Abstract
This article presents the results of the energy saving and efficient use of resources upon implementation of innovative technologies at the Novotroitsk plant of chromium compounds (NPCC).
Research hypothesis. A dolomite-free technology is more attractive from economic and environmental perspectives if compared with a conventional technology of sodium monochromate production.
Research objective: to calculate energy consumption, chrome losses and pollution emission dynamics when producing sodium monochromate at NPCC.
Research methods: analysis of statistics.
It was NPCC specialists who have developed a dolomite-free sodium monochromate production technology based on research by T. Averbukh and P. Pavlov. The technology implies refusal of an inert filler by means of reuse of non-metallic residues.
The article demonstrates that a transition to the new technology has made it possible to achieve the following results:
- to reduce the cost of production due to the fact that there was no need to purchase dolomite and limestone (160,000 tonnes of raw materials per year would be purchased for production needs),
- to reduce energy consumption and equipment maintenance costs when drying and grinding dolomite,
- to reduce chrome losses with production wastes - sodium monochromate sludge,
- and, consequently, to decrease the chrome ore consumption rate for production.
Calculations performed in the work showed that the specific consumption of natural gas for the 1st quarter of 2015 decreased by 252.33 Gcal / t. Calculations of the annual capacity showed savings of over 13.87 million Gcal / year. The dolomite-free technology has affected a dramatic reduction in toxic sludge formation (by 9,046 tonnes / quarter - 37.6%) and chrome losses in production wastes (by 330.6 tonnes / quarter - 25.2%).
The environmental effect from the dolomite-free technology implementation has been calculated. The effect lies in the fact that the sludge output rate has reduced from 2.5 to 1.1 tonness per tonne of monochromate, which means reduction in the volume of waste disposal in a sludge collector. Cessation of pollution emissions from dolomite-oriented production processing stages such as unloading, storage, grinding and drying of raw materials has shown that the total volume of solid emissions decreased by 13.5% with increasing sodium monochromate output by 32.4%.
In general, the transition to the dolomite-free technology proves the feasibility of basic principles of sustainable use and a transition to sustained development in the chemical industry. The results presented in the work show that, if compared to existing technology, the dolomite-free technology greatly excells in such characteristics as energy efficiency, environmental friendliness, cost of production. The technology also supports chromium-containing raw materials of almost all global manufacturers, including low chrome ores and concentrates.
Keywords
Chrome, sodium monochromate, resource-saving technologies, sludge, energy consumption.
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