I

WORLD ENVIRONMENT CENTER

UKRAINE -- --..A

WASTE MINIMIZATIONIENERGY CONSERVATION DEMONSTRATION PROJECT

"MARKOCHIM" COKE OVEN AND BY-PRODUCTS PLANT

IN MARIUPOL ,'

Final Report I.r..-

USAIDMEC COOPERATIVE AGREEMENT NO. ANE-0004-A-00-0048-00

World Environment Center 419 Park Avenue South

New York, New York 10016

SEPTEMBER 1997 L

BESa"AVAILA8L E COPY

WMDP - "Markochim" Coke Oven & Hy-Products Plant - Final Report

Project Description: Improvements in combustion efficiency at coke oven battery

Project Type: Energy ConservationIWaste Minimization Project

Country: Ukraine

Industrial Sector: Coke

Funding Source: United States Agency for International Development

Participants: Markochim Coke Oven and By-products Plant and World Environment Center

Project: Install in-situ oxygen analyzer to obtain continuous, reliable oxygen analyses in flue gases.

WMDP - "Markochim" Coke Oven & 13y-Products Plant - Final Report

REPORT DISTRIBUTION:

Alexandra Burke, Bureau for Europe and New Independent States, United States Agency Ihr International Development

Iiobert F. Ichord, Jr. Chief, Energy & Infrastructure, Bureau for Europe and New Independent States, United States Agency for International Development

Robert A. Archer, Deputy Chief, Energy & Infrastructure, Bureau for Europe and New Independent States, United States Agency for International Development

1,ea E. Swanson, Director, Environment Development, USAID Regional Mission for Ukraine, Belarus and Moldova

Natalia Kulichenko, USAID Regional Mission for Ukraine, Belarus and Moldova

Patricia A. Swahn, Document Acquisitions, United States Agency for International Development

Ties van Kempen, CH2M Hill, Ukraine

Nicholas P. Cheremisinoff, Environment Policy & Technology Project, IJkraine

Yuri Gostev, Technical Director, "Markochim"

Nicolay Polytayev, Deputy Chief Engineer, "Markochim"

Svjatoslav Kurulenko, Head of Department, Donetsk Oblast, Department of Ministry of I'nvironmental Protection, Ukraine

Gregory Shmatkov, National Academy of Sciences, Ukraine

Gennady Merkhelevitch, WEC Coordinator, Ukraine

Antony G. Marcil

'fhomas J. McGrath

Romuald Michalek

Bohdan Aftanas

Frank Szymborski

WMDP - "Markochim" Coke Oven &I. By-Products Plant - Final Report

REPORT DISTRIBUTION: (continued)

Ilsnest J. Bolduc

Valerie Sepe

Philip Breese

John Oberlatz

Richard Cornman

File

WMIIP . "Markochim" Coke Oven & 13~~-l'roducts Plant . 1:inal Report

TABLE OF CONTENTS

Section Page

I .

1 I .

I11 .

IV .

v .

VI .

VII .

VIII .

Introduction .................................................................................... - 1

Executive Summary ............................................ .'. ............................. 2

........................................................................... General Background 3

Description of Project ........................................................................ - 4

Personnel ............................................................................................ 4

Chronology of Project ........................................................................ 4

Close-out of Ceremony ...................................................................... 5

Appendix 1 . Diagram of Oxygen Analyzer Installation ................. 6

Appendix 2 . Final Estimate of Benefits .......................................... 7

Appendix 3 . ~ i s t of Close-out Ceremony Participants .................... 8

Appendix 4 . Certificate of Recognition ........................................... 9

WMDP - "Markochim" Coke Ovcn & l3y-l'roducts I'lant -

Final Report

I. INTRODUCTION

In September 1995, an amendment was added to the United States Agency for International Development's (USAID's) and World Environment Center's (WEC's) Cooperative Agreement No. ANE-0004-A-00-0048-00 to include Ukraine as one of the additional countries to receive WEC's technical assistance, training and information dissemination services related to urban and industrial pollution.

WEC'activities in Ukraine are implemented in two phases as follows:

Phase I - Initiated in October 1995. Under this phase, the program focuses on reduction of environmental pollution caused by industrial activities through waste minimization. This includes better utilization of natural resources and conservation of energy, with emphasis on financial benefits. Waste Minimization Demonstration Projects (WMDP) were established at four industrial enterprises in the Donetsk region. The goal is to demonstrate to these enterprises the cost savings and reduction in environmental pollution Srom waste minimization and to encourage the incorporation of this program into the permanent policy of plant management.

Phase I1 - Initiated in September 1996. This program is similar to Phasc I, with additional emphasis on energy conservation, specifically on reduction of natural gas consumption. Six Waste MinimizationIEnergy Conservation Demonstration Projects (WMIECDP) are being implemented at various plants in Donetsk and Dnipropetrovsk regions.

This report describes the benefits achieved from implementing a demonstration project at the "Markochim" Coke Oven and By-products Plant in Mariupol, which was one of the lour enterprises selected for a WMDP under Phase I in the Donetsk region. The project was initiated in December. 1995 and concluded in September 1997 with a close-out meeting in Mariupol.

Final findings and benefits resulting from this Waste Minimization Demonstration Project as prepared by "Markochim" are presented in this report (See Appendix 2). Highlights of the close-out ceremony are also described.

WMDP - "Markochim" ('oke Ovcn & I3!'-l'roducts I'lant -

1:inal Report

!I. EXECUTIk ,I; SUMMARY

Pursuant to the technical assistance program for Central and Eastern Iiuropean countries by the United States Ageno?. for International Development, the World Environnient C'enter (WEC) conducted an Energy Conservation/Waste Minimization Demonstration I'rqject (ECIWMDP) at the "Markochim" Coke Oven and By-Products Plant in Mariupol, Ilonetsk region, Ukraine.

The WEC team visited the "Markochim" Coke Oven and By-products Plant in December 1995 and jointly with Markochim personnel recommended implementing an Energy ConservatioidWaste Minimization Demonstration Project to reduce the use of coke oven gas for underfiring of the coke ovens and eventually conserve natural gas in Ukraine. This involved installing an in-situ oxygen analyzer for continuous measurement of the excess oxygen in the flue gas which would permit improved control of the flow of combustion air. The project was subsequently implemented with the fdlowing results as confirmed by Markochim Plant management.

Project Description rn Equipment Provided by WEC

Improvements in combustion efficiency at coke oven battery

Oxygen Analyzer & Combustion Efficiency Systems @, ., cost of $21,000

Projected Benefits

Monetary

Payback less than 7 months

Environmental1 Energy

Conservation * * Reduced consumption of' coke-oven gas by 2,730,000 m3lYear; reduced emissions of CO? by 2500 tons per year

A close-out ceremony Lvas conducted on September 15, 1997 at the Markochim Plant which summarized the results of the demonstration project. Formal ownership of the WEC-supplied instrumentation was transferred to the Markochim Plant during the close- out meeting.

Details of thc I<C/WMDP are provided in Progress Report No. 1 issued in February 19%.

* Based on value of coke-oven gas of $ 14.60/lOOO m3

": Based on data obtained by Markochim during second quarter performance in 1997

WMDP - "Markochim" Coke Oven & BJ.-Products Plant - Final Report

111. GENERAL BACKGROUND

"Markochim" Coke Oven and By-Products Plant is located in the city of Mariupol, population 600,000, located on the northern shore of the Sea of Azov. due south of the city of Donetsk.

There are two large steel plants in the city, Illycha and Azovstal, which have a combined capacity of 12.8 million tons per year. The Coke Oven and By-Product Plant "Markochim" is located adjacent to the Azovstal steel plant and supplies metallurgical coke and coke oven gas to that facility.

At the time of the first visit to Markochim, the coke plant consisted of a line of five batteries. Four of the batteries were older, smaller batteries of 61 ovens, built in the 1950's with a designed capacity of 450,000 tonneslyear each. The #1 Battery began operation in 199 1. It contains 65 ovens and has a designed capacity of 930,000 tonnes per year.

'The plant also contains the necessary coal handling (preparation), coke chemical (by- product) and coke handling operations to complete the facility.

IV. DESCRIPTION OF PROJECT

The transformation (coking) of coal into coke is an endothermic process during destructive distillation. A great amount of heat is required to drive off the volatile portion of the coal (28%) to produce the final result, coke. The end product is approximately 00% pure carbon. The volatile matter that is driven off is then either condensed, stripped out of the gas (tar, naphthalene, light oils, ammonia), or continues on as coke oven fuel gas (composed of hydrogen, methane, heavier organic gases and inerts such as nitrogen and carbon dioxide). Approximately one-third of the total gas produced is returned to the battery to provide fuel for the process through combustion in brick walls of flues separating individual ovens.

Since a relatively large percentage of the fuel gas a battery produces is returned for underfiring, thus resulting in a significant quantity of heat input into the battery, economies can be realized with good combustion control. This would reduce air emissions. energy usage and increase coke oven gas availability for sale to Azovstal. An additional benefit would be reduction of "r ich combustion excursions which cause the stack plume to darken. An in~provement in heating of the coke may also be realized.

In joint discussions with plant personnel concerning coke technology, a project was identified which could provide benefits to the plant and which met WEC guidelines. The project was to improve control of the combustion process to heat the ovens by installing a combustion monitor. This instrument measures oxygen content in the flue gases. as a

means to reduce usage of excess air, thus conserving energy. It was originally estimated that a 1.5% reduction in coke-oven heating cost was possible, which would reduce the usage of excess air by 308,000 m3/day thus conserving the energy required to heat this quantity of air.

As a result of the installation of the oxygen analyzer, Markochim reports an estimated daily reduction in coke oven gas consumption of 7595 m3/day which is valued at 205 hrivnasiday. (See page 1 of Appendix 2). For 360 days operation per year and at 1.84 I~rivnasidollar, the estimated annual benefit is $40,000.

V. PERSONNEL

During the plant visits and during subsequent engineering effort, the key participants included:

Markochim Coke Oven Plant - Yuri Gostev, Technical Director

- Nicolay Polytayev, Deputy Chief Engineer

World Environment Center - Dr. Bohdan Aftanas, Program Manager John Oberlatz, Consultant

- Richard W. Cornman, Sr., Volunteer Specialist - Gennady Merkhelevitch, WEC Coordinator

VI. CHRONOLOGY OF PROJECT

October 1995 Reconnaissance visit by WEC team

Ilecember 1995 Follow-up visit by WEC team to identify the project

February 1996 Recommendation issued for Oxygen Analyzer installation

June 1996 Instrumentation ordered by WEC

September 1996 Instrumentation arrival at Markochim

December 1996 Instrumentation installed and data collection initiated

September 1997 Close-out of Project

WMDP - "Markochin~" Coke Oven & 13y-Products I'lant -

Final Report

O n September 16, 1997 a close-out ceremony was held at the Markochim Coke Oven and By-Products Plant to formally conclude the demonstration project. There were 21 participants representing the plant management and the municipal and regional xhinistration, the United States Agency for International Development, the World Ihvironment center and the local press and television.

'lhe ceremony was chaired by Mr. Yuri Gostev, Technical Director, who in his opening statement, expressed his satisfaction with the results of the demonstration project, which he considered as a first step in implementing a plant-wide waste minimization and energy conservation program. Also he indicated the company's interest in future cooperation with the WEC, specifically on the Impact Program. Mr. Thomas J. McGrath of the World Environment Center outlined WEC7s current and upcoming programs in Ukraine, and thanked the plant management for their interest and cooperation.

Ms. Lea E. Swanson, from the United States Agency for International Development, expressed the Agency's appreciation for Markochim Coke Oven and By-products Plant's participation in the program. Also, she briefly described other funded activities by USAID in Ukraine.

A short presentation of the completed demonstration project, including its environmental and financial benefits, was made by Mr. Nicolay Polytayev, Deputy Technical Director, at the Markochim Coke Oven and By-Products Plant. At the conclusion of the ceremony. Ms. Swanson, on behalf of USAID, transferred ownership of the equipment to the Markochim Coke Oven and By-products Plant and presented the plant with a Certificate of Recognition.

A list of the close-out ceremony participants is included in Appendix 3.

WMIII' - "Markochim" C'okc Ovcn & 112~~-l'rod~1cts Plant - Final Report

APPENDIX I

DIAGRAM OF OXYGEN ANALYZER INSTALLATION

k l a c h l n e S i d e

+&--~omn~on Waste IIeat Flue

Control R o o m

WMDP - "Markochim" C'okc Oven & 13) -1'roducts I'lanl -

1:inal Report

APPENDIX 2

FINAL ESTIMATE OF BENEFITS

(Prepared by "Markochim")

BEST AVAILABLE COPY

REPORT on use o f WC-?GO and M A X - 5 Gas XnaLyzern

a t M A R C X H I K P l a n t

( I t was made f o r WEC., New Ybrk)

Below is g ive3 a c a l c u i a t i ~ n o f ga& a a v i n g an t l c ipa t t sd f o p t h e

second q u a r t e r of 1997, w h i c h was done exuc3ly on t h e sane b m i a as

$he one p r e v i o u s l y made fay che first t h r e e m n t h s o f the year , Rkcess oxygen i n t h e c.ornbuction ~ r c l c h c t s cropped from 6.4% to 4.,5!6.

A i r consumption d a i l y reduction is u s follows: 3 4-00; X (8.96 - $ ..16> = ~ D G ,.,a00 m- .

U n f o r t u n a t e l y , it ic a o t j ios.s lb ie t o ?c?nclude thst , hers is, in addision to %he aLcve, agy n a v i n g regarding o t h e r variables, f o r t h e h e a t i n g of The coke oven 'ba t te ry is c s n t r n 2 l e d noG v l a oxygm

canten"$ of t h e conitmati,an r~radurzs, an& iz is done t .s main ta in f i ecossa ry q u a l i t y Level of tte coke b e i n g grscivced u n d a r chansee of

The p r t a b l e ~ R B ~ n a l : i a e r s M A X + aps brsing u ~ e 3 it all. coke oven bat;$-

eriew a v a i l a b l e a t t h e p i a n t tnas r e s u l t e d i n r e h c i n g a number o f t h e l abora to ry s t a f f : nos less t h a n by t w o emplo:seea, 8r.d in redtlcing

*

the l a n g h of tine neer2eb $ 5 get t h e ~ ~ t t e r g h o a t ~ h ,

BESTAVAILABLE COPY

CENTER, NOY Y0rh3

APPENDIX 3

LIST OF CLOSE-OUT CEREMONY PARTICIPANTS

i to I I

THE CLOSE OUT CERSMONY AT "PARCOCXIM" COX5 FLANT

DATE: September 16, 1397 YROJECT: WM & EC Demonstration Pro , jec t

lr The ...- Plant ' e P e r s o n ~ e Yuri Gostev

Nickolas Politnyev

Valery A1.yokhi.n

P e t e r Bandar t chuk V l a d i n S r O l e y n i k o v

Calina Cropovs

Yckaterina Levtchenko

T e c h n i c a l D i r e c t o r Deputy T~chnlcnl D i r e c t o r Assistant t o t h e Board Chairman C h i e f E n g i n e e r D e p ~ t y Head of Production B Technical Department Transia t c r Chief E d i t o r the Ylant's "Xokscchimic"

' 8: Minis*-of Envircnrnental I ? s s t ec t ion and Nuclear Safeby of Ukra ine --.__ . --."I-------.-.-

Dr.Svystoelav %ur+ulenko Yadim Mamula

k&EPA: Douglas McCunry Joh2 Johnson

Daniel Thonpson

klan Farrnes @S&3AID:

Lea Swanson

Hend, Deparcmenz of I n t e r n a t i o n a l Relations

Head of Donetsk Office Head of Mariupol Off ice

Frogran Manager, Off ice o f I n t e r n a c - i o n a l A c t i v i t i e s

I l i rec tor of Envizonmental Degwr"vmnt Regional Piifision f o r Ukraine

E ~ . E n v i r o n m n t a l P a l l c y & Taz@Ag&y i?ro;i,eck :

Barbara James Kyiv Offics NLckoZas C h e r e m i n l n o f f U i r e c t o z * Donetsk O f f ice

7 , WEC: Thomas McSrat3 Vico Pref t ident Cennady F s r k h e l e v i c c 3 In-Count ry C o o r d i n a t o r

4- t 3 . "Strntg~ia" m v i m n : : ~ z n : a l Protect:on Coordination Censer : -- l r i n a S u t o r i n a Chairman

WMIII' - "Markochin~" Coke Oven & 113) -I'roduc~s Plant - Final lieport

APPENDIX 4

CERTIFICATE OF RECOGNITION

WORLD ENVIRONMENT CENTER rrncler- its cooperative ;igt*ecment with the

United States Agency for International Development presents its

Certificate of Recognition to

"Marltochirn" Coke Oven & By-products Plant Mariripol, Ukraine

Antony G. Marcil, President & CEO