China - Liaoning Environmental Project : environmental assessment (Vol. 10 of 12) : Report on EI : Benxi smoke-dust improvement project coal loading & unloading processes in no. 1-4 ovens

Environmental p Assessment/Analysis Reports , Report E0040 China - Liaoning Environmental Project EA Category B Environmental Assessment 10 of 12 September 1993 This report has been prepared by the Borrower or its Consultant J U N 0 9 1994 ENVIRROWW.AI. ASSES SMERY REPORT FOR BNK SMKE-DST IMPROVM2Y PRCOEC"r (Coal-loiadingz Arid Unloading Processes in No. 1-4 Ovens) Beijing Environment Assessment Corporation Oct. 1992 Beijing -Lik Jis w -ý 14 ig ,fE BP in6 ENVIR?.OFTEMTAL ITE!rACT ASSESMEMIT CERTTFICATE (sued ) ;cv .- 目目b日目Uー一協り，……戸’・一J一月圏口n園柳酬門P口h戸り甲甲ず一卼ー”&&-&..&&&.&’・い‘・…－&．』州．．・→一り→ーーーーー→■ (.1か・’1((1-1,1! 測コい油 盗 &，肝 The preparation work of this EA report f or " Benxi Smoke-dust Improvement Project ", which deals with the processes of coal- loadimg and coal-unloading from coke ovens, is main responsible for Beijing EA Corporation. The major personnel are to be as follows: Chief manager: Wu Zhicheng Project chief: Hu Taiqin Technical chief: Zhang yongming Examiner: Li Zaigong Editor: Hu Taiqin The anticipates attended to this work and their qualifications are listed below: Name Professional position Specialty Li Zaigong director engineer Environmental senior engineer Assessment Mu Taiqin EF section director Environmental senior engineer Chemical Zhang Yongming senior engineer Environmental Engineering Li Youliang senior engineer Environmental Management CONTENT 1. Introduction 2. Relative policies, standardr and management system 3. Proposed project 3.1 Necessi'ty of the proposed project 3.2 General 3.3 Process 3.4 Main process equipment 3.5 Investment estimation 3.6 Proposed project schedule 4. General environment 4.1 Natural environment 4.2 Social and cultural environment 5. Environmental impact analysis 5.1 General of production 5.2 Pollutants discharge during coking production 5.3 Pollution retardation on effected area 5.4 Reducing impacts from local pollution as project completed 5.5 Analysis of environmental benefits 5.6 Analysis of social and economic benefits 5.7 Conclusion 6. Alterratives comparison and analysis 7. Plan for migrating negative impacts on the environment 8. Environmental management and staff training 9. Environmental monitoring and supervisior prograir 10. Involvement of Affected Group and Nongovernmental Organization Reference documentary Annexes 1. Introduction The city of Benxi, located in the east of Liaoning province China, is one of the main industrial raw material baseg in the State and has contributed a great on the National economic development. But for the past years, the environmental Protection have been overlooked during the economic development. Therefore, the air pollution in the city have become seriously and the " disappeared city" is named for- Benxi due to not being found from the satellite. The heavy pollution are not only limiting social and economic development but threatening public health. So it is initial need to improve environment quality. In this case, " Seven- year plan for improvement of major pollution resources in Benxi " has been prepared by the Municipality, in which Benxi Coking Factory, one of the heavy pollution resources in the city, has been included. Based on the World Bank Project Preparation Mission Memoria for "Liaoning Environmental Project" and the "Application Report for WB Loan on Benxi Environmental Proposed Project" in Dec.10, 1991, the proposed project (smoke-dust improvement of the coal-loading & unloading processes for 4 coke ovens in Benxi coking factory), as one of the environmental projects, has been identified by World Bank. Meanwhile, the EA work for this proposed project is required by WB and Benxi EPB. The WB committed Liaoning EPB responsible for the work on the organization 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. The EA Outline Report of this proposed project has been put forward and sent to Liaoning EPS in Feb. 1992, and it reviewed and approved by experts from different fields and Liaoning EPB. This EA Report will focus on the detailed and comprehensive environmental impacts as/after the proposed project completed. So it was prepared based on the approved the Outline. The final report will be submitted both in English and Chinese -versions. 2. Relative Policies. Standards and Manaaement System 2.1 Relative (reference) laws, policies, standards involved in this report are to be as follows: 1) Chinese Science and Technical Policy Guidebook --- Technical Policy for Environmental Protection 2) " Environmental Protection Management Regu' tion for New Works " ( State EPB 86 No 003 ) 3) Air Pollution Control/Improvement Law of P.R.China 4) National Atmosphere Quality 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 .._.__._--.FIGURE 1 GEOGRAPHICAL POSITION MAP OF BENXI CITY PEOPLE'S REPUBLIC OF CHINA Igl file ./5 Table 2.1 Structure of Benxi Environmental Protection Management System Engineering Division: 5 Environ- Plan Division: 6 mental Depart- Development Section: 6 ment M B and u e S - Management Division: 7 n n t managers B i x a e c i f . office: 7 of L. i f I xp E each i a P 153 Propagation and Education 1 B Centre: 3 mine i t and/or 7 Science and Technology - Section: 2 -yfactory ---Personnel Section: 3 Environmental Monitoring ---Station: 61 -E:dvironmental Science ---Institute: 29 ----Supervision institute: 24 Production Mne/Minera Engineering Workshops Plant section 3. Proposed Proict 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 existing staff are 2,796. The annual total industrial production value is 497 million Yuan and 27.09 million Yuan annual net 2 =4-its. The design production capacity is 3.7 million coke tone per year. This plant is one of the major pollut.on '"sources in the city. During the coking production, smoke-dust with high temperature disperse from coal-loading & unloading processes of 4 ovens and cause very serious risk to health. According to statistic data, amount of 3.476 Kg various pollutants in the discharged dust as one tone coke product. The part of these pollutants are shown as following: TSP --- 2.407 Kg BaP --- 2.789 Kg BSO --- 0.876 Kg The coke production in 1991 was 1.547 million tone, but the pollutants 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 both for public environment and the operation workers. BaP, one of pollutants, is a very strong substance for inducing cancer. It is known that the incidence of cancer is higher in the coking production field than the other jobs. According to the research study of Beijing medical institute in 1977, the death rate of the coking workers from lung cancer is 8.5 times than the people who work in the contrast areas. Benxi Labor Health Research Institute and the Coking Plant have made an extensive investigation at 16 coking plants spreading over China at period 15 years (during 1971-3985), the conclusion is that the incidence of lung cancer for the workers who work at the top or side of oven will be intensively higher than the other job, and it is no difference between the trend of lung cancer's incidence on the coking workers and the distribution of BSO concentration at the coking operation site. Since that, the Government at each level pay great attention to the issue and published official document (health 87 No 60) in 1987, identifying lung cancer is an occupational disease of the coking worker and shall be protected. In addition, the mountains and hills surrounding Benxi make it in a "closed" special environment and the discharged dust (especially the concentration of air pollution) accumulated or increased instead of easily diffusion. Therefore, very evidently, during coking production, it is two processes --- coal loading and coal unloading that discharge a large dust have formed the initial, really pollution resources. So it is necessary to make improvement for existing production process in the plant that will bring better air quality for the whole city. 3.2 General 3 This proposed project also have been identified as key EP scheme in State Metallurgical Department and belonged to technical innovation scheme. During production, a large of coal/coke dusts and raw gas uncontrolled discharge. In this case, TSP, as carrier, bring cancer-induced substance: BaP and BSO disperse and forming heavy air pollution in the extensive range. So catching and collecting TSP is the main approach to control BaP, BSO disperse. The purpose of this project focus on improving/management smoke-dust from processes of coal-loading and unloading at 4 coke ovens in order to change existing condition thoroughly. The dimensions and design productionkAfor,existing 4 coke ovens are given in TaBt .1 Table 3.1 . Oven No No.1 No..3 NO.4 dimension Ben -- 76 58 -II 58 -I and type coupling, down jet coal-loading holes in 5 3 carbonating house effective capacity in 23 m3 21.6 mm carbonating house battery Moe ±f oven 60 65 design production/year 800,000 t 900,000 t 3.3 Processes 3.3.1 Coal-ustaprovemen in the Coal-loading Process Loading coal into the carbonating house is the main process during coking production. 17.5 - 18 tone coal can be loaded on each house at one time for the four ovens respectively, the loading takes three minutes and the interim time of each loading is eight minutes. At present, the method of gravity coal loading on the larry car is adopted during coal loading process. This method causes the coal a quick gravity falling speed, and making the dust in the oven insufficient time to be exhausted off from the rising main pipe because the pressure of the oven is very high. Therefore, the mechanical feed method which can control the coal loading speed will. be adopted and replace the existing d one. In addition, the other facilities for dust exhausting, burning devises and purifier shall also be equipped for the dispersed/escaped dust in order to remove/burn BaP, BSO in the collected dust. As the coal loading by the mechanical feed method, the ammonia water spraying with high pressure will be firstly started to make a negative pressure in the carbonating house. and then the.larry car will be waited under the coal loading opening in each oven. Before the cover of the opening automatically opened, the connector on the car and the guide valve on the dust-catching main pipe will be jointed closely and the guide sleeve for coal loading be dropped, also the blower at the ground dust collection station started through the control system. The small part of dust caused by the coal in the oven through the guide sleeve will be exhausted off into the dust collection system under the action of a negative pressure by aqua-ammonia spraying, and the most part of the dust will be drawn off to the burning house, sufficiently burnt through the coal loading guide sleeve. The electric lighter devise shall *be installed in the guide sleeve and automatically burning as the dust flow into. The micro-granulated dust shall also be thoroughly burnt. and then the burnt dust will be collected in the beg type dust collector for purifying by connector, guide valve, main pipes and dry cooler. The purified dust (final emission) can be discharged from chimney through the silencer. The schematic process of this method is shown in Figure 3.3 The advanced features of the above proposed alternative are as following: (1) Mechanical loading devise on the coal car is suitable for the coal with B-14 % water concentration. The mix. coal loading time is 200, and only less 15 seconds allowance for the small part of dust dispersed!escaped from the coal loading opening. The efficiency of catch/collection dust will be 98 % more. (2) the concentration will be less 50 mg/m in final emission after purifying on the ground level station. (3) less than 3 g/t BSO in above treated .dust by burning and coal tar absorption as its final emission. (4) this process/method has been used in other EP improvement projects which have been undertaken by KROPP-KOPPERS Coopy g German*p (r? . U 3.3.2 Coke-dust improvement in the coal-unloading process After 17.5 hrs. dry carbonating, the coal loaded in the carbonating house can be changed into coke. The new producted coke with very high temperature at this time shall be unloadeo out from the house through the guide screen, and then fulling 5 into the coal-quenching car. In this process, especially when the newly product -- coke pulling out, a large of smoke will be dispersed/escaped with higher concentration of coke powder/dust to the air. According to the different type of ovens and production process, it is considered that the amount of 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 this process has been undertaken by Anshan Coking and Refractory Engineering Design Institute. The proposed proposal of coke powder/dust catch/collection on the ground level station .is recommended. The characteristics of the alternative are as following: (1) attaining some 98 % coke powder/dust catching/collecting rate as coal-unloading process carrying out (2) less than 50 mg/mO concentration in the final emission, as purifying devise installed on the around level station used. (3) better reliabili, for the operation, which,vbased on successful experiencge-ho6me and abroad. is (4) but, high required consumption foe electric power and production cost as well as land occupation. The schematic process of proposed alternative shows in Figure 3.2 In order to collect coke powder/dust in the period of unloading process, the additional dust catching cover will be added on the existing coke blocking machine which installed at top of the coke-quenching car, closely sealed both at the sides 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 and adjust it to the right place onto the guide channel. Meanwhile, the exhausting guide valve along the main collection pipe will be started by the starter so that the dust catching cover and the main pipe can surely be connected. After the coke quenching car stopped at right place, the blowers on the ground station will be operated to exhaust the dust by telescopic signals. For other hand, the coal unloading operation will begin with other signals. The dust produced at this operation will be collected, through the exhausting cover connector, guide valves, main pipes and cooler, into the b$-type collection/catching purifierr After purifying, the treated dust can be emissioned from chimney before the discharge treatment system (blowers, hydraulic cou ler and s ncer). The ash (remainings of the treated dustl 11 beras_ fuel, thrcigh the collecting system (scraper conveyor, multi- lifter)4transported to the sintering plant r6 Figure 3.1 Schematic proposed alternative for coal-loading process oven -aqua-ammonia spraying loading raw coal lo- gas collec- recovery opening ading openi. tion system workshop raw gas -dry cooler scraper device dust guide bag type ash discharge pre-painting sleeve collector valve conveyor burning blower conveyor discharge house valve connector silencer storage ore-painting r Fstoage tstorage tank; guide chimney ash discharge valve valve dust guide atmosphere wetting - vehicle pipe screwing 1j removal The location of the dust collection/catching devises for the oven No.1 and 2 are proposed on the top of No.1 oven. Owning to the site limitation, devises for oven No.3 and 4, will be at the southwest and south of the No.3 oven respectively. 7 Figure 3.2 Schematic proposed alternative for coal-unloading process coke dust from unloading process I - 1 dust exhaust dust exhaust cover on the cover on qu- ash guide screen enching car connector cooler on scarper the pre-dust conveyor _Icollector guide valve ] lifter bag type dust collector dust flow I storage pipeline p tank dust final wetting & emission tscrewing (atmosphere) .- blowerI disposal chimney silencer transport 3.4 Main process equipment 3.4.1 Main equipment for the proposed process of coal loading Seat improvement are shown on Table 3.2. 3.4.2 Main equipment for the proposed process of coal- unloading dut -vppevemer are shown on Table 3.4. 8 Table 3.2 Main equipment for the proposed rocess o-f coal loading dust-i i.p riont No. Name and Specification Quantity set 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 2 power transfer 250 KW 7 motor N= 250 KW 2 8 connection valves and pipe networks 2 9 silencer 2 10 Ipipeline S = 6, dia.-7500 j 2 11 metal structure(ladder, platfor., bracket) 2 12 coMpressed air system(inc.drat-ing device' 2 1 3 icoal 1-- 1eqe&-A T o:- Table 3.3 Imported equiprent for proposed coal loading process 'No. No.enclature Quantity Remark 1 screwing 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 pro mf- coal- unloading tst- ±,.p re m No. Name Dimension Quantity set 1 dust exhaust.cover on the coke stainless 2 blocking 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 2 Q=168000aM/h 7 hydraulic coupler N=630 KW 2 8 motor N_=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 and unloading processes improvement) for the four ovens will be 58,7907 million Yuan. The detailed costs for each component are summarized as follows: Coal-loading process system cost (million Yuan) civil construction 1.82 dust collection device 4.735 existing process upgrading 10.35 electrical works 0.3 imported tech/quip. fee .6.4933 sub-total 23.6983 10 TABLE 3.5 PROJECT PROGRESS CHART A992W1993 1994. 1995 1996 6171819110l 1112 1 2131415 6 71819 10l 1121I 12 3 415 6 7 8 911 11112 lI2 3 415 6 7 8 911 11112 11213 415, FEASIDILTY STUDT AND REVIEW FOREIGN CONSULTANTS %%9 PRE--QUALIFICATION N$ FOREIGN BIDDENO CONTRACT SIGN AND DECOMFFEC J ORi!UCN DESION LOC.AL PREIMIINARY DESIGN ----- CONSTRUCTION DE~SIGN EQUIPMENT MAKINO INSTA.LATION COMMISStoNING START OPERATION. AND ACCEPTANCE Coal-unloading process system cost (million Yuan) civil construction 0.85 dust collection device 10.021 existing process upgrading 1.3 electrical works 0.3 imported tech/quip. fee 1.443 general.drawings transportation 0.27 demolish 0.11 others 9.2 physical contingency 4.8 price reservation 6.7984 sub-total 48 749e ;q' C47~~ 3.6 Proposed project schedule Task due to Feasibility study review/assessment Sep. 1992 Technical advice by international Dec. 1992 consultant Quotation, tendering and contract June. 1993 effectiveness Preliminary design and foreign design Jan. 1994 Detailed design for construction Aug. 1994 Equipment manufacture and supply June.1995 Works installation Aug. 1995 Test and commissioning 17ov. 1995 Operation and acceptance Dec. 1995 Tha detailed implementation schedule/a'e 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, 41019' E, surrounded by mountains and hills.(I0 - 300 r average above sea level). The city proper is actually itr the valley of Taizi river basin with 43.2 km2 and tbi, constructed-area cf the city at present is 69 Km. The Coking Factory is located on the southwest of Benxi. Benxi belonas to the northern warm te:lerature zone and continental monsoon climate. East direction wind prevai3s in this area. but for the Coking factory, the pr-vailing wind is southwest direction. The annual average wind speed is 2.8r/s, and the annual windless frequency is 124. The average temperature is Gr.00o, 1 37.30C mi. and -32.30C min.) Because of this especial topography, the condition of air diffusion is 13 rTrlFYT AT: r I.I.,ITT'J r'NTF , P# I- I T I 911 sto. 0 lstfrlcs1iut FI. 1 -:a u Cotekven na låh -LEGEND, o .s1 -- ssu- 0m hat Firame ia: ~h 0 etFr FInt t2oae Spems ane hube not good and also it is very difficult for the polluted smoke,dust to be dispersed. This is one of major natural characteristics of the area. 4.2 Social and cultural environment Benxi Municipality controls four districts and two counties (Pingshan, Hingshan, Xihu and Nanten districts and Benxi, Huaizhen counties). According the statistic data in 1990, total population in the urban area is 919,000, including Pingshan 320,000, Mingshan 259,000 and Xihu 242,000. The principal activities of Benxi are heavy industrial production of steel & Iron, coal and construction material etc. The total industry production value in 1990 was 4.332 billion Yuan, including heavy industry 3.447 billion Yuan which occupied 79.57 % of the total. Education. and culture: 8 universities ( 5 adult colleges), 25 polytechnic schools, 145 middle and high schools. All together is 702. one museum, three culture relic authorities, one archaeologic team. seven theaters, eight public libraries and eight culture museums. public health service: there are 83 hospitals, three sanitoriums and nine epidemic protection stations in the city. The environment monitoring center of Benxi is responsible for the routine monitoring work of air environment, Taizi river water quality and urban noise. Within the Benxi city, there is no any special religions and people customs as well as natural protection area. 5. Environmental Impact Analysis 5.1 General of production At present, there are four coke ovens in Benxi factory which equal to 145.71 million Yuan fixed assets. The main products and its output in 1991 were: coke 1.547 million t, crude tar 65,100 t, amine sulphur 17,700 t, benzenes 19,630 t and industrial benzene 6,350 t. The production output and its raw material (coal) consumption for 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 raw material - coal used in the coking production have been undertaken 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 18 hours 15 minutes and the details for each oven are: Coke oven No. Average operation cycle time 1 18 hours 21 minutes 2 18 hours 22 minutes 3 18 hours 09 minutes 4 18 hours 09 minutes The average operation cycle time include: carbonating time plus operation time (about 7 minutes of coal loading, unloading and trimming operation). The maintenance period and required time for the 4 ovens in 1991 are 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 the ovens No.1 to 4, the pollutants in the dust discharged from the processes (loading and unloading) have been analyzed and shown on 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 the working site of the oven area is.summarized in the Table 5.4. 5.3.2 Existing air pollution within the area of the Coking factory The monitoring work have been carried out based on the 13 requirement of National Air Environmental Quality Standard, class III (AEQS) and the result ar given in the Table 5.5. Table 5.2 Resources & components for raw coal used in coking production resources Heilong Kailuan Fushun Fushun Shanxi of coal -jiang Hutai Longfeng type gas plump gas coking coking Year S % 0.522 1.38 0.52 0.56 0.78 1988 T 326499 440535 220439 472070 615563 Year S % 0.5 1.47 0.56 0.57 0.79 1989 T 324302 128962 462746 574641 405851 Year S % 0.51 1.45 0.52 0.58 0.80 1990 T 366766 414274 678420 351564 89316 Year S % 0.51 1.62 0.52 0.60 0.91 1991 1 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 Pollutants discharged from the coking production process TSP- BSO BaP Kg/t coal .0.454 0.499 0.908 x 10- coal loading Kg/h 117.4 129.11 0.235 t/y 1029.1 1131.1 2.06 Kg/t coal 11.383 0.0363 1.816 x 102 coal un, -II I loading Kg/h 357.85 9.39 4.6 x 10- t/y 31-.8 82.28 0.0412 total. t/y 416-3.9 --.13.38 2.1 14 Table 5.4. Three main pollutants in the dust within the coke oven areas pollutant BaP BSO TSP 122.308 ug/11.29 Vg/m3, top of oven 41.8 mg/m3 pollutant m3 top of 1.67 pg/m3 side of oven top of oven oven . Istandard I 1 0.15 mg/m for opera- 0.15 Vg/M ( U.S.A. standard ) 10 Mg/M3 tion area exceeded 149 8.6 4.18 times 11.13 Table 5.5 Existing air pollution within the area of the Coking factory pollutant SO TSP dustfall fconcentration 0.155 mg/M.3 1.096 mg/M3 88.65 t/km2/nonth AEQS, class 3 0.10 mg/ma 0.50 Mg/M3 10.00 t/k.m2/month exceeded times 1.55 2.19 8.87 5.4 Pollution retardation on effected area The proposeO project for the coal loading process is composed of: 1) high pressure aqua-ammonia spraying to the carbonating house through the rising pipes in ord:r to nnkp the n,7g;tive pressure in the house to exhaust the dust, and 2) burning the dust collected/exhausted from the coal loading holes by the blowers, and then purifying at the ground level station. It is estimated that the efficiency of thp dust purifying reliability can be reached to about 98 % and the dust concentration in the final emission be less than 50 mg/r3. The proposed project for the coal unloading process is planned to install the additional dust catching covers and other devises concerned to catch the dust during the unloading op(ratiorn through the cooler, b#g type collector, and then purification. Based on the results in Feasibility Study, the efficiency of the dust purifying reliability can be reached to about 95 % and the dust concentration in the final emission be less than 50 mg/m. According to the U.S. statistic data concerned on coking production in 1979, and based on calculation of 1.7 million t/y coke production , the pollutants in the dust from the two 15 processes of the four ovens before and after the proposed project completed have been anticipated and shown in the Table 5.6. Table 5.6 Pollutants in final emission after the proposed project completed (four ovens) TSP BSO BaP coal Kg/t coal 1.1 x 103 1.24 x 10-2 2.26 x 10-5 loading Kg/h 2.85 3.21 5.8 x 10-3 t/y 24.93 28.11 0.051 coal K/t coal 7.57 x o2 1.98 x 10-3 9.9 x 107 unloading Kg/h 19.59 0.51 2.56 x 10- t/y 171.68 4.49 0.00224 total t/y 196.56 32.6 0.0513 The comparison of the pollutants from dust emission on the four ovens before and after the proposed project completed are listed on the Table 5.7. . Table 5.7 Comparison for pollutants in the dust discharge Item TSP BSO BaP Total before project(t/y) 4163.9 1213.4 2.1 5379.4 after project (t/y) 196.6 32.6 0.05 229.2 adoan ...utt4ng4t/y) 3967.3 1180.8 2.05 5150.2 rate a e 95.3 97.4 97.6 95.7 5.5 Analysis of environmental bene'its .The environmental benefits have er .mated after the proposed project completed and listed to be as follows: 16 Pollutant Amount '- , Rate of OW _rim t/y ) ( 4 ) T.S.P. 3967.3 95.3 BSO 1180.8 97.4 BaP 17 97.6 From above environmental assessment, the amount of dust at the final emission time will be reduced largely after the proposed project (coal loading and unloading processes) completed. In this case, the pollutants concentration in the final emission compared with before will also be fallen away at the leeward and side-wind areas of the working site. Table 5.8 gives the comparison of three pollutants concentration before and after the proposed project operation. According to the data listed in the table, it can be seen that the better improvement of air quality around/near the ovens can be gained, such as at the area of 100 m from the oven, BaP concentration will reduce about one tenth as proposed project completed. Therefore, it is obvious that the benefits of the proposed project is worth and a better distribution on the environment. Table 5.8 Comparison of pollutants distribution at leeward/near oven area monitoring before project after project point I BSO BaP TSP BSO BaP I TSP (mg/m) (Ug/m ) img/m2) (mg/m2) (ug/m) (ng/m') on top of 0.27 1.5 1.78 0.16 0.88 0.75 oven sides of 0.175 0.55 2.28 0.04 0.068 0.55 oven 100 m 0.08 0.12 0.79 0.012 0.012 0.40 leeward The comprehensive environment impacts brought by proposed project implementation at different stages have been estimated and given in Table 5.9. It is seen that nearly no any impacts during/on the project construction period, and a large of advantage/positive effects can be brought with the proposed project. 17 Table 5.9 Environmental impacts during the proposed project implementation potential effects (construction) effects (after completed) area to be polluted adverse. no positive adverse no positive air quality BaP V V BSO T.S.P V water resources / soil V noise: en-site c(T-site aa society: residentio-I -remove- i_e__Mv _ _ _ _ v employment living house _v econory 5.6 Analysis o ca n-conomi. benefits In Benxi Coking Factory, there are 91,900 people living in the area where industrial smoke/dust pollution discharged. In this case, the public health were and are still affected at the different range. The investigations concerned in the aspect were undertaken 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 the first of the death rate in various cancer in the city of Benxi. 18 Table 5.10 Distribution of main malignant tumors in the city, 1987 Name of total death rate ratio in No. in proposition for cancer death (1/1 various order people upon age 40 No. million) 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 4 100.00 gus leukae- 34 4.01 3.76 5 44.12 mia intes- 26 3.06 2.88 6 69.23 tines The existing total staff in the factory are 2,769. The death rate from cancer (1987-1992) have been investigated and listed in the Table 5.11. From above.fableA i t can be seen that 44 persons died from cancers in past six years, which equal to 7.3 person /year. so the death rate of cancer (2.6/1000) is very high and it indicate what a serous air pollution is. As the proposed project completed, it is really true that the lung cancer - occupational disease for the coke worker will be better controlled and the workers at the post of coking production will not only get rid of the dangerous operation at heavy polluted condition which lasted many years, and working under the acceptable condition ( complying with State EP standard), but also free from the twisted mentality and Icng- term depressing in their spirit formed in the past condition which strong cancer-induced substances 'exist and intruded to the health at any time. In return, the improved working condition will stimulate the workers more effects for coking production. In addition, the proposed project will need some new employees after it completed (9 persons for the coal loading process, and 11 for unloading). Although small number, it, will indeed settle a part of employment issue and improve their living standard. 19 Table 5.11 Statistics list of cancer death for coking staff in the factory time death No.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 project completed are estimated as follows: The direct benefit: 3,695 t coke and coal powders can be recovered per year, which, based on value of 150 Yuan/t, equal to 554,300 Yuan/year. The indirect benefit: less incidence rate of cancer can increase factory's net income. The average production value of one worker in a year is 30,000 Yuan, if he or she has a disease, this value will be zero, and furthermore the medical fees and wage shall be paid 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 on main production processes (coal-loading & unloading). Based on existing pollution discharge feature that BaP and BSO absorbed on the TSP, the advanced necessary technology will be adopted and the most equipment for the proposed project can be manufactured in the State. The expected environmental benefits will be gained. (refer to Table 5.12) 2) The direct economic benefit from the coal and coke powders recovery will be valued to 554,300 Yuan/y and the indirect benefit, certainly equal to a large sum of seeable value, will be from reduced incidence cancer rate by workers/staff on the post 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 improve existing heavy polluted production environment within the area of the factory to meet the Sanitary Requirement and play a great pole on the whole environment of Benxi city. So it is not only feasible but necessary to carry out this proposed 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 of coal-loading in the world: (1) spraying high pressure aqua-ammonia or steai into the rising pipe in order to make the negative pressure in the carbonating house 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 blower installed on the larry, car to draw off the dust from the coal loading opening, then burning, washing, purifying in the car before' the final emission but the effectiveness is not as expected. (3) based on (1) process, added ground level station to collect/catch .burnt dust (ash) after burning on the larry car, and then purifying before the final emission. This method can realize the best expected efficiency of dust collection and treatment. In order to get the best efficiency of collecting dust, and at last, to meet the requirement of "Discharge Standard (DB21-60- 29)" stipulated by Liaoning Province The method (3) above mentioned is chosen (refer to 3.3.1). 21 Two alternatives for the ground level station have been put forward. Both alternatives are composed of 3 components: 1) spraying high pressure aqua-ammonia as coal loading operation to force the dust flowing from- the loading opening. 2) catch the escaped/dispersed dust from the opening and burnt in the larry car. 3) collect the burnt dust (ash) to the ground collection station for further purifying and then final emission. Alternative'l: cooling dust collection system; that is employing of metal feature, heat radiation and transportation, to reduce the temperature of the collected/catched dust to 1200C at the outfall, and then catch into the beg collector in which the filter material made by cheaper priced polyester blanket. The efficiency of dust collection/ catch (by weight) can be reached upto 99.5 %. Alternative II: air cooling dust collection system; that is using natural air to reduce smoke/dust temperature to 2000 at the outfall. Because the temperature is higher than that in alternative I, the special filter material (NOMEX) in the beg type collector shall be adopted. The efficiency of dust collection/ catch (by weight) also can be reached upto 99.5 %. Through the comparison of the civil cost, annual power consumption, land use, construction period and environmental benefit, most parts are the same for the two alternatives but the filter material. In this aspect, the unit price of filter material (NOMEX) used in alternative II is 10 times expensive than the general polyester used in alternative I. So the alternative I :is chosen and the schematic process is given in Figure 3.1. 6.2 Options for dust collection in coal-unloading process There are three options for dust control used in the process of coal-unloading in the world: (1) equipped a movable dust collection car. The catch cover on the car with purifier shall spread above the top of the coke guide shed and the quenching car. The dust collection car and the coke blocking machine shall be synchronously moved. (2) a large dust extracting cover shall be equipped on the coke blocking machine. the catched dust will be sent to the ground level station for purifying after collection. (3) construct a large shed beside the oven and installed the coke blocking machine and the quenching car. The.dust will be extracted from here to the collecting station. The third option is not suitable for the expected proposal because it need large investment and more land requisition. So the comparison only deal with other two alternatives.0 22 Alternative I: dust collection by a movable dust collection car with the thermal-buoyancy cover; The principle is employing the feature of dust thermal-buoyancy to catch the rising dust, and then showering and purifying. But the length at lower part of the cover shall be two third longer than the length of the quenching car, and the top of the exhausting pipes shall be 1.5- 3 m higher than the top of the oven. The other concerned structures such as guide rail, clarifier, wastewater tank shall be constructed and some software, sprayer head (4 sets) ,fittings will be imported which equal to 739,000 RBM Yuan. On this cost * base, the dust collection rate will be about 90 % and the dust purifying efficiency will be 92 %. Alternative II: dust collection at ground level station; install the additional dust catch cover on the coke blocking machine. The processes for dust cooling, collection, purifying, and final emission will be operated at the station. and then collecting the ash (burnt dust), as fuel, transport to the Sintering plant regularly (see 3.3.2). The design ash concentration at the entrance of the station will be 10 g/m3 and the dust concentration in the final emission can be reached to 50 mg/M3 . 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 obviously better than Alternative I, especially, on availability, reliable technology and no more imported equipment required. So the alternative II is chosen. So, the dry cooling dust collection syster for the coal load-ng process improvement and the ground level dust collection (station) system for the coal unloading process is the selected alternative for the proposed project (hereinafter called comprehensive alternative I). the comparison with the other comprehensive alternatives are listed in the Table 6.1. 23 Table 6.1 Comparison of comprehensive alternatives comprehensive comprehensive Name 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 4 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/m annual coal,coke recovery 3695.4 t/y 3275.8 t/y Plan For Migrating Negative Impacts 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 41-43 oC at top of oven; - 36-430C in the coal larry car. and the radiation 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. In order to improve the working condition (above mentioned), it is required to provide necessary facilities: moveable ventilation blowers for reducing high temperature and radiation, workers' rest house and the temperature drop devises installed in the larry car and coke blocking machine. 7.3. Noise control To reduce the noise from the coking production, the silencers will be equipped on the outfalls of blower.the sound insulator be used in the instrumentation house and adding air conditioner. 24 Through these measures, the noise level in the operation area can be reduced to 85 dB (A) to meet the requirement of Noise Control Standard. 7.4 Production water management The water used in process is mainly for blower cooling, through the recovery system to collect used cooling water for reuse water 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 by transportation. 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 retired at the sanatoriums, such as the better places of Beidaihe, Dalian, Xingcheng or Benxi hot spring. Health check for all staff regularly in schedule plan, and educate health knowledge. and also implement shower system in each workshop, grant protection cloths, masks, gloves and medicine etc. 8. Environmental Management And Staff Training 8.1 It is recomiended that one director of Benxi Coking Factory be in charge of the environmental managerent. especially for the proposed project. Under his (her) leadership, a Environmental Protection Division, and five sections will be set up. The schematic organizaticn structure is shown on the following: 25 Schematic organizations for environmental protection Director in charge of Environmental Protection * 0 Environmental Protection Division Environmental Environmental Education Management Environmental Environmental Landgreening Engineering Environmental Monitoring The work scape of each section are to be as following: * Environmental Management section: prepare the environmental management regulations and protection plan, check the technical measures to be carried out as well as the treatment facilities operation, determining pollution factors, issue the licenses for allowing wastes discharge, collect charges and deal with EP accidents. * Environmental Engineering section: organize and coordinate the EP engineering installation and operation, examine and accept the routine maintenance of the EF facilities. * Environmental Monitoring section: responsible for the routine environmental quality monitoring within the area under its power. * Environmental Landgreening section: responsible for landgreening within the factory, and manage the routine works. t Environmental Education section: responsible for the EP propagation and education to all staff in the factory to raise the individual EP consciousness. 8.2 Staff training 8.2.1 advice foreign EP consultants to undertake technical study 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 new production processes. 9. Environmental Monitoring And Supervision Program 9.1 The Environmental monitoring station of Benxi Coking Factory will be responsible for the whole environmental monitoring work. 9.1.1. Monitoring content: The pollutants to be monitored in the factory will be S02, NO, CO. TSP, dustf all and BaP. 9.1.2. Monitoring points: The points for TSP monitoring will be located on the five places (Jiaoyi, Jiaore, Flower house, Tar workshop and sulphur acid workshop). and also five places for dustfall monitoring (Jiaoyi, Recovery workshop, Coal storage, EP and administration buildings). 9.1.3 Air monitoring frequency: for S02, N04, CO, TSP monitoring 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 by production); 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 who in charge of EP works as well as EP section besides it is to be filed. The response from the above will be given to the production adjustment and maintenance sections in order to ipake a quick measures. The EP section will analyze the results of each month to find out relationship between discharge and environmental pollution as well as pollution factors, then put out suggest4ons to the director. 10. Involvement Of Affected Group And Noncovernmental Organization As the serious environmental pollution exist in Benxi city, especially in the area/near the factory, the public health and living quality of the people have been endangered. In past 12 years, the appeal and reports, even the complain and protest have been put forward from the vario.us fields. According to the non-completed statistic data, The- complain letters concerned about environmental pollution have achieved upon 1731, most of them focused on local air pollution, the details are shown in Table 10.1. 27 Table 10.1 Compliances (letter, visitor) in the past 12 years. Benxi Year Total No. of Waste Waste Noise Other Compliance 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 Political Consultative Conference in 1992, Mr. Zhao Fushen, 185 committee member, raised the proposal of "continue to strength the management of environmental protection control, to achieve a distinct success". It reflected people's strong idea which the air pollution from Benxi Coking factory must be eliminated. The proposed projects mentioned above is start the process movement to resolve the.whole pollution problem for Benxi environment. In order to protect the people's rights, the investigation of the public attitudes and acceptable degree for this proposed project have been undertaken within the part of residents who have living in Benxi city during the project preparation period, the results are given in Table 10.2. From the table, it is seen that 100 % are favor for this proposed project. 28 Table 10.2 Public opinion poll for the proposed project in Coking factory Be n.- i people occupation and professional local 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 35 of public against 0 0 0 0 0 opinion poll No 0 0 0 0 0 reaction percentage (M) 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 Liaoning Environmental 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 Encyclopedia 6) Environmental Protection Standards Manual 7) 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 m3 of Pollutant sampling time II class III class daily average 0.30 0.50 T.S.P randorn once 1.00 1.50 annual daily 0.06 0.10 average S02 daily average 0.15 0.25 random once 0.50 0.70 daily average 0.10 0.15 NOx random once 0.15 0.30 daily average 4.00 6.00 CO random once 10.00 20.00 30