TOGLIATTIAZOT IS IN THE CLEAN ZONE

Environmental safety programs in the chemical industry are among the most sophisticated ones, and a significant part of investments is spent in this sphere. A good example is Togliattiazot, one of the world's largest ammonia producers.

Industrial Ecology

Industrial and ecological safety development program at OJSC Togliattiazot (TOAZ) focuses on continuous environmental monitoring, emission reduction and waste utilization. The company implements this in accordance with Investment and Modernization Plan until 2022. Particularly, it includes modernization of all 7 operating ammonia plants, air compressors, replacement of reaction tubes and heat exchangers.

Ecological Monitoring

Environmental compliance monitoring is conducted by two laboratories: sanitary-industrial and BTP laboratory. Samples are collected not only on the industrial site, but also in the Sanitary Protection Zone (SPZ) of the company.

Special attention is paid to the water quality. For example, surface water sampling is carried out in Saratov water basin on a regular basis at two points: 1 km above the wastewater outlet of the North industrial hub (this is a baseline sample used as a benchmark for comparison) and 0,5 km downstream. In the area of the underwater line of the wastewater discharge collector, sampling is carried out at 50 m above and below the line. Wastewater toxicity is analyzed, and from May to September sampling on the Volga River is conducted for microbiological studies.

Atmospheric air monitoring is carried out by the company’s portable laboratory. This laboratory is able to simultaneously analyze tens of environmental air components in a real-time mode. The key device of the measuring complex is a highly sensitive infrared spectrometer - interferometer, which automatically analyzes composition of the atmospheric air every 2—4 minutes in 20 components.

The content of ammonia, nitrogen oxide and dioxide, carbon oxide, formaldehyde, hydrogen sulfide, sulfur dioxide and methanol in the air is under control. These are just some of the components monitored.

Along with the industrial site, the atmospheric air condition is controlled in the SPZ. Four points near residential communities must be obligatorily controlled (as per the analytical schedule), but in fact the number of them is much greater. Other companies in Togliatti have no such equipment; that is why Togliattiazot ecological monitoring staff takes measurements at the most congested intersections and in case of accidents at other plants, following requests of Rospotrebnadzor (Russian Federal Consumer Rights Protection and Human Health Control Service).

The company’s short-term plan is purchasing of a next-generation portable laboratory at the cost of more than RUR 10 mln. Its capabilities are even greater: counters will be more sensitive, the laboratory will be able to operate in the off-line mode — from a battery — up to 12 hours, and its own emissions (yet, it’s based on a truck) will be minimized. Further, when operating at a speed of up to 40 km/h, it can take measurements every 5 m. The laboratory will be able to create a contaminant concentration map on a real-time basis and store a large archive of such data, which will be a useful aid in a deep analysis.

Wastewater treatment

For several years, TOAZ has been implementing an overhaul program for the biological treatment plants (BTP) and the water treatment system. Within a few years TOAZ, which purifies not only its own wastewater, but also the wastewater of several districts of Togliatti, has managed to reduce its wastewater specific amount by 32% per production unit.

Before entering BTP, company’s wastewaters undergo preliminary treatment at 9 local units available in all main shops, and then mixing at the wastewater monitoring and preparation unit. Actually, this is a complex, which includes mechanical treatment; after that, wastewaters enter sedimentation basins, then they undergo biological treatment proper (using microorganisms), filtration and ultraviolet disinfection in three up-to-date units. With the appearance of these units, chloration (and penetration of chlorine compounds into the Volga River) has been excluded from a disinfection process in 2007–2008.

In the coming years, TOAZ is planning to invest up to RUR 5 bln. into new water treatment technologies and treatment plant modernization. This is stated in one of the provisions of Investment and Modernization Plan until 2022. Currently, pilot tests of various technologies are being carried out at a pilot-plant unit. For example, a technology using membrane bioreactor and reverse osmosis unit are being tested now. The most viable solution is to be chosen before November. At the same time, a contract for development of a feasibility study of this modernization and for implementation of the project main engineering solutions is being prepared.

Fresh Air

In 2014–2015, TOAZ conducted urea and ammonia production modernization, which reduced atmospheric emissions and prevented soil contamination. Modernization in 2014, which excludes natural gas combustion heater at three home-manufactured ammonia plants (АМ-76), reduced annual pollutant emission by 90 t.

And a reformer heater modernization at Chemico ammonia plants, with which TOAZ began 35 years ago, has made it possible to implement modern technologies and conditionally divide carbon oxides into «clean» and «unclean» groups: the «unclean» group is flared, and the «clean» one is used in urea, methanol and CO2 production. Up to 75% of carbon dioxide is reused; this number meets globally accepted indices.

In the interest of the Volga Region citizens

Attention to the ecology doesn’t end inside TOAZ Sanitary Zone. In 2013, at the IV International Ecological Congress ELPIT-2013 (TOAZ was a sponsor), a partnership agreement between JSC Togliattiazot and a national park «Samarskaya Luka» (Samara Bend) was signed. This is a major local tourist center and a preferred resort of Togliatti citizens. As part of the agreement, recreational facilities in the territory of the Molodetsky Barrow, the most frequented place of the 75-kilometer-long ridge of Zhiguli Mountains, were reconstructed, works on preservation of an historical monument in Shiryaevo Village were conducted (calcareous factory facilities of a well-known Saratov merchant Georgy Vanyushin, built in the early20th century). Interactive models of the objects were constructed on the observation deck of the Popov Mountain, a huge number of joint volunteer actions and environmental actions were arranged.

ТОАЗ efforts are not vain: in September 2015, Togliatti ranked among the top five Russia’s best cities in «Waste Management» according to the ecological rating prepared by the Ministry of Natural Resources and Environment of the Russian Federation. Following last year's results, TOAZ was again awarded a prize in the Leader in Industrial Ecology in Russia nomination.

Dated 22.10.15