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Coal: you can not dust

How to deal with "black dust" in the Far Eastern ports, found out at the terminal "Daltransuglya" EastRussia

The coal terminal in Muchke Bay, Khabarovsk Territory, owned by Daltransugol JSC (SUEK Group) is one of the largest in the Far East: since the spring of 2017 the enterprise has reached an annual capacity of 24 million tons. Large amounts of processing, it would seem, inevitably entail an increased load on the environment - after all, coal, as is known, with overload "dust". And how sharply the society treats the appearance of coal dust in the ports, a recent "straight line" with President Vladimir Putin showed where the boy from Nakhodka complained about the actions of the local stevedore. At the same time, modern technologies make it possible to make the process of coal transfer as harmless as possible to the environment. True or not, EastRussia decided to find out at the facilities of Daltransugol.

Coal: you can not dust
Photo: Daltransugol
Dust "eat" foam and fog
 
Favorable price conditions make it profitable for Russia to export coal through the Pacific ports: transshipment rates in the Far East are increasing year by year, new projects are being announced for tens of millions of tons annually, and by 2025, according to some forecasts, coal export volumes from the macroregion may to double. The "coal boom" observed in recent years has the opposite side: the load on ecosystems on the part of stevedores is growing. Protests over the growth of transshipment volumes are traditionally heard in the two most developed regions of the Far East, from the point of view of port logistics: Khabarovsk and Primorye. 


 
Meanwhile, many stevedores began to try to radically reduce the damage from transshipment for the environment even before the growth of volumes. In the port of Vanino of the Khabarovsk Territory, where a significant share of coal is shipped annually, the largest stevedore remains JSC Daltransugol, a subsidiary of SUEK. Over the solution of the problem of dust suppression in the company began to work in 2012 year.
As part of the program "Modernization of dust suppression systems", explains the deputy head of the department of environmental protection and environmental control of JSC Daltransugol Yulia Dolgopolova, at the coal terminal of JSC Daltransugol, a full cycle of dust suppression is being created - for the Far Eastern coal ports this is a unique system that is constantly being improved. In fact, this is an ongoing process of purchasing more and more new equipment designed to reduce the impact of coal transshipment on the environment. So, in 2013 for cleaning coal dust from the territory of coal warehouses, in order to prevent the spread of dust by the wind, a vacuum mobile cleaning plant "SCANIA" was purchased. Technologies of dry collection and transportation of coal dust and coal spills using vacuum equipment of the Swedish company "DISAB Vacuum Technology" were introduced, including stationary vacuum installations in the buildings of transfer stations and a car dumper were put into operation. "This has made it possible to significantly improve the microclimate and air in the working area of ​​the industrial buildings of the enterprise," says Yulia Dolgopolova.
 
In 2014, the company continued to solve the problem of dusting in a coal warehouse: it purchased two stationary WLP1200 dust suppression units, with the possibility of remote control and operation in winter at low temperatures. In the gallery of the car dumper, a coal irrigation system was installed on the belt, in the galleries and the transfer station. This is a foaming system applied at the terminal of JSC Daltransugol for the first time in the world. This innovative dust suppression method has many advantages from an operational point of view, including: minimal water consumption, higher dust collection efficiency and increased wetting effect. From an environmental point of view, the use of foam provides a harmless and neutral biodegradation of the reagent, rapid dispersion without stirring. Considering that foam binds dust best even from very oily coals, it was decided that it is best to completely cover all the coal on the conveyor belt with it, from the very beginning of the exit from the car dumper. Further, the foam encloses a significant part of the dust, which is released in the overfills, when transporting coal to the piles.
 
In the same year, in order to absorb coal dust during unloading of cars and stop its further spread in the air of the working area in the building of car dumpers at an elevation of 6,240 above the receiving hoppers of the feeders and at an elevation of 0,000 m, the installation of irrigation units - foggers was performed.
 
Hover your mouse over the carin to zoom in


Dust less help the control station

In 2015, in order to reduce the dusting process during loading operations from the warehouse to the ship, a dust suppression system was installed at the terminal on the stacker-reclaimer No. 2. This technology was applied at the terminal of JSC Daltransugol for the first time in Russia. In the same year, in order to reduce the dusting of coal on the belt when loading onto a ship, a DUSTEX® dispersion system was installed in the transfer station. In 2016, an additional CENTURION 200 / -1812 vacuum loader was purchased to remove coal dust from the territory of coal warehouses in order to prevent the spread of dust by the wind.
 
Within the framework of the Eastern Economic Forum, the Ministry of Natural Resources and Environment of the Russian Federation, the Federal Service for Supervision of Environmental Management, the government of the Khabarovsk Territory and JSC SUEK signed a number of agreements on September 2, 2016. The documents were signed by the Minister of Natural Resources of Russia Sergey Donskoy, the head of the Federal Service for Supervision of Natural Resources Artem Sidorov, the Governor of the Khabarovsk Territory Vyacheslav Shport and the General Director of JSC SUEK Vladimir Rashevsky.
 
The signed documents provide, in particular, for the implementation of complex environmental protection measures in JSC Daltransugol. Their implementation is scheduled for 2017-2019. In 2017, within the framework of the implementation of the quadrilateral agreement, Daltransugol JSC started to solve the assigned tasks.
 
The station for automated control of atmospheric air SKAT was purchased and installed in the residential area in the village of Toki. The station was manufactured in St. Petersburg by OPTEK JSC by order of Daltransugol JSC. Its cost amounted to 7 million rubles. The station is designed for continuous automatic measurement of the mass concentration of pollutants in the ambient air, as well as for recording meteorological parameters, air temperature, relative humidity, speed and direction of the air flow and atmospheric pressure. The newest equipment collects, registers, processes, visualizes and stores all received data.
 
The station consists of an ecological module equipped with measuring instruments - gas analyzers for the determination of nitrogen dioxide, automatic information and measuring systems, a sampling system, data storage and transmission equipment, meteorological equipment. The station has the most modern video surveillance and fire and security alarm systems. After the acquisition of the station, without waiting for the release of the method for determining the dust of coal in the atmospheric air, the company's management decided to complete the station with a gas analyzer to measure the mass concentration of suspended particles in real time. Currently, procurement procedures are underway to purchase this device. After the release of the method for determining the dust of coal, the automated station will be equipped with a device specializing in such measurements.


 
On dust suppression - hundreds of millions and guns
 
But this will not be limited to this in 2017 at Daltransugol. The technical director of the company, Vladimir Dolgopolov, says that another of the activities highlighted in the four-party agreement is the purchase and installation of a DUSTEX dust suppression system in the car dumper hall, at all levels of the car unloading station up to -17 m from the floor level in the building. The equipment supplier is the Russian company EIM Engineering LLC together with a German manufacturer. Delivery and installation are expected in September 2017, the cost of the installation will amount to RUB 48,5 million.
 
"The DUSTEX dust suppression system will be aimed at minimizing dusting at coal transfer points by spraying an air-water mixture with nozzles," explains Vladimir Dolgopolov. water is sprayed using compressed air, as a result of which a droplet spectrum of 20-40 microns is achieved, capable of enveloping coal dust.Installation of the system will reduce dust emission when unloading cars, increase the fire safety of production facilities, reduce the volume of airborne coal dust, which is a source of environmental pollution, and the level of dustiness in the air of the working area at workplaces will decrease. "
 
In 2017, the company, as planned, will supply and install four WLP-1200 dust suppression units along the perimeter of two coal warehouses, Vladimir Dolgopolov continues. The supplier is the same EIM Engineering LLC together with an Italian manufacturer. The total cost of the equipment is 108 million rubles.  
 
In addition to two stationary dust suppression units already installed at the terminal of JSC Daltransugol, the installation of four more will allow achieving an even greater effect in the fight against dust in the open areas of the enterprise. The dust suppression system ensures efficient irrigation of stacks of coal with minimal water consumption, leaving no puddles, since irrigation occurs in the form of mist spray, covering a large area, and at the same time effectively suppressing dust. Due to the use of an electromechanical system of rotation, the angle of rotation of the guns is 340 degrees. 
 
The cannons will be installed: one - along the northern side of the coal warehouse # 4, the second - along the warehouse # 5, the third - at warehouse # 2, south side, and the fourth - at warehouse # 2, north side. Additional irrigation cannons will create a curtain between the coal storage, the water area of ​​the Muchke Bay and the territory of the residential zone. “This is especially true in the case of east and southeast winds, when the coal dust blown out from the pile, previously, without measures to reduce dust formation, was significant,” emphasizes Vladimir Dolgopolov.
 
In addition, the company will continue to install irrigation systems directly to stalkers-reclaimers, which for the first time made in 2015 year, creating a unique practice for Russia. "The acquisition of another dust suppression unit on the stacker-reciter is another step to combat dusting during the loading and unloading activities of the enterprise," says the technical director of Daltransugol. 
 
According to him, the modern dust suppression system consists mainly of:
- two fogging guns, which are installed on the boom of the stacker-reclaimer;
- two tanks with water, the volume of 13 cubic meters each, which are installed on the loop car;
- a pumping unit located on a trolley;
- a system of pipelines between the reservoir, the pumping unit and the fogging gun.
 
The supplier of equipment for the stalker-reclaimer of JSC "Daltransugol" in 2017 is TAKRAF (Germany). The cost of equipment will be 62,5 million rubles. The equipment is planned to be installed at the beginning of 2018. 

Implementation of the above listed dust suppression systems in a complex manner will reduce dust emissions by 44.3%. It is also advisable to note that the effect of the measures already implemented is confirmed by the results of regular laboratory measurements of atmospheric air quality at control points and at the border of the SPZ of JSC Daltransugol. During the studies conducted, no excess of the established standards was noted. Moreover, if in 2013-2014. the concentration of dust in the atmospheric air was 0,145 mg per cubic meter, then in 2016 the figures decreased to an average of 0,075 mg per cubic meter. These achievements are very important for JSC DTU, because environmental protection and ecology are the main, priority direction in the implementation of the economic activities of the coal terminal - the strategy of sustainable development.
 
Daltransugol will also continue design work on "Modernization of treatment facilities for surface and industrial effluents of the terminal's industrial zone" with the subsequent implementation of this project in 2018 - 2019. Modernization of the existing treatment facilities will allow to reuse purified water from the production area of ​​the enterprise for dust suppression measures, as well as increase the productivity of wastewater treatment to 400 cubic meters per day. The cost of design work will amount to 8,6 million rubles.
 
Additionally, within the framework of environmental protection measures, JSC Daltransugol is working on equipping the hydraulic structure of pier No. 5 with a system for collecting and discharging surface rain and melt water into the general water recycling system of the enterprise. At the current time, project documentation has been developed and work is underway to purchase equipment and implement this project. The cost of this project will be RUB 13 million. This design will ensure the protection of the Muchke Bay water area from pollution and clogging.
 
It should also be added that in 2017, JSC Daltransugol acquired the second car on the basis of the KamAZ truck "AQU-15 Water Truck" with an irrigation system for warehouses. And now in the park of JSC "Daltransugol" two such cars.
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