Àlmagul Agibayeva, Aset Tagibaev, Eleonora Dzhakashova,

Laura Alzhanova

M.H. Dulaty Taraz State University, 080000, Taraz, Tole bi 60, Republic of Kazakhstan

The influence of plant producing glass empties on the environment

It is the purpose of the study to research of the influence of emissions of the industrial base of the “Yuzhniy -3” branch of JSC “Glass works SAF” on environment and efficiency of environmental activities of the enterprise.

The only existing glass plant producing glass empties in Kazakhstan is JSC Glass Company “SAF” was founded in 1999. The industrial base of the “Yuzhniy -3” branch of JSC “GP SAF” has 1 industrial site with 40 sources of harmful emissions into the atmosphere, including mobile trucks, among them 32 sources are organized. Regulatory emission of harmful substances in 2010 is 17.7066 g/s, 473.8298 tons/year [1].

Source of water supply of the enterprise is its own borehole (¹ 0184/21a) water consumption is carried out for industrial and domestic use, as well as watering on green spaces and hard surfaces with water, in accordance with a special Permitting for use. On industrial platform domestic sewage and sewer water are formed. Amount of waste water is 0.03 m³/day, 109.5 m³/year. Sewer and melting water drainage from the territory of the gas station is provided into a sewage treatment system.

As a result of activities of the company following types of waste are formed industrial waste, municipal solid waste (MSW) and rubbish from the territory; given the number of employees at the 417 people per year, municipal solid waste is produced at 600 tons/year. At storage of solid waste and overflow of metal containers it is possible to contaminated sites their placement and drainage of contaminated runoff after rain.

Implementation of timely, effectively and well developed environmental activities is a key element in reducing the harmful effect of the enterprise on the environment.

Upon the glass manufacture process, air-polluting compounds like nitrogen oxides, sulfur dioxide and particulates are released. The last are even more of a health issue since the particles of metals, chemicals, acids and dust that the particulates are comprised of are so tiny (10 micrometers or even smaller) that they are able to easily enter the nose and throat and reach the lungs, where they produce quite some damage.

It is the purpose of the study to research of the influence of emissions of the industrial base of the “Yuzhniy -1,2” branch of JSC “Glass Plant SAF” on environment and efficiency of environmental activities of the enterprise.

Methods of investigation - account and checkup of the sources surge plant were conducted by a conventional methods. Sanitary-hygienic, sanitary-microbiological tests and measurements of physical factors (including the analysis of groundwater meeting to the requirements SanR&N^* 30200204) held once in three month by the Center for sanitary-epidemiological inspection of the Almaty region, according to an annually renewed agreement.

^* - Sanitary Regulations and Norms

According to the draft manual section of the borehole, the monitoring the volume of fresh water extracted from the borehole, the carried out daily using water meters of STV^*-80 mark, having a quality certificate and passed the state quality control. Dynamic and static groundwater level is measured once in three month with electric level measurer, the temperature of underground water - once a quarter with thermometers. Data are recorded in the log standard pattern.

As a result of investigation the following facts were obtained.

The only existing glass plant producing glass empties in Kazakhstan is JSC Glass Company “SAF”. JSC “Glass works “SAF” was founded in 1999 on the basis of three branches: the branch “Yuzhniy – 3” (Almaty region), the branch “Yuzhniy-1, 2” (Zhambyl region) and the branch “Vostok - steklo” (East Kazakhstan region). The main activity of the company is production of glass. Productive capacity is 250 million conventional bottles per year. The “Yuzhniy - 3” branch of JSC “Glass works SAF” is located in an industrial zone Pervomaiskiy vill., on the territory of former “Remstroytechnika” and borders:

• on the north - the territory of oil depots and Almaty broiler farm;

• on the west, east and south - the industrial objects "Remstroytehnika;

• on the south – at a distance of 570 meters is a railway Almaty, Zhambyl Otar;

• on the west - at a distance of 280 meters river Aschybulak.

The nearest residential area of "Remstroytehnika is located at a distance of 560 meters in a south-easterly direction from the outermost source.

The nearest habitation area is Karasu village situated at a distance of 1800 meters in a south-easterly direction from the site.

The industrial base of the “Yuzhniy -3” branch of JSC “GP SAF” has 1 industrial site with 40 sources of harmful emissions into the atmosphere, including mobile trucks, among them 32 sources are organized. Regulatory emission of harmful substances in 2010 is 17.7066 g/s, 473.8298 tons/year.

Emission sources are the following:

-Two chimneys on a 1, 2 glass melting furnaces as fuel gas from Bukhara is used. Nitrogen oxides, sulfur dioxide, carbon monoxide, dust charge (20-70% SiO₂) are released into the atmosphere.

-General exchange ventilation of the producing plant shop, packaging of finished products plastic film. Carbon monoxide and acetic acid are released into the atmosphere:

- Tube of the aspiration system of from the of transport line of cullet and batch. Inorganic dust (more than 70% SiO₂) is released in the air.

- Tube of the aspiration system of from the hopper furnace ¹ 1. Inorganic dust (more than 70% SiO₂) is emitted in air.

- Tube of the aspiration system of from the hopper furnace ¹ 2. Inorganic dust (more than 70% SiO₂) is released in the air.

-Pipe of the gas cleaning system of the drying drum from feldspar concentrate. Inorganic dust (more than 20% SiO₂) is released in the air.

- Pipe of the gas cleaning system of the drying drum from sands. Inorganic dust (more than 70% SiO₂) is released in the air.

- Pipe of the gas cleaning system of the drying drum from limestone or dolomite. Dryer drum turns works either on limestone or on dolomite. Inorganic dust (less than 20% SiO₂) is released in the air.

^* - Water Meter Technical

- Tube of the aspiration system from the sand processing line. Inorganic dust (more than 70% SiO₂) is released in the air.

-A single pipe from two aspiration systems from the crusher and polygonal bolter of limestone or dolomite. Crusher and screen work in turn either limestone or on dolomite. In the air is released inorganic dust (less than 20% SiO₂);

- Tube of the aspiration system from the limestone or dolomite. Transportation of the materials in turn works line of transport either on limestone or dolomite. Inorganic dust (less than 20% SiO₂) is released in the air.

- Tube of the aspiration system on the line processing and transporting of soda ash (systems operate in turn, with single source). In the atmospheric air is blown sodium carbonate powder is blown up into the atmosphere.

- Tube of the aspiration system the line processing and transporting of sodium sulfate. air Dust sodium sulfate is blown into the atmospheric air.

- Tube of the aspiration system the line of transporting of feldspar concentrate after drying. Inorganic dust (less than 20% SiO₂) is emitted into the atmospheric air.

- Tube of the aspiration system the line of transporting of feldspar concentrate. Inorganic dust (less than 20% SiO₂) is emitted into the atmospheric air.

- Tube of the aspiration system the line of processing and transporting of feldspar concentrate. Inorganic dust (less than 20% SiO₂) is emitted into the atmospheric air.

-A pipe of the aspiration system from the line processing of cullet. Inorganic dust (more than 70% SiO₂) is released in the air.

-A pipe of the aspiration system of the weight line number 1 on the compilation batch cullet. Inorganic dust (20-70% SiO₂) is released in the air.

-A pipe of the aspiration system of the weight line number 2 on the drafting of the charge. Inorganic dust (20-70% SiO₂) is released in the air.

-A pipe from the aspiration system from the dosing-mixing line drawing of the charge. Inorganic dust (20-70% SiO₂) is released in the air.

-A pipe of the aspiration system B from the line of transportation charge. Inorganic dust (20-70% SiO₂) is released in the air.

-A pipe of the aspiration system the cullet processing line. Inorganic dust (more than 70% SiO₂) (source 23) is released in the air.

-Gate opening number 1. Emission of harmful substances occurs during unloading and the pouring of raw materials: sands, feldspar concentrates, dolomite, limestone and cullet are blown into the atmosphere. Dust sand and cullet (over70% SiO₂), dust feldspar concentrate and limestone (less than 20% SiO₂) are blown into the atmosphere.

-Gate opening number 2. Emissions of harmful substances occurs during unloading and pouring of soda ash into the air dust soda ash (sodium carbonate) is ejected.

-Maneuvering of vehicles on the parking is accompanied by combustion of fuel during engine operation: hydrocarbons, carbon monoxide, soot, nitrogen oxides, sulfur dioxide and benzo(a) pyrene are emitted.

-RMC^*-general exchange ventilation. When processing of carbon steel in grinding and surface grinding machines, abrasive dust (inorganic silicon containing 20-70% SiO₂) and metal (particulate substances) is released. At cooling and lubricating of cutting tools on turning, drilling, milling, cross-planning, jig boring, and surface grinding machines with engine oil, oil sprays (oil). When operating of acetylene generator nitrogen oxides are emitted. When surfacing alloy C-27 welding aerosol (inorganic dust less than 20% SiO₂), oxides of chromium and nickel are released.

-The exhaust pipe of the cyclone chamber from blasting mold sets. When processing of mold sets metal dust and small particles of sand (inorganic dust 20-70% SiO₂) are allocated.

^* - Mechanical repair shop

-General exchange ventilation of the welding section of the RMC. At the welding section of RMC work: welding machine of manual arc welding and cutting machine carbon steel propanbutan mixture. When welding many electrodes are used. Iron oxide, manganese dioxide, hydrogen fluoride are released into the atmosphere.

-Gas cutting of carbon steel by propanbutan mixture. Iron oxide, carbon monoxide, manganese oxide, oxides of nitrogen are emitted.

-The exhaust pipes of diesel power-station. Carbon monoxide, nitrogen oxides, hydrocarbons, soot, sulfur dioxide, formaldehyde, benzo(a)pyrene are allocated by engine installation.

-Respiratory valve of tanks of diesel fuel. To reserve diesel fuel of glass melting furnaces and diesel generators used two underground tanks with 75m³ capacity each. C12-C19 hydrocarbons and hydrogen sulfide are allocated.

-Emissions (leakage) at the stop and control valves, safety valves on the flanges of gas-storages.

-Storage backup of (emergency) fuel for the feeders of glass, annealing furnaces and output part of glass melting furnaces as which used liquefied petroleum gas. There are nine underground storage tanks with liquefied petroleum gas. Principal emission at the source is a hydrocarbon.

-In the lab out determining of the quality of the supplied raw materials, Fumes of sulfuric acid and fluoride (tetraflouride silicon) are released into the atmosphere.

-A carpenter's shop moldings and joinery blanks (trays for glassware) are produced. Wood dust arises when processing of timber.

-Maneuvering of trucks on the territory: hydrocarbons, carbon monoxide, soot, nitrogen oxides, sulfur dioxide and benzo(a)pyrene are emitted into the atmosphere.

-When filling bowser trucks with diesel fuel fumes of petroleum products: limiting hydrocarbons C12-C19, hydrogen sulfide (source ¹ 38) are emitted.

-Shunting locomotive in transportation-wagons out of the impasse of stations: hydrocarbons, carbon monoxide, soot, nitrogen oxides, sulfur dioxide are emitted.

Source of water supply of the enterprise is its own borehole (¹ 0184/21a) water consumption is carried out for industrial and domestic use, as well as watering on green spaces and hard surfaces with water, in accordance with a special Permiting for use.

The limit of water consumption is 91.5 thousand m³ per year, 250 m³/day including:

-drinking water: 50 m³/d; 18,250 m³/year;

-industrial water: 200 m³/d; 73,000 m³ per year [2].

On industrial platform domestic sewage and sewer water are formed. Domestic waste water is discharged into the reservoir JSC “Remstroytehnika”. Amount of waste water is 0.03 m³/day, 109.5 m³/year. Sewer and melting water drainage from the territory of the gas station is provided into a sewage treatment system. Contaminated waste water comes into a sewage treatment plant by gravity, after cleaning the water is used to irrigate the territory. Sewer and melting water drainage from the rest of the site is provided along pedestrian walkways, transportation, highways and into lower terrain relief. Driveways and sidewalks are covered by asphalt concrete and framed by borders. Industrial waste water that could be released onto the ground, and thus become a source of groundwater pollution in industrial processes are absent. Water wells are equipped with a pressure gauge to determine the water pressure, water meters, valves for water sampling and piezometers for determining the dynamic groundwater level.

According to the quarterly account given to the Balkhash-Alakol basin inspection, information obtained as a result of the primary account of water, and once a year is a statistical report on the fence, use and disposal of water (Water Industry) is made.

Formation, temporary storage, transportation, disposal or recycling of waste planned during of the exploitation are potential sources of exposure on the environmental components. As a result of activities of the company following types of waste are formed:

-Industrial waste;

-Municipal Solid Waste (MSW);

-Rubbish from the territory;

Industrial wastes include:

-about 50 tons of metal scrap is formed a year, which on is passed to “Vtorchermet” recycling enterprises.

-when operating vehicles and tractors up to four tires are worn and produces up to 0.3 tons of waste motor oil. Tires are hands in rubber company RTI^* for recycling and waste oil are sent to oil refinery for regeneration;

-Fluorescent lamps used to illuminating of the premises and territory. The enterprise uses fluorescent lamps in the amount of 478. Every year, 1000 lamps become useless, which, in order to prevent pollution of the environment from highly toxic wastes are sent for recycling to LLC^** “Synap plus” "according to the contract.

-oil and solid residues collected in rainwater treatment plants are used for manufacture of asphalt and concrete.

-municipal and solid waste and rubbish collected in containers, and then disposed of in landfills according to contract with the utilities.

Given the number of employees at the 417 people per year, municipal solid waste is produced at 600 tons/year. At storage of solid waste and overflow of metal containers it is possible to contaminated sites their placement and drainage of contaminated runoff after rain. To avoid such situations regular removal of solid waste and disinfection of containers and sites for their installation should be performed. So, for monitoring the impact of waste production it is necessary constantly monitor the timely removal of waste.

For all wastes passports of hazardous wastes is developed and the records of movement of these wastes is kept. Reports on hazardous waste in according to the form is given anually ¹ 316-p dated November 2, 2007.

To prevent the harmful effects of waste water the following activities are implemented:

-Monitoring of water consumption and wastewater volumes.

-Control after the technical condition state of vehicles in order to avoid spillage of fuels and lubricants.

-Organization of data collection and storage of waste, excluding the impact on groundwater.

-Conducting of routine preventive maintenance of equipment.

Monitoring of the impact on a surface and ground water should be reduced to monitoring of the implementation of environmental measures.

In order to protect soil from pollution, the company executed the following activities:

-The entire area free from buildings and landscaping covered with asphalt concrete and lined with curbs.

-Container filling units’ oil storage and fueling of vehicles is mounted on concrete pad, framed with curbs;

-A special concrete pad for installation of closed metal containers for the collection of solid waste, which prevents contamination of soil is organized.

-The organization of relief made with the account of surface water, not contaminated with petroleum products from the sites of warehouses on the topography of the green stripes [3].

^* - technical rubber product company

** ^- Limited Liability Company

Internal audits at the plant JSC Glass works "SAF" are held weekly. Responsible for conducting internal audits is an engineer-ecologist. During the course of internal audits it is monitored:

-performing of environmental measures provided by program of industrial environmental control;

-following the manufacturing instructions and rules relating to environmental protection;

-performing îf the conditions of permits for special nature;

-accuracy of reporting on the results of environmental control;

- testing of every object emitted on environment.

If violations indentions to the list of violations specifying is given the pointing methods of their eliminating and deadline. According to the results of internal audits the responsible for the environment makes a written report to the head of the company and keeps industrial monitoring.

Thus, we can effectively assess the impact of a glass containers plant to producing on the environment and timely develop environmental activities. Implementation of timely, effectively and well developed environmental activities is a key element in reducing the harmful effect of the enterprise on the environment.

References

1. Working draft "Assessment of the environmental impact of the plant for the production of glass, in 2000, Almaty

2. Draft standards for maximum permissible emissions of pollutions into the air plant to produce glass, 2007, Almaty

3. The program of "environmental control" branch of the “Yuzhniy -1,2”, JSC “Glass works "SAF"” at 2007-2012 years., Almaty