dustImprovement Project ", which deals with the processes of coal-loadiaig and coal-unloading from coke ovens, is main responsiblefor Beijing EA Corporation. The major personnel are to be asfollows:
Chief manager: Wu Zhicheng
Project chief: Mu Taiqin
Technical chief: Zhang yongming
Examiner: Li Zaigong
Editor: Mu Taiqin
The anticipates attended to this work and their qualificationsare listed below:
Nlame Professional position Specialty
Li Zaigong director engineer Environmentalsenior engineer Assessment
Mu Taiqin EP section director Environmentalsenior engineer Chemical
Zhang Yongming senior engineer EnvironmentalEngineering
Li Youliang senior engineer EnvironmentalManagement
CONTENT
1. Introduction
2. Relative policies. standards and management system
3. Proposed project
3.1 Necessity of the proposed project3.2 General3.3 Process3.4 Main process equipment3.5 Investment estimation3.6 Proposed project schedule
4. General environment
4.1 Natural environment4.2 Social and cultural environment
5. Environmental impact analysis
5.1 General of production5.2 Pollutants discharge during coking production5.3 Pollution retardation on effected area5.4 Reducing impacts from local pollution as project
completed5.5 Analysis of environmental benefits5.6 Analysis of social and economic benefits5.7 Conclusion
6. Alterr.atives comparison and analysis
7. Plan for migrating negative impacts on the environment
8. Environmental management and staff training
9. Environmental monitoring and supervisior program'
10. Involvement of Affected Group and tiongovernmientalOrganization
Reference documentary
Annexes
1. Introduction
The city of Benxi, located in the east of Liaoning provinceChina, is one of the main industrial raw material bases in theState and has contributed a great on the Ilational economicdevelopment. But for the past years, the environmentalprotection have been overlooked during the economicdevelopment. Therefore, the air pollution in the city havebecome seriously and the " disappeared city" is named forBenxi due to not being found from the satellite. The heavypollution are not only limiting social and economicdevelopment but threatening public health. So it is initialneed to improve environment quality. In this case, " Seven-year plan for improvement of major pollution resources inBenxi n has been prepared by the Municipality, in which BenxiCoking Factory, one of the heavy pollution resources in thecity, has been included.
Based on the World Bank Project Preparation Mission Memoriafor "Liaoning Environmental Project" and the "ApplicationReport for WB Loan on Benxi Environmental Proposed Project" inDec.10, 1991, the proposed project (smoke-dust improvement ofthe coal-loading & unloading processes for 4 coke ovens inBenxi coking factory), as one of the environmental projects,has been identified by World Bank. Meanwhile, the EA work forthis proposed project is required by WB and Benxi EPB. The WBcommitted Liaoning EPB responsible for the work on theorganization and review EA reports from each proposed project.Beijing EA Corporation, under State Metallurgical Department,was invited to join this the work by Benxi Project Office. TheEA Outline Report of this proposed project has been putforward and sent to Liaoning EPE in Feb. 1992, and itreviewed and approved by experts from di!rerent fie.ds andLiaoning EPB. This EA Report will focus on the detailed andcomprphensive environmental impacts as/after the proposedproject completed. So it was prepared based on the approvedthe Outline. The Final report will be submitted both inEnglish and Chinese versions.
2. Relative Policies, Standards and Manaaement System
2.1 Relative (reference) laws, policies, standards involvedin this report are to be as follows:
1) Chinese Science and Technical Policy Guidebcok--- Technical Policy for Environmental Protection
2) " Environmental Protection Managemezit Regu tionfor New Works n t State EPB 86 No 003 )
3) Air Pollution Controlf1lmprovement Law of P.R..China4) National Atmosphere Quali ty Standard (GB3095-82)5) Requirements of The World Bank Operational Manual
OD 4.00 --- Annex A
2.2 Benxi environmental protection (EP) management/crganization system.: Refer to Table 2.1
1
£~~~~~~~
J b~~~~- -- ---. - - -
FIGURE 1
GEOGRAPHICAL POSITION MAP OF BENXI CITY
PEOPLE'S REPUBLIC )OF CHINA
...................
Table 2.1 Structure of BenxiEnvironmental Protection Management System
Engineering Division; 5
Environ-Plan Division: 6 mental
Depart-Development Section: 6 ment
H B andU e S Management Division: 7B ni n t managers
B i x ae c i f loffice: 7 ofz. i fxp E eachi a P 153 Propagation and Education
1 B Centre: 3 mineit /or
Y ~~~~Science and TechnologySection: 2 fact ory
Personnel Section: 3|
Environmental MonitoringStation: 61
Environmental ScienceInstitute: 29
ISupervision Institute: 24
Production Mine/Mineral EngineeringWorkshops Plant section
3. ProDosed Proiect
3.1 Necessity of the proposed project
Benxi Coking factory is a larger scale complex plant,production coke as main product and with 20 more other by-products. The area of the plant is 49.65 km2 and existingstaff are 2,796. The annual total industrial production valueis 497 million Yuan and 27.09 million Yuan annual net
2
(pclt.nezf.is. The design production capacity is 3.7 million coke
tone per year.
This plant is one of the major pollutl.on '"sources in thecity. During the coking production, smoke-dust with hightemperature disperse from coal-loading & unloading processesof 4 ovens and cause very serious risk to health.
According to statistic data, amount of 3.476 Kg variouspollutants in the discharged dust as one tone coke product.The part of these pollutants are shown as following:
TSP --- 2.407 KgBaP --- 2.789 KgBSO --- 0.876 Kg
The coke production in 1991 was 1.547 million tone, but thepollutants during production discharged upto 4,894 t in total.these pollution dispersed near the ground surface level,spreading in unorganized form and brought a great threat bothfor public environment and the operation workers.
BaP, one of pollutants, is a very strong substance forinducing cancer. It is known that the incidence of cancer ishigher in the coking production field than the other jobs.According to the research study of Beijing medical institutein 1977, the death rate of the coking workers from lung canceris 8.5 times than the people who work in the contrast areas.Benxi Labor Health Research Institute and the Coking Planthave made an extensive investigation at 16 coking plantsspreading over China at period 15 years (during 1971-3985),the conclusion is that the incidence of lung cancer for theworkers who work at the top or side of oven will beintensively higher than the other job, and it is no differencebetween the trend of lung cancer's incidence on the cokingworkers and the distribution of BSO concentration at thecoking operation site. Since that, the Government at eachlevel pay great attention to the issue and published officialdocument (health 87 No 60) in 1987, identifying lung cancer isan occupational disease of the coking worker and shall beprotected.
In addition, the mountains and hills surrounding Benxi make itin a "closed" special environment and the discharged dust(especially the concentration of air pollution) accumulated orincreased instead of easily diffusion.
Therefore, very evidently, during coking production, it is twoprocesses --- coal loading and coal unloading that dischargea large dust have formed the initial, really pollutionresources. So it is necessary to make improvement for existingproduction process in the plant that will bring better airquality for the whole city.
3.2 General
3
This proposed project also have been identified as key EPscheme in State Metallurgical Department and belonged totechnical innovation scheme.
During production, a large of coal/coke dusts and raw gasuncontrolled discharge. In this case, TSP, as carrier, bringcancer-induced substance: BaP and BSO disperse and formingheavy air pollution in the extensive range. So catching andcollecting TSP is the main approach to control BaP, BSOdisperse.
The purpose of this project focus on improving/managementsmoke-dust from processes of coal-loading and unloading at 4coke ovens in order to change existing condition thoroughly.
The dimensions and des2. roducti o forAexisting 4 cokeovens are given in .1
Table 3.1
Oven No No-1| No.2 No.3 NO.4
dimension Ben -- 76 58 -II 58 -Iand type
coupling, down jet
coal-loading holes in 5 3carbonating house
effective capacity in 23 mS 21.6 mecarbonating housebattery U4e!Af oven 60 65
design production/year 800,000 t 900,000 t
3.3 Processes
3.3.1 Coal-aust mprovemen in the Coal-loading Process
Loading coal into the carbonating house is the main processduring coking production. 17.5 - 18 tone coal can be loaded oneach house at one time for the four ovens respectively, theloading takes three minutes and the interim time of eachloading is eight minutes.
At present, the method of gravity coal loading on the larrycar is adopted during coal loading process. This method causesthe coal a quick gravity falling speed, and making the dust inthe oven insufficient time to be exhausted off from the risingmain pipe because the pressure of the oven is very high.Therefore, the mechanical feed method which can control thecoal loading speed will. be adopted and replace the existing
4
one. In addition, the other facilities for dust exhausting,burning devises and purifier shall also be equipped for thedispersed/escaped dust in order to remove/burn BaP, BSO in thecollected dust.
As the coal loading by the mechanical feed method, the ammoniawater spraying with high pressure will be firstly started tomake a negative pressure in the carbonating house. and thenthe_larry car will be waited under the coal loading opening ineach oven. Before the cover of the opening automaticallyopened, the connector on the car and the guide valve on thedust-catching main pipe will be jointed closely and the guidesleeve for coal loading be dropped, also the blower at theground dust collection station started through the controlsystem. The small part of dust caused by the coal in the oventhrough the guide sleeve will be exhausted off into the dustcollection system under the action of a negative pressure byaqua-ammonia spraying, and the most part of the dust will bedrawn off to the burning house, sufficiently burnt through thecoal loading guide sleeve. The electric lighter devise shallbe installed in the guide sleeve and automatically burning asthe dust flow into. The micro-granulated dust shall also bethoroughly burnt. and then the burnt dust will be colleted inthe beg type dust collector for purifying by connector, guidevalve, main pipes and dry cooler. The purified dust (finalemission) can be discharged from chinney through the silencer.The schematic process of this method is shown in Figure 3.3
The advanced features of the above proposed alternative are asfollowPing:
(1) mechanical loading devise on the coal car issuitable for the coal with B-14 % water concentration. Themix. coal loading time is 200, and only less 15 secondsallowance for the small part of dust dispersed/escaped fromthe coal loading opening. The efficiency of catch/collectiondust will be 98 % more.
(2) the concentration will be less 50 mg/m in final emissionafter purifying on the ground level station.
(3) less than 3 g/t BSO in above treated dust by burning andcoal tar absorption as its final emission.
(4) this process/method has been used in other EP improvementprojects which have been undertaken by KP.OPP-KOPPERS CofpS
d Germany, a3.3.2 Coke-dust improvement in the coal-unloading process
After 17.5 hrs. dry carbonating, the coal loaded in thecarbonating house can be changed into coke. The new productedcoke with very high temperature at this time shall be unloadedout from the house through the guide screen, and then fulling
5
into the coal-quenching car. In this process, especially whenthe newly product -- coke pulling out, a large of smoke willbe dispersed/escaped with higher concentration of cokepowder/dust to the air. According to the different type ofovens and production process, it is considered that the amountof coke powder/dust for production one tone coke, in general.is in the range of 0.4 -- 2 Kg.
The proposed alternative for improvement/management thisprocess has been undertaken by Anshan Coking and RefractoryEngineering Design Institute. The proposed proposal of cokepowder/dust catch/collection on the ground level station .isrecommended. The characteristics of the alternative are asfollowing:
(1) attaining some 98 % coke powder/dust catching/collectingrate as coal-unloading process carrying out
(2) less than 50 mg/im concentration in the final emission, aspurifying devise installed on the ground level station used.
_K4; 1zi1ft tis. vrve{es> i osrV iOC-jVc:;7 betA n 6s7hTn.)
(3) better reliabili tor -tne operation, whichvbased onsuccessful experienc$ 4he.: and abroad. s
(4) but, high required consumption foe electric power andproduction cost as well as land occupation.
The schematic process of proposed alternative shows in Figure3.2
In order to collect coke powder/dust in the period ofunloading process, the additional dust catching cover will beadded on the existing coke blocking machine which installed attop of the coke-quenching car, closely sealed both at thesides and the top between the cover and the guide channel.
As the time required to operate coal-unloading at any oven,the coke blocking machine will pick up the oven gate andadjust it to. the right place onto the guide channel.Meanwhile, the exhausting guide valve along the maincollection pipe will be started by the starter so that thedust catching cover and the main pipe can surely be connected.After the coke quenching car stopped at right place, theblowers on the ground station will be operated to exhaust thedust by telescopic signals. For other hand, the coal unloadingoperation will begin with other signals. The dust produced atthis operation will be collected, through the exhaustingcover connector, guide valves, main pipes and cooler, intothe bk-type collection/catching purifierr After purifying, thetreated dust can be emissioned from chimney before thedischarge treatment system (blowers, hydraulic coupler and X~ ilncer). The ash tremainings of the treated dust ,xVI be ^*iafuel,thrclgh the collecting system (scraper conveyor, multi-lifter>);transported to the sintering plant
r6
Figure 3.1Schematic proposed alternative for coal-loading process
oven aqua-ammonia spraying
loading raw coal lo- gas collec- recoveryopening ing openi. tion system workshop
raw gas dry cooler scraper device
dust guide bag type ash discharge pre-painting1sleeve collector valve J conveyor v
burning blower conveyor discharge 1house valve
|connectr silencer | |storage tank pre-paintinglconnector silencer IsIraI I storage tank
guide chimney ash dischargevalve valve
dust guide atmosphere wetting vehiclepipe screwing J removal
The location of the dust collection/catching devises for theoven No.1 and 2 are proposed on the top of No.1 oven. Owning tothe site limitation, devises for oven No.3 and 4, will be'at thesouthwest and south of the No.3 oven respectively.
7
Figure 3.2Schematic proposed alternative for coal-unloading process
Icoke dust from unloadingprocess
dust exhaust dust exhaustcover on the cover on qu- ashguide screen enching car
c connector cooler on scarper1 the pre-dust conveyorcollector
guide valve lifterbag type dustcollector
dust flow storagepipeline I tank
purified wdust |
final . wetting emission ' screwing
(atmosphere) . blower II I ~~~~~~~~disposal
|chimney | | silencer Ietransport
3.4 Main process equipment
3.4.1 Main equipment for the proposed process of coalloading dst- iv4w-oce7* are shown on Table 3.2.
3.4.2 Main equipment for the proposed process of coal-unloading dust +ivp--vm-er are shown on Table 3.4.
8
Table 3.2 Main equipment for the proposed cZrjws .of coalloading =i . iont
No. Name and Specification Quantityset
1 bag type dust collector 920 m2 2
2 dry cooler 2
3 ash, dust powder transportation devise 2
4 pre-painting device 2
5 blower H = 6500 Pa; Q = 3300 m3/h 2
6 speed adjustable hydraulic coupler 2power transfer 250 KW
7 motor N= 250KW 2
8 connection valves and pipe networks 2
9 silencer 2
10 pipeline S = 6, dia.-7500 j 2
11 |metal structure(ladder, platfcr-, bracket)| 2
12 lco-.pressed air systen(inc.drateing device' | 2
1 Icoal r?-eej
Table 3.3
Imported equiprent for proposed coal loading process
1'N. No-enclature Quantity I Remark
1 screwina drive device 4 sets all for
2 oven cover starter and gear motor 4 sets coal-
3 lighter in the burning house 4 sets loaded
4 ~electronic elenents 4 sets van
5 software 2 sets
9
Table 3.4 Main equipment for the proposed r l coal-unloading i n -
No. Name Dimension Quantityset
1 dust exhaust,cover on the coke stainless 2blocking machine steel
2 auto.gate valve & fixed wind pipes 2
3 distinguishing house 2
4 dust cooler T = 80 C 2
5 bag type filter/collector 4500 m2 2
6 centrifugal blower H=5500 Pa 2Q=16800m 2/h
7 hydraulic coupler N=630 KW 2
8 motor N1=630 KW 2
9 ash transportation device 2
10 silencer and exhausting pipe 2
11 metal structures 2
3.5 Investment estimation
The estimated cost of proposed project (both coal-loading andunloading processes improvement) for the four ovens will be58,7907 million Yuan. The detailed costs for each component aresummarized as follows:
Coal-loading process system cost (million Yuan)
civil construction 1.82dust collection device 4.735existing process upgrading 10.35electrical works 0.3imported tech/guip. fee .6.4933
sub-total 23.6983
10
r~~~~~~-
TABLE 3.5 PROJECT PROGRESS CHART
1992 19931 1994. 199S 19966 171 8 9110 111121 23416719101 Z 1 234 5 789 101IZ1 Z3 5 3 6 910If12 23 4
I'MSIDILrTY STUDY
AND RtEVIEW
FOREIGN ~. **
CONSULTANTS r -…T1PRE-QUALIFICATION
FOREIGN BIDDING… W *ICONTRACT SION AND
r,ORI-JCN ES(GN…M,Z"
LOCAL PRELIMUNARY _ 1 - _
CONSTRUCTION -4. * N* I
DESION .
m .CQUIPME-NT MAKINGINSTALLATIONCOMMISSIONINO - ------- …-…
START OPERATION.AND ACCEPT ANCE
…- H…--1
Coal-unloading process system cost (million Yuan)
civil construction 0.85dust collection device 10.021existing process upgrading 1.3electrical works 0.3imported tech/quip. fee 1.443general,drawings transportation 0.27demolish 0.11others 9.2physical contingency 4.8price reservation 6.7984
sub-total G.79e073Cp C47 C
3.6 Proposed project schedule
Task due to
Feasibility study review/assessment Sep. 1992Technical advice by international Dec. 1992consultantQuotation, tendering and contract June. 1993effectivenessPrelimninary design and foreign design Jan. 1994Detailed design for construction Aug. 1994Equipment manufacture and supply June.1995Works installation Aug. 1995Test and commissioning flov. 1995Operation and acceptance Dec. 1995
T1ha detai'led implementation schedule'.eAe given in Table 3.5.
4. General Environment Conditions
4.1 Natural environment
The city of Benxi is located in the east of Liaoning Province,123047' N4, 41'019 E, surrounded by mountains and hills (Dr, -300 r average above sea level). The city proper is actually irthe valley of Taizi river basin with 43.2 km 2 and t1',constructed-area cf the citwy at present is 69 Km,2.
The Coking Factory iS located on the southwest of Benxi.
Benxi aeloncs to the northErn warm te:.-erature zone andcontinental monsoon clinate. East directior. wirid prevai3s int6.is area. but for the Coking factory, the pr-vailing wind issouthwest direction. The annual average wind speed is 2.8r/s,and the annual windless frequency is I2 . The averagetemperature is r. 0 C!o, I 37.3 0 r ri:-.. and -32.3 0 C min.) Becauseof this especial topography, the conditiorn of air diffusion is
13
I.;*.T IT r': *3- ::F7lYT *T-: r('J.!.rJTT:' lN1'PraI. PT* : T
7~~~4
. -. ~ ~ ~ ~ ~ ~ ~ ~ ~ -
|~* 1 / / wrtD10
5L2
r ; / Coke %less aid lebt!
14
not good and also it is very difficult for the pollutedsmoke,dust to be dispersed. This is one of major naturalcharacteristics of the area.
4.2 Social and cultural environment
Benxi Municipality controls four districts and two counties(Pingshan, Hingshan, Xihu and Nanfen districts and Benxi,Huaizhen counties). According the statistic data in 1990, totalpopulation in the urban area is 919,000, including Pingshan320,000, Mingshan 259,000 and Xihu 242,000.
The principal activities of Benxi are heavy industrialproduction of steel & Iron, coal and construction material etc.The total industry production value in 1990 was 4.332 billionYuan, including heavy industry 3.447 billion Yuan which occupied79.57 % of the total.
Education. and culture: 8 universities ( 5 adult colleges), 25polytechnic schools, 145 middle and high schools. All togetheris 702. one museum, three culture relic authorities, onearchaeologic team. seven theaters, eight public libraries andeight culture museums.
public health service: -there are 83 hospitals, three sanitoriumsand nine epidemic protection stations in the city.
The environment monitoring center of Benxi is responsible forthe routine monitoring work of air environment, Taizi riverwater quality and urban noise.
Within the Benxi city, there is no any special religions andpeople customs as well as natural protection area.
5. Environmental ImDact Analysis
5.1 General of production
At present, there are four coke ovens in Benxi factory whichequal to 145.71 million Yuan fixed assets. The main products andits output in 1991 were: coke 1.547 million t, crude tar 65,100t, amine sulphur 17,700 t, benzenes 19,630 t and industrialbenzene 6,350 t.
The production output and its raw material (coal) consumptionfor past years are shown in Table 5.1.
12
Table 5.1
Year
Item 1988 1989 1990 1991
coke production (t) 1591136 1450828 1449341 1546993
coal consumption (t) 2079605 1896500 1900340 2037744
The investigation of resources and components for the rawmaterial - coal used in the coking production have beenundertaken and listed in the Table 5.2.
Four shifts were carried out in the coking operation in 1991.The average operation cycle time (or for each batch) was 18hours 15 minutes and the details for each oven are:
Coke oven No. Average operation cycle time
1 18 hours 21 minutes2 18 hours 22 minutes3 18 hours 09 minutes4 18 hours 09 minutes
The average operation cycle time include: carbonatina time plusoperation time (about 7 minutes of coal loading, unloadina andtrimming operation).
The maintenance period and required time for the 4 ovens in 1991are shown as follows:No.1 and 2: Oct. (6 hours respectively)No.3 and 4: June. (8 hours) and Oct. (7 hrs. 20 min.)
5.2 Pollutants discharge during the coking production
Based on calculation of 170 t/y coke production capacity on theovens No.1 to 4, the pollutants in the dust discharged from theprocesses (loading and unloading) have been analyzed and shownon the Table 5.3.
5.3 Existing pollution on effected area
5.3.1 Existing air pollution in the area of ovens
The investigation of three pollutants in the dust from. theworkina site of the oven area is.summarized in the Table 5.4.
5.3.2 Existing air pollution within the area of the Cokingfactory
The monitoring work have been carried out based on the
13
requirement of Plational Air Environmental Quality Standard,class III (AEQS) and the result ar given in the Table 5.5.
Table 5.2Resources & components for raw coal used in coking production
resources Heilong Railuan Fushun Fushun Shanxiof coal -jiang Hutai Longfeng
type gas plump gas coking coking
Year S % 0.522 1.38 0.52 0.56 0.781988
T 326499 440535 220439 472070 615563
Year S S 0.5 1.47 0.56 0.57 0.791 9 8 9 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _
T 324302 128962 462746 574641 405851
Year S S 0.51 1.45 0.52 0.58 0.801990
T 366766 414274 678420 351564 89316
Year S 0.51 1.62 0.52 0.60 0.911991 __ _ __ _ _ __ _ _ __ _ __ _ _
T 376983 454417 124302| 415700 666342
Note:- S = Sulphur concentration in the coal listed in the table.T = actual consumption tones of the coking production.
Table 5.3 Pcllutants discharged from the coking production
processi TSP- BSO BaP
Kg/t coal .0.454 0.499 0.908 x 10o-coal
loading Kg/h 117.4 129.11 0.235
t/y 1029.1 1131.1 2.06
c Kg/t coal 1.383 f 0.0363 12.816 x 10 coal unl -|| loading Kg/h 357.85 9.39 4.6 x lo.
t/y 31'- .8 82.28 0.0412
total. t/y 416_l.9 .13.38 2.1
£ 14
Table 5.4. Three main pollutants in the dust within the coke ovenareas
pollutant BaP BSO TSP
122.308 iug/11.29 Vg/m3, top of oven I 41.8 mg/mr3I pollutant Im top of 11.67 yg/m° side of oven top of oven
jovenI
Istandard I l 0.15 mg/mr l l
for opera- 0.15 (g/M3 U.S.A. standard ) 10 mg/m3
tion area
exceeded 149 8.6 4.18times 11.13
Table 5.5 Existing air pollution within the area of the Cokingfactory
pollutant J so TSP I dustf all
fconcentration 0.155 mg/M3 1.096 mg/,n j88.65 t/k.2/kronth
{AES, class 3 0.10 mg/.3 o 0.50 mg!./. llO.0 t/k,mz/month:
exceeded times 0 1.55 2.19 j 8.87 l
5.4 Pollution retardation on effected area
The proposed project for the coal loading process is composedof: 1) high pressure aqua-ammonia spraying to the carbonatinghouse -through the rising pipes in ord*:r to mnke the ne~gativepressure in the house to exhaust the dust, and 2) burning thedust collected/exhausted from the coal loading holes by theblowers, and then purifving at the ground level station. It isestimated that the efficiency of thp dust purifying reliabilitycan be reached to about 98 % and the dust concentration in thefinal emission be less than 50 mg/rn3.
The proposed project for the coal unloading process is plannedto install the additional dust catching covers and other devisesconcerned to catch the dust during the unloading op(ratior.throuah the cooler, b#g type collector, and then purification.Based on the results in Feasibility Study, the efficiency of thedust purifyina reliability can be reached to about 95 ' and thedust concentration in the final emission be less than cn mgQ/r.
According to the U.S. statistic data concerned on cokingproduction in 1979, and based on calculation of 1.7 million t/ycoke production , the pollutants in the dust from the two
15
processes of the four ovens before and after the proposedproject completed have been anticipated and shown in the Table5.6.
Table 5.6 Pollutants in final emission after the proposed projectcompleted (four ovens)
I__________ TSP j SO BaPcoal 1 Kg/t coalj 1.1 x 10'3 1.24 x 10-2 2.26 x 10-5 l
loading Kg/h 2.85 3.21 5.8 x 103
t/y 24.93 28.11 0.051
coal Kg/t coall 7.57 x 1io2 1.98 x 10-3 9.9 x 10'7
unloading Kg/h 19.59 0.51 2.56 x 101
t/y 171.68 4.49 0.00224
total tfy 196.56 32.6 0.0513
The comparison of the pollutants from dust emission on the fourovens before and after the proposed project completed are listedon the Table 5.7. .
Table 5.7
Comparison for pollutants in the dust discharge
Item TSP BS0 BaP Total
before project(tfy) 4163.9 1213.4 2.1 5379.4
after project (t/y) 196.6 32.6 0.05 229.2
~Ž~'...utting(t/y) 3967.3 1180.8 2.05 5150.2
rate o 95.3 97.4 97.6 95.7
5.5 Analysis of environmental bene its
.The environmental benefits have es mated after the proposedproject completed and listed to be as follows:
16
Pollutant Amount VL-cvu R Rate of fCt-t4ingt/y ) ( 9 )
T.S.P. 3967.3 95.3BSO 1180.8 97.4BaP 17 97.6
From above environmental assessment, the amount of dust at thefinal emission time will be reduced largely after the proposedproject (coal loading and unloading processes) completed. Inthis case, the pollutants concentration in the final emissioncompared with before will also be fallen away at the leeward andside-wind areas of the working site. Table 5.8 gives thecomparison of three pollutants concentration before and afterthe proposed project operation. According to the data listed inthe table, it can be seen that the better improvement of airquality around/near the ovens can be gained, such as at the areaof 100 m from the oven, BaP concentration will reduce about onetenth as proposed project completed. Therefore, it is obviousthat the benefits of the proposed project is worth and a betterdistribution on the environment.
Table 5.8
Comparison of pollutants distribution at leeward/near oven area
monitoring before project after projectPOint i
BSO BaP TSP BSO BaP 1 TSP
(mg/mi) ,(.g/m.) img/m2) (mg/mi) (pg/ms) ({ng/m¼1)
on top of 0.27 1.5 1.78 0.16 0.88 0.75ovenJ__
sides of 0.175 0;.55 2.28 D.04 0.068 T 0.55oven ________
100 m | 0.08 0.12 0.79 0.012 0.012 0.40
The comprehensive environment impacts brought by proposedproject implementation at different stages have been estimatedand given in Table 5.9. It is seen that nearly no any impactsduring/on the project construction period, and a large ofadvantage/positive effects can be brought with the proposedproject.
17
Table 5.9 Environmental impacts during the proposed projectimplementation
potential effects (construction) effects (after completed)area to bepolluted adverse no positive adverse no positive
air quality
BaP v v
BSO
T.S.P 'Iv
waterresources .
soil v
noise:
eP-site v
c(T-site sf | v |
society:
res identL|vI
r __ _ _ _ _cc 4 _ i lenployment l _ ____-_l
livinghouse __ _ _v j
econory v
5.6 Analysis ofS =cononi. benefits
In Benxi Coking Factory, there are 91,900 people living in thearea where industrial smoke/dust pollution discharged. In thiscase, the public health were and are still affected at thedifferent range. The investigations concerned in the aspect wereundertaken in 1987 and the results are given in the Table 5.10.
From the Table 5.10, it is seen that the lung cancer is on thefirst of the death rate in various cancer in the city of Benxi.
lB
Table 5.10Distribution of main malignant tumors in the city, 1987
Name of total death rate ratio in tNo. in proposition forcancer death (1/1 various order people upon age 40
No. mill-ion) tumors % years
lung 290 34.17 32.08 1 95.17
stomach 164 19.32 18.14 2 96.34
liver 145 17.08 16.04 3 94.48
esopha- 57 6.72 6.31 4 100.00gus
leukae- 34 4.01 3.76 5 44.12mia
intes- 26 3.06 2.88 6 69.23tines
The existing total staff in the factory are 2,769. The deathrate from cancer (1987-1992) have been investigated and listedin the Table 5.11.
From a bev&-ableA bit can be seen that 44 persons died fromcancers in past six years, which equal to 7.3 person /year. sothe death rate of cancer (2.6/1000) is very high and it indicatewhat a serous air pollution is.
As the proposed project completed, it is really true that thelung cancer - occupational disease for the coke worker will bebetter controlled and the workers at the post of cokinaProduction will not only get rid of the dangerous operation atheavy polluted condition which lasted many years, and workingunder the acceptable condition ( complying with State EPstandard), but also free from the twisted mentality and lcng-term depressing in their spirit formed in the past conditionwhich strong cancer-induced substances exist and intruded to thehealth at any time. In return, the improved working conditionwill stimulate the workers more effects for coking production.
In addition, the proposed project will need some nlew emnployeesafter it completed (9 persons for the coal loading process, and11 for unloading). Although small number, it, will indeed settlea part of employment issue and improve their living standard.
19
Table 5.11 Statistics list of cancer death for coking staff inthe factory
time death NJo.from cancer lung cancer occupation
1987 8 2
1988 8 4
1989 7
1990 3 1
1991 10 4
1992 8 3
'total 44 14
Direct and indirect economic benefits after the projectcompleted are estimated as followSs:
The direct benefit: 3,695 t coke and coal powders can berecovered per year, which, based on value of 150 Yuan/t, equalto 554,300 Yuan/year.
The indirect benefit: less incidence rate of cancer can increasefactory's net income. The average production value of one workerin a year is 30,000 Yuan,- if he or she has a disease, this valuewill be zero, and furthermore the medical fees and wage shall bepaid by the factory. Based 10,000 Yuan/year of an illed person,the cost will be up'to 40,000 Yuan.
5.7 Conclusion
1) The proposed project focus on the air pollution formed onmain production processes (coal-loading & unloading). Based on-existing pollution discharge feature that BaP and BS0 absorbedon the TSP, the advanced necessary technology will be adoptedand the most equipment for the proposed project can bemanufactured in the State. The expected environmental benefitswill be gained. (refer to Table 5.12)
2) The direct economic benefit from the coal and coke powdersrecovery will be valued to 554,300 Yuan/y and the indirectbenefit, certainly equal to a large sum of seeable value, willbe from reduced incidence cancer rate by workers/staff on thepost of coking production and operation.
20
Table 5.12 Environmental benefits after project
Item Unit Quantity
TSP amount reduced t/y 3967.34
BSO amount reduced t/y 1180.78
BaP amount reduced t/y 2.05
BaP amount reduced in Benxi 24.2
3) The completion of the proposed project will surely improveexisting heavy polluted production environment within the areaof the factory to meet the Sanitary Requirement and play a greatpole on the whole environment of Benxi city.
So it is not only feasible but necessary to carry out thisproposed project whether from the aspect of environmental,social and economic.
6. Alternatives Comparison And Analysis
6.1 Options for dust collection in coal-loading process
There are three methods for dust control used in the process ofcoal-loading in the world:
(1) spraying high pressure aqua-ammonia or steami into the risingpipe in order to make the negative pressure irn the carbonatinghouse for collecting/catching dust when each loading operation.This methods can reduce 40 % (single pipe) to 80 % (twine pipes;of the dust escape.
(2) with spraying high pressure aqua-ammonia, the exhaust blowerinstalled on the larry_Icar to draw off the dust from the coalloading opening, then burning, washing, purifying in the carbefore the final emission but the effectiveness is not asexpected.
(3) based on (1) process, added ground level station tocollect/catch -burnt dust (ash) after burning on the larry car,and then purifying before the final emission. This method canrealize the best expected efficiency of dust collection andtreatment.
In order to get the best efficiency of collecting dust, and atlast, to meet the requirement of "Discharge Standard (DB21-60-29)" stipulated by Liaoning Province The method (3) abovementioned is chosen (refer to 3.3.1).
21
Two alternatives for the ground level station have been putforward. Both alternatives are composed of 3 components: 1)spraying high pressure aqua-ammonia as coal loading operation toforce the dust flowing from' the loading opening. 2) catch theescaped/dispersed dust from the opening and burnt in the larrycar. 3) collect the burnt dust (ash) to the ground collectionstation for further purifying and then final emission.
Alternative :: cooling dust collection system; that is employingof metal feature, heat radiation and transportation, to reducethe temperature of the collected/catched dust to 1200C at theoutfall, and then catch into the beg collector in whi.ch thefilter material made by cheaper priced polyester blanket. Theefficiency of dust collection/ catch (by weight) can be reachedupto 99.5 %.
Alternative II: air cooling dust collection system; that isusing natural air to reduce smoke/dust temperature to 200°C atthe outfall. Because the temperature is higher than that inalternative I, the special filter material (NOMEX) in the begtype collector shall be adopted. The efficiency of dustcollection/ catch (by weight) also can be reached upto 99.5 %.
Through the comparison of the civil cost, annual powerconsumption, land use, construction period and environmentalbenefit, most parts are the same for the two alternatives butthe filter material. In this aspect, the unit price of filtermaterial (NOMEX) used in alternative II is 10 times expensivethan the general polyester used in alternative I. So thealternative I is chosen and the schematic process is given inFigure 3.1.
6.2 Options for dust collection in coal-unloading process
There are three options for dust control used in the process ofcoal-unloading in the world:
(1) equipped a movable dust collection car. The catch cover onthe car with purifier shall spread above the top of the cokeguide shed and the quenching car. The dust collection car andthe coke blocking machine shall be synchronously moved.
(2) a large dust extracting cover shall be equipped on the cokeb3ocking machine. the catched dust will be sent to the groundlevel station for purifying after collection.
(3) construct a large shed beside the oven and installed thecoke blocking machine and the quenching car. The.dust will beextracted from here to the collecting station.
The third option is not suitable for the expected proposalbecause it need large investment and more land requisition. Sothe comparison only deal with other two alternatives.0
22
_- _- _.. ..- _ ___ . _ .. - _ -. ..... --. ._ . _ . __ ... .... .... .... -... _ -_..... _ ...... .'fl _, .~ .ra...........
Alternative I: dust collection by a movable dust collection carwith the thermal-buoyancy cover; The principle is employing thefeature of dust thermal-buoyancy to catch the rising dust, andthen showering and purifying. But the length at lower part ofthe cover shall be two third longer than the length of thequenching car, and the top of the exhausting pipes shall be 1.5-3 m higher than the top of the oven. The other concernedstructures such as guide rail, clarifier, wastewater tank shallbe constructed and some software, sprayer head (4 sets),fittingswill be imported which equal to 739,000 RBM Yuan. On this costbase, the dust collection rate will be about 90 % and the dustpurifying efficiency will be 92 %.
Alternative II: dust collection at ground level station; installthe additional dust catch cover on the coke blocking machine.The processes for dust cooling, collection, purifying, and finalemission will be operated at the station. and then collectingthe ash (burnt dust), as fuel, transport to the Sintering plantregularly (see 3.3.2). The design ash concentration at theentrance of the station will be 10 g/m3 and the dustconcentration in the final emission can be reached to 50 mg/x3.The schematic process is given in the Figure 3.2.
Through the comparison the civil cost, annual power consumption,land use, environmental benefit, the alternative II is obviouslybetter than Alternative I, especially, on availability, reliabletechnology and no more imported equipment required. So thealternative II is chosen.
So, the dry coolina dust collection system for the coal load-ngprocess improvement and the ground level dust collection(station) system for the coal unloading process is the selectedalternative fcr the proposed project (hereinafter cal2edcomprehensive alternative I). the comparison with the othercomprehensive alternatives are listed in the Table 6.1.
23
Table 6.1 Comparison of comprehensive alternatives
comprehensive comprehensiveName of component alternative I alternative II
total cost of proposed project 59,633,700 53,619,300
inc: foreign cost 2,917,000 3,625,700
amount of total metals 2208 t 1307 t
land occupation 794 hec. 280 hec.
annual electric consumption 5.5 million kwh 2,98 m kwh
construction period 2 year 2 year
cost of coke powder recovery 1782.45 Yuan/t 1759.35 Yuan/t
operation cost 4,205,100 3,614,400
environmental benefits best better
cost for unit dust improvement 292.49 Yuan/ms 261.55 Yuan/m8e.=~~~__ -. 1
annual coal,coke recovery 3695.4 t/y 3275.8 t/y
7. Plan For Miaratincx Neqative Imzacts On The Environment
7.1 Air pollution control(see 3.3.1; 3.3.2)
7.2 Temperature drop in operation area
Within the existing coking operation area, temperature is 41-43OC at top of oven; 36-43°C in the coal larr.y car. and theradiation strength (J/min. cm2) is 8.4-29.3 at top of oven; 3.3-4.2 in the larry car; 20.9-29.3 at the oven opening and 20.9-4.19 on the coke blocking machine.
-JY In order to improve the working condition (above mentioned), itis required to provide necessary facilities: moveableventilation blowers for reducing high temperature and radiation,workers' rest house and the temperature drop devises installedin the larry car and coke blocking machine.
7.3. Noise control
To reduce the noise from the coking production, the silencerswill be equipped on the outfalls of blower.the sound insulatorbe used in the instrumentation house and adding air conditioner.
24
Through these measures, the noise level in the operation areacan be reduced to 85 dB (A) to meet the requirement of NoiseControl Standard.
7.4 Production water nanagement
The water used in process is mainly for blower cooling, throughthe recovery system to collect used cooling water for reusewater supply ( 94.3 % reuse rate). and no water pollution.
7.5 Land-greening within the factory
Planting trees and grass to reduce the effects of dust,radiation and generate more negative oxygen ion bytransportation. The greening cover rate is planned to 15 %within the area of factory.
7.6 Welfare facilities
Making staff recuperate regularly for health and after retiredat the sanatoriums, such as the better places of Beidaihe,Dalian, Xingcheng or Benxi hot spring.Health check for all staff regularly in schedule plan, andeducate health knowledge. and also implement shower system ineach workshop, grant protection cloths, masks, gloves andmedicine etc.
8. Environmental Manaaement And Staff Trainina
8.1 It is recormiended that one director of Benxi Coking Factorybe in charge of the envircnmental manageJer.t. especiallyfor the proposed project. Under his (her) leadership, aEnvironmental Protection Division, and fivze sections willbe set up. The schematic organizaticn structure is shown onthe following:
2)5
Schematic organizations for environmental protection
Director in charge ofEnvironmental Protection
- - . I
EnvironmentalProtection Division
Environmental | EnvironmentalE ducation l [_Management
Environmental 1 [ EnvironmentalLandgreening Engineering
I Environmental|LNoni toringl
The work scape of each section are to be as following:
* Environmental Management section: prepare the environmentalmanagement regulations and protection plan, check the technicalmeasures to be carried out as well as the treatment facilitiesoperation, determining pollution factors, issue the licenses forallowing wastes discharge, collect charges and deal with EPaccidents.
* Environmental Engineering section: organize and coordinate theEP engineering installation and operation, examine and acceptthe routine maintenance of the EV facilities.
* Environmental Monitoring section: responsible for the routineenvironmental quality monitoring within the area under itspower.
* Environmental Landgreening section: responsible forlandgreening within the factory, and manage the routine works.
t Environmental Education section: responsible for the EPpropagation and education to all staff in the factory to raisethe individual EP consciousness.
8.2 Staff training
8.2.1 advice foreign EP consultants to undertake technicalstudy and it is estimated about 168 m/m power.
8.2.2 local technical training lectures to improve staff's
26
operation skill in order to meet the requirements of newproduction processes.
9. Environmental Monitoring And Supervision Proaram
9.1 The Environmental monitoring station of Benxi Coking Factorywill be responsible for the whole environmental monitoring work.
9.1.1. Monitoring content: The pollutants to be monitoredin the factory will be S02, NO, CO, TSP, dustf all and BaP.
9.1.2. Monitoring points: The points for TSP monitoringwill be located on the five places (Jiaoyi, Jiaore, Flowerhouse, Tar workshop and sulphur acid workshop). and alsofive places for dustfall monitoring (Jiaoyi, Recoveryworkshop, Coal storage, EP and administration buildings).
9.1.3 Air monitoring frequency: for S02, N04, CO, TSPmonitoring will be once a month, three days of sampling(morning, noon and afternoon); for BaP once every season,5 days of sampling, (additional random sampling required byproduction); the dustfall sampling on 25th every month,unless permitted, no allowance delay or gc ahead).
9.2 Supervision
The monitoring results shall be quickly sent to the director whoin charge of EP works as well as EP section besides it is to befiled. The response from the above will be given to theproduction adjustment and maintenance sections in order to ieakea quick measures.The EP section w11l analyze the results of each m.onth tc findout relationship between discharge and environmental pollutionas well as pollution factors, then put out suggest-ons to thedirector.
10. Involvement Of Affected Group And NonaovernmentalOrQanization
As the serious environmental pollution exist in Benxi city,especially in the area/near the factory, the public health andliving quality of the people have been endangered. In past 12years, the appeal and reports, even the complain and protesthave been put forward from the vario.us fields. According to thenon-completed statistic data, The com.plain letterc concernedabout environmental pollution have achieved upon 1731, most ofthem focused on local air pollution, the details are shown inTable 10.1.
27
Table 10.1Compliances (letter, visitor) in the past 12 years. Benxi
Year Total No. of Waste Waste Noise OtherCompliance air water
80 96 31 16 48
81 113 41 20 52
82 131 47 23 61
. 83 94 37 16 41
84 163 60 31 72
85 156 45 30 78
. 86 191 81 38 69
87 169 64 30 68
88 - 204 88 28 50
89 205 94 19 65
90 156 78 17 31
91 . * = ,
92 53 24 14 14
Total 1731 690 282 649
* Note: To date no information/data for 1991 to be received yet.
At the Fifth Meeting of the Seventh Municipal People's PoliticalConsultative Conference in 1992, Mr. Zhao Fushen, 185 committeemember, raised the proposal of "continue to strength themanagement of environmental protection control, to achieve adistinct success". It reflected people's strong idea which theair pollution from Benxi Coking factory must be eliminated. Theproposed projects mentioned above is start the process movementto resolve the. whole pollution problem for Benxi environment.
In order to protect the people's rights, the investigation ofthe public attitudes and acceptable degree for this proposedproject have been undertaken within the part of residents whohave living in Benxi city during the project preparation period,the results are given in Table 10.2. From the table, it is seenthat 100 % are favor for this proposed project.
28
Table 10.2Public opinion poll for the proposed project in Coking factoryBe n:.- i
people occupation and professional localS ~~~~~~~~~age-
number tech. cadre teacher worker resi- addre-staff dent ss
Ping-165 18 - 60 30 30 20 50 35 shan
dist.
results favor 30 30 20 50 35of
public against 0 0 0 0 0opinionpoll No 0 0 0 0 0
reaction
percentage (%)of favor 100 100 100 100 100
Reference Documentary
Main Reference. Literature and Information
1) The World Bank Operational Manual OD 4.00 - Annex A,October 1989
2) Memo. of World Bank Mission for China LiaoningEnvironmental Protection Project Preparation
3) Policy Directive for China Science and Technology -Technical Policy for Environmental Protection
4) Ervironmental Quality Annual Report of Benxi (1991)5) China Big Encyclopedia6) Environmental Protection Standards Manual7) Feasibility Study Report for Benxi smoke-dust improvement
project (coal-loading and unloading processes in oven No.1- 4)
29
Annexes
Attached Table 1 Air Quality Standard (GB3095-82)
N&me concentration limited level mg/normal m3of _ _ _ _
Pollutant sampling time 1I class III class
daily average 0.30 0.50T.S.P
randomn once 1.00 1.50
annual daily 0.06 0.10average
S02 daily average 0.15 0.25
random once 0.50 0.70
daily average 0.10 0.15NOx
random once 0.15 0.30
daily average 4.00 6.00co
random once 10.00 20.00
30
