Assessment of the current air quality situation in gang thep thai nguyen factory and proposal mitigation solution

THAI NGUYEN UNIVERSITY UNIVERSITY OF AGRICULTURAL AND FORESTRY DO MINH THUY TOPIC TITLE: ASSESSMENT OF THE CURRENT AIR QUALITY SITUATION IN GANG THEP THAI NGYEN FACTORY AND PROPOSAL MITIGATION SOLUTION BACHELOR THESIS Study Mode: Full-time Major: Environmental Science and Management Faculty: International Training and Development Center Batch: K43-Advance Education Program Thai Nguyen, 30/09/2015 Thai Nguyen University of Agriculture and Forestry Degree Program Bachelor of Environmental Science and Management Student name Do Minh Thuy Student ID DTN 1153110231 Thesis Title Assessment of the current air quality situation in Can Thep Thai Ngyen factory and proposal mitigation solution Supervisor Assoc Prof Dr Do ThiLan Abstract: Study about air situation in Can Thep Thai Nguyen Factory and pose measurements As alarming problem about air pollution in the world in generally and in Viet Nam particularly under the negative effect of metallurgical industry, I would like to implement my study to assess the air quality status of steel rolling factory of TISCO and propose measures of mitigate pollutants and poison gas treatment technology By methods such as collecting secondary data, application theory, conducting the actual survey in factory All data through real practicing are processed and showed into statistical tables, charts, reasonable adjustment and included in the report The main reference source is from report of environmental monitoring of Can Thep Thai Nguyen Factory beside some other data of environment and metallurgy in Viet Nam and in the world as well as professional reference materials In the result, although most air parameters of TN Rolling Mill within in permitted standard, some factor as NH3, NOx and TSP are increasingly over time It is necessary to pose some measurements in both management and technology as SNCR to prevent environment accident in the future Because of conducting in the real survey in workshop be operating and kiln stack, it should be limited Furthermore, factory cannot statistical dust and exhaust emission, so it is impossible to get accurate results on air emissions load Keywords: Can Thep Thai Nguyen Factory, Air pollution, Iron and steel plants, environment, SNCR Number of pages: 58 Date of submission: October 30, 2015 i ACKNOWLEDGEMENT After a period of studying at Thai Nguyen University of Agriculture and forestry, I have equipped myself with basically professional knowledge As the consensus of the university, the dean committee of International Training Center and the direct instruction of Assoc.Prof Dr Do ThiLan, I conduct my bachelor thesis: "Assessment of the current air quality situation in Can Thep Thai Ngyen factory and proposal mitigation solution ” During researching, with the hearted guidance of Assoc.Prof Dr Do ThiLan and supporting from leadership of Can Thep Thai Nguyen Factory, I finished my thesis Therefore I express my deepest gratitude to teachers in the International Training Center and Natural Resources and Environment Faculty, especially Assoc.Prof Dr Do ThiLan who directly guide me in implementing thesis Besides I would like to thank for the leadership of Can Thep Thai Nguyen Factory facilitating me to finish investigation Due to limited professional qualifications, my thesis may be inevitable shortcomings I would like to receive the assistance of whole teachers to my thesis become better Thank you very much! ii TABLE OF CONTENTS LIST OF FIGURES LIST OF TABLES LIST OF ABBREVIATIONS PART I INTRODUCTION 1.1 Research rationale 1.2 Research’s objectives 1.3 Research questions and hypotheses 1.4 Limitations 1.5 Definitions PART II: LIERATURE REVIEW 2.1 Theoretical base 2.2 The legal basis 12 2.3 An overview of the domestic and foreign research situation 12 PART III METHODS 20 3.1 Methods of collecting secondary data 20 3.2 The actual survey methods 20 3.3 Practical methods 25 3.4 Statistic and data processing methods 25 PART IV RESULT .26 iii 4.1 manufacturing technology process 26 4.2 Air environment status in Thai Nguyen Can Thep factory 28 4.3 Commenting and evaluation on the status of air sources in Can Thep Thai Nguyen Factory 38 4.4 Research of measures for air pollution mitigation in Can Thep Thai Nguyen Factory 39 PART 5: DISCUSSION AND CONCLUSION 53 5.1 Discussion 53 5.2 Conclusion 54 REFERENCES 57 iv LIST OF FIGURES Figure 1- Technology diagram 26 Figure 4.2 Figure 2- Chart of substances concentration changing in kiln stack exhaust emissions during years 37 Figure 3- Chart of noise level in manufacturing area during years 37 Figure 4- Chart of noise level in outside manufacturing area during years 38 Figure 5- Diagram of exhaust fumes treatment technology 41 Figure 6- Diagram of SNCR technology 48 Figure 7- Diagram of Fabric Filter Equipment 51 LIST OF TABLES Table 1- Pollution loads from the stacks of ISDEMIR 15 Table 2- Air quality in the project area of Ma Ong Industrial zone 18 Table 1- Synthesis list of sampling and monitoring equipment 20 Table 2- Synthesis of sampling location 21 Table 3- Sampling methods according to TCVN standard 23 Table 4- Sampling technicalities 24 Table 1- Sources of emissions from the plant's activities 28 Table 2- Sampling result in the steel rolling area 29 Table 3- Sampling result at the billet kiln 29 Table 4- Sampling result at the finished product storage 30 Table 5- Sampling result in the factory’s office 30 Table 6- Sampling result at the southern residential area; main port of TISCO company 31 Table 7- Sampling result in the 17th household of residential area, Cam Gia Ward, Thai Nguyen City, far 200 meters from the plant to the northeast 31 Table 8- Sampling result in the residential area to the southwest, far 200m from 32 Table 9- Result of measuring and analyzing dust, noise in the manufacturing area in 2015 32 Table 10- Result of measuring and analyzing dust, noise in the outside of manufacturing area in 2015 33 Table 11- Result of measuring and analyzing kiln stack emission in 2015 34 Table 12(a) - Comparison of air quality in factory area between years 2013, 2014, 2015 34 Table 13(b) - Comparison of air quality in factory area between years 2013, 2014, 2015 35 LIST OF ABBREVIATIONS BTNMT: Natural resources and environment ministry QCVN: National technical regulations on environment TISCO: Thai Nguyen Iron Stock Co- operation WHO: World health organization PART I INTRODUCTION 1.1 Research rationale Currently, air pollution is a pressing problem for the urban, industrial and handicraft villages environment in Viet Nam at present Air pollution has a negative impact on human health (particularly cause respiratory diseases), ecosystems and climate change (greenhouse effect, acid rain and ozone depletion) The stronger industrialization and urbanization, the more sources of pollutants as well as pressure changing air quality Environmental protection requirements are increasingly important (Dang, 2003) Thai Nguyen Steel Rolling Mill is one of the important investments in projects to renovate and expand production of Thai Nguyen Joint Stock Company in the first phase, which was completed and operated in 2005 With the modern technology of Danieli (Italy), capacity of 300,000 tons / year has increased total producing capacity of Thai Nguyen JSC to 550,000 tons / year (Can Thep Thai Nguyen Factory) With great production capacity above, emissions into the environment from Can Thep Thai Nguyen Factory in the producing process is significant It partly contributed to the problem of ambient quality changing in factory The pollutants derive from combustion of fossil fuels such as coal, FO oil created: CO2, CO, SO2, NOx and unburned organic matter: soot, dust, losing process, leaked on technology line, the process of transport of volatile chemicals, dust In particular, the CO, CO2, SO2, NOx and dust in emissions being released during producing have more potential causing air pollution and human health - To absorb nitrogen oxides people use water, alkaline solution, acids and oxidizers  Absorption efficiency Depending on the exposed area between the flue gases and liquids, duration of exposure, environmental concentration and reaction rates between the absorber and emissions b, For dust Based on the concentration of dust, chemical properties, physical properties, demand for air circulation and filter dust away from the air is divided into levels: - Cleaning: only retain dust particles of size> 100 mm (preliminary filter) - Intermediate cleaning: not only big particles but also small particles are retained Dust concentration after filtering is about 30 - 50 mg / m3 - Refined cleaning: can filter dust particles smaller than 10 mm with high performance Dust concentration after filtering is only 1-3 mg / m3 4.4.2.2 Proposing schemes Measures to limit and handle pollution from noise and vibration: Pollution being caused by noise and vibration in the steel mill with capacity 300.000 ton/year will impact on workers directly Some measures limiting the noise pollution will be implemented: - To minimize noise at source and allocate anti-noise devices such as earplugs for employees working in the noise departments - To isolate reasonably sources of noise into private locations - The great shocking machine was concerned to deal during laying the foundation 45 - Noise and vibration emitted in production chain are mostly from the actuator of the machine, but the equipments are imported from DANIELI - ITALIA having high quality, running without vibration and less noise - To install silencers system in some locations that wind blowing out - Planting trees around the factory to create noise separators Measures of reducing thermal pollution and against heats: From the beginning the workshops was designed so that make use of advantage of natural ventilation windows at the maximum Factory is ventilated, great workshops height (about 14 -16m) Workshops are arranged window system, natural ventilation skylights around the house To use insulated roofs and roofing walls At work, ventilators and coolers are equipped for the workers Also around the workshops are airy so heat dispersion is relatively good Measures to prevent environmental incidents: The environmental problems can occur in the factory due to fire Factory is likely to fire because of fuel oil, flame welding and cutting So the explosion prevention regulations were strictly carried out Machinery and equipment working at high temperatures and high pressures have clear origin and strict implementation of periodic inspection regime Factory has sufficient earthling system for the equipment, machinery, buildings as well as the firefighting equipment, water system Measures of sanitary - occupational safety: To comply thoroughly the provisions of labor safety for employees, organize training annually for employers and periodic times/year for workers 46 To inspect and surveillance periodically the health of workers and staffs, timely detect occupational diseases To organize annual work environment inspection for the direct producing areas to ensure the working environment of the employees are the best Management measures: Raising the environmental consciousness of workers through media programs billboards, posters - To build regulations on environmental protection in the factory as follows: - Regulations on the functions and responsibilities of each office and workshop in industrial hygiene- safety and environmental protection - Regulation on the powers of managers in the implementation of their duties - Regulation of reward for the collective and individual having initiatives in the reducing pollution for factory - Regulations dealing with the collective and individual acts of irresponsibility in occupational safety - explosion prevention - environmental protection The factory is being implemented environmental management system ISO 14000 by Thai Nguyen Steel Joint Stock Company: - To strengthen education on safety, industrial hygiene, environmental protection - To inspect and supervise regularly the implementation of procedures and technical rules to ensure industrial safety - To establish specialized forces and appropriate means to actively deal and tackle the consequences quickly when incidents occur 47 Proposal selection exhaust gases treatment technology for Can Thep Thai Nguyen Factory: From the results obtained during the survey in Can Thep Thai Nguyen factory in March 2015 showed that emissions of NOx, NH3, and dust in the kiln kiln stack of the plantis increasing over the years So we need to have the appropriate remedial measures for kiln stack emissions in order to limit the exceeding permitted standard in the coming years Proposal NOx treatment technologies for kiln stack Kiln stack need to be installed SNCR system to control NOx emission levels SNCR technology is advanced technology So the kiln stack is not necessary to install other treatment systems With this technology, NOx emissions can be reduced to 800 mg/Nm3 Factory can install additional SNCR system to minimize the amount of dust dispersed into the atmosphere Figure 6- Diagram of SNCR technology (Source: Report on status of air quality in Hon Chong Xi Mang Company) 48 In steel production line, factory should install NOx control technology in source base on SNCR technology (Selective Non Catalytic Reduction) The principle being applied to reduce NOx is a chemical reaction between NOx being generated during combustion and ammonia (NH3) in the form of gas at a temperature of 800 – 1100 0C, as follows: 4NO + 4NH3 + O2 → 4N2 + 6H2O 6NO2 + 8NH3 → 7N2 + 12H2O Reducing agent may be ammonia in gaseous or liquid, or urea aqueous solution CO(NH2) 25 - 45% by weight At temperatures over 200 ° C, urea is decomposed into CO2 and NH3 Solution 40% urea is diluted with water being pumped inside and be atomized via two nozzles of level and The purpose of level spraying is to cover maximum surface with the highest retention time, and level spraying is to optimize efficiency Capacity urea is controlled by measuring the concentration of NOx at the kiln stack By keeping constant solvent capacity and urea solution, atomized efficiency is maintained during reducing NOx Proposal of dust treatment technologies for kiln stack: Depending on the selection filter level, the factory can use the dust filters as follows: The dry dust collecting equipment based on mechanism: Dry dust collecting equipment include the main following types: Dust-deposition chamber and Cyclon: single cyclon and combinatorial cyclone The wet dust collector: in the wet dust collector, dust collecting process is often accompanied by the process of cooling air and gases absorption Therefore the 49 devices of this type are often used to solve simultaneously the problems: dust revocation, gas absorption and gas cooling for treating exhaust fumes from burning fuel sources, or emissions from metallurgical kiln The wet dust collectors can reclaim dust sized from 100 - 0,1am with performance from 85-99% The wet dust collectors include the main types as follows: Empty gas washing equipment and Gas washing with cushioning material equipment Equipment ESP: ESP equipment operating under the principle of ionized dust and separate them from the gas stream passing through magnetic field This equipment can filter extreme small dust particles (size from 10 - 0,005am) with significantly high efficiency (85-99%) and has many advantages such as lower energy costs, high temperature, easy automation Dust filter using membrane: operating principle of this device is using porous material to retain dust when dust streams pass through that membrane These devices are classified into several types as follows: Oil refinery equipment and Fabric Filter Equipment Fabric Filter Equipment is the most reasonable technology to handle dust volume arising from producing process with its advantages as follows: - Very high collection efficiencies possible (99.9 + per cent) with a wide range of inlet grain loadings and particle size variations Within certain limits fabric collectors have a constancy of static pressure and efficiency, for a wider range of particle sizes and concentrations than any other type of single dust collector - Collection efficiency not affected by sulfur content of the combustion fuel as in ESPs 50 - Reduced sensitivity to particle size distribution - No high voltage requirements - Flammable dust may be collected - Use of special fibers or filter aids enables sub-micron removal of smoke and fumes - Collectors available in a wide range of configurations, sizes, and inlet and outlet locations Figure 7- Diagram of Fabric Filter Equipment (Source: Hitachi plant construction, Ltd) Operating Principle: Firstly air including dust passes through a filter fabric Initially dust particles larger than the gap between the fibers will be retained on the surface of cloth base on sieve principle, the smaller particles cling on the fiber surface 51 by collisions, gravity, and electrostatic attraction Gradually, obtained dust layers are thickning that create filter aid membranes retaining small dust particles When air accesses in the direction from outside to inside of bag, the bag has to stretching frame being made by metal to keep bag from out of flat situation during working With this scheme, mouth bag being connected with sieving surface always turn upward Filter surface reverting can conduct after stopping the air passing through the device and clean the dust on the cloth in ways: - Mechanical vibration by a special structure - Backward blowing by compressed air or clean air Air load capacity of conventional filter cloth is 150 -200 m/h Resistance of device is about 120 ~ 150 kg/m2 Dusted cycle is 2-3 h Filter efficiency reaches 99.8% and filter tiny particles is due to filter aid layer After a period, thick extreme dust layer will raise over resistance of the membrane, we have to stop gas passing through and remove the dust on the cloth This operation is called filtering capability reverting 52 PART 5: DISCUSSION AND CONCLUSION 5.1 Discussion 5.1.1 The current situation of air in Can Thep Thai Nguyen factory? Environmental quality in research area is generally good, most of the analyzed indicators are within the permitted standards and ensure the Viet Nam regulations Most of the calculated values are guaranteed ISO regulations for industrial environments The handling equipment and modern ensured TCVN of environment The plant invested properly for installation of some waste handling equipment and modern to ensure TCVN of environment as well as measures to ensure safety and prevent environmental incidents 5.1.2 The possible management and technology solution to reduce air pollution of the Can Thep Thai Nguyen factory? Factory implemented well environmental protection, meet most of the requirements for environmental protection However, to improve further environmental protection, factory has to install new exhaust gas treatment system for kiln stacks that have emissions capacity is increasing over time the NO2 processing system and bag filter equipment should be installed to ensure respective emission standards, and contribute to better environmental protection Although the study has been finished, there were some limitations such as the parameters on air may be affected by emission from others factory surrounding the Can Thep factory because their close distance The result just was taken during the short time of months Can Thep Thai Nguyen factory is one small branch of TISCO company, so that the reasearching result will not represent for whole company 53 5.2 Conclusion Based on preliminary research, technology analysis of Can Thep Thai Nguyen factory and assessment of both negative and positive impact to the environment of the project, we can make some recommendations as follows: With whole scene of pollution and its impacts, it is an alarm for not only the factory but also workers, staff of company and authorities in environmental protection It is urgency to prevent air pollution by thorough solutions The factory is being implemented environmental management system ISO 14000 by Thai Nguyen Steel Joint Stock Company It should strengthen education on safety, industrial hygiene, environmental protection as well as inspect and supervise regularly the implementation of procedures and technical rules to ensure industrial safety In addition, Can Thep Thai Nguyen factory need to establish specialized forces and appropriate means to actively deal and tackle the consequences quickly when incidents occur 54 The main Port of Thai Nguyen JSC The factory’s office 55 The steel rolling area The finished product storage 56 The billet kiln The Kiln Stack of factories 57 REFERENCES Anh, N.B (2013) Pollution from the steel industry: Who is responsible for pollution Jounal of Labour Bac Ninh monitoring stations Report on Environmental Impact Assessment in rolling steel factory of Dat Phat Company (pp 32-47) Can Thep Thai Nguyen factory retrieved from://tisco.com.vn/f=Company&p=5&id=92 (accessed on 10/3/2015) Co, H.K & CTV Environmental techniques Technical science publisher Hanoi Cuong, P.H (2015) Industrial development accompany with environmental protection Institute for policies and development Dang, P.N (2003) The air environment Ha Noi Science and Technology Publisher Environmental monitoring report in Nhon Trach industrial zone, Nhon Trach, Dong Nai province Hitachi plant construction, Ltd Hoa (2013) Air pollution on flora and fauna Retrieved from: http://voer.edu.vn/m/anhhuong-cua-o-nhiem-khong-khi-doi-voi-dong-thuc-vat/66423e35 (accessed on 5/4/2015) Hoa, H T- Be V V (2012) Air pollution retrieved from: http://vietsciences2.free.fr/giaokhoa/biology/moitruongvaconnguoi/onhiemkhongkhi.ht m (accessed on 11/4/2015) Institute of information technology– Ha Noi national university (2013) Controlling air pollution Journal of Science And Technology J Environ Sci Eng (2011 Oct) Assessment of air quality in and around a steel industry with direct reduction iron route Handbook of resource, 53(4), pp 437-42 Noise and vibration in production Journal of Occupational Safety, (2) Report on status of air quality of Hon Chong Xi Mang Company 58 Researching group (2010) Cleaner production for steel industry Retrieved from: http://text.123doc.org/document/2451874-san-xuat-sach-hon-nganh-luyen-thep.htm (accessed on 22/5/2015) Science library Retrieved from: http://www.thuvienkhoahoc.com (accessed on15/3/2015) Tahir.M and Aysel T A (2010) Management of air quality in iron-steel industry region in south-eastern turkey and emission inventory of several pollutants Middle East Technical University Thai Nguyen monitoring stations (November 2013) Report on environmental impact assessment in the Steel Rolling Mill, LuuXa-Thai Nguyen The environment monitoring report of Can Thep Thai Nguyen factory The National Assembly of Vietnam (2014) Law on Environment Protection The National Center for Science and Technology Information (2013) Environment Bulletin in October 2013 Triet, L.M - Tuan,N.D (2010) Status of air pollution and handling technology in key economic areas in southern ( pp 8-13) Environment and natural resources institute Ho Chi Minh National University Trieu, N.V (2008) Source of air pollution Retrieved from: http://www.td-in.com/bv/xu-lykhi-thai/nguon-goc-gay-o-nhiem-khong-khi-40.aspx (accessed on 22/3/2015) VNA / Vietnam (26/06/2010) London is Europe's top air pollution Journal of Law, pp 34-52 59 ... solve the problem of air pollution in Can Thep Thai Nguyen Factory, the implementation of thesis: ? ?Assessment of the current air quality situation in Can Thep Thai Ngyen factory and proposal mitigation. .. Assessment of the current air quality situation in Can Thep Thai Ngyen factory and proposal mitigation solution Supervisor Assoc Prof Dr Do ThiLan Abstract: Study about air situation in Can Thep Thai Nguyen. .. 4.3 Commenting and evaluation on the status of air sources in Can Thep Thai Nguyen Factory 38 4.4 Research of measures for air pollution mitigation in Can Thep Thai Nguyen Factory