Process efficiency and environmental impact
The chemical industry is one of the sectors with the strongest impact on the natural environment. This area represents a particular challenge for the Grupa Azoty Group as a whole, and also imposes special responsibility on us.
The chemical industry is one of the sectors with the strongest impact on the natural environment. This area represents a particular challenge for the Grupa Azoty Group as a whole, and also imposes special responsibility on us. All our companies operate in compliance with the relevant environmental laws and regulations, and on the basis of appropriate permits. However, given the scale and scope of our activities as well as the potential we have, in our environmental protection efforts we want to go beyond what is strictly required by law. Every year, we spend millions on installations that reduce our negative impact on nature.
| Five key companies of the Grupa Azoty Group |
Capex on environmental projects in 2017 [PLN ‘000] |
|---|---|
| Grupa Azoty S.A. | 10,349 |
| Grupa Azoty Kędzierzyn | 70,065 |
| Grupa Azoty Police | 65,250 |
| Grupa Azoty Puławy | 52,500 |
| Grupa Azoty Siarkopol | 550,000 |
| Total for five key companies of the Grupa
Azoty Group |
748,164 |
BEST PRACTICE
Grupa Azoty S.A. collaborates with Reliability Solutions, a company established by graduates of the AGH University of Science and Technology. Our joint effort led to a test implementation of a modern PdM class RSIMS system at the V KGZ unit. Using modern artificial intelligence algorithms (e.g. Deep Learning), the system analyses vast amounts of data (e.g. sensor data, maintenance data, environmental data) to identify any indicators of deteriorating technical condition of the monitored machinery. The system monitors in real time about 300 process parameters of a unit and detects complex multi-level interdependencies which may indicate an imminent failure. The algorithms can also be used to identify probable causes of failures, allowing us to find the optimum way to operate the installations.
By applying PdM (Predictive Maintenance) techniques we can not only improve technical safety, but also reduce the number of unplanned stoppages, improve availability and, consequently, production efficiency, which is of paramount importance, especially in the case of critical equipment.
See what investments have been made by our Group companies to increase environmental efficiency:
Grupa Azoty Police
Our investment projects:
- Grupa Azoty Police spent more than ten million złoty on environmental projects at the Pigments Business Unit, Poland’s only plant producing titanium white. The lion’s share of this expenditure related to installations used for the removal of sulfur oxides from production gases: two modern desulfurisation reactors equipped with a new, more efficient catalyst, were added to the existing set of two. In order to reduce the pollutant emissions, the filters were modernised by modifying their technology, the way they are mounted, and the type of fabrics used. As a result, sulfur oxide emissions were reduced by at least five times, and are now about three times lower than the limit imposed under the Industrial Emissions Directive (IED).
- In 2017, modernisation of the ammonia unit was completed. The work had been undertaken to reduce the energy intensity of the ammonia production process.
- Upgrade of the urea granulation tower.
- The company is in the process of upgrading its phosphoric acid production technology by implementing the dihydrate hemihydrate DA-HF process to replace the DH dihydrate production method. This technology change will improve the efficiency of phosphoric acid production while reducing consumption of thermal energy and lowering the volumes of waste phosphogypsum generated in the process and phosphorous consumed as a process input.
- Grupa Azoty Police has been gradually replacing all compressors used in its operations – in 2017, work was commenced on replacement of compressor no. 1 in zone 266. The new devices consume more than 35% less electricity than the ones used so far, which translates into annual electricity savings of 3.4 thousand MWh.
- In 2016, modernisation of the condensate management system at the sulfuric acid unit was completed, resulting in a 38% drop in steam heat consumption.
- In 2017, construction of a flue gas desulfurisation system at the power centre was completed and start-up of the EC II CHP plant commenced. The desulfurisation process is based on the wet ammonia scrubbing method, a by-product of which is ammonium sulfate used as a component of mineral fertilizers. (See diagram ‘Flue gas desulfurisation using the wet ammonia scrubbing method’). Given the form of sulfur present in this compound (directly available to plants), ammonium sulfate is one of the most valuable sources of sulfur in the manufacture of fertilizers.
The method of flue gas scrubbing with the use of ammonia water is based on conversion of sulfur dioxide into ammonium sulfate (IV) in a reaction with ammonia and subsequent oxidation of the resultant ammonium sulfate (IV) to ammonium sulfate (VI). With this method, a mineral fertilizer, i.e. ammonium sulfate, can be obtained without producing sulfuric acid (VI). In the process, gases are scrubbed of SO2, SO3, HCl, HF, and similar components.
BEST PRACTICE
In 2017, two cameras were installed in the falcon nest 80 meters up one of the flue stacks at the Police-based company. Thanks to the online broadcast, everyone can watch the life of the bird family – the birth of the chicks, their first attempts at flying, or learning how to hunt. Observation of the falcon nest is conducted as part of a project implemented by the Council of the Peregrine Falcon Restitution Programme in Poland. The observation is documented, and the chicks are ringed.
Bird lovers can also watch dozens of species in the vicinity of large phosphogypsum heaps in the Grupa Azoty Police’s wastewater treatment plant zone. Artificially created water reservoirs and the surrounding meadows became home to nearly 180 bird species, including almost 80 wetland bird species, such as bitterns, common goldeneyes, grebes, red kites, cormorants, corncrakes and aquatic warblers. However, the most precious jewel among the winged inhabitants of the wastewater treatment plant zone is the common shelduck, one of the few birds nesting underground. Common shelducks live in deserted fox, badger or rabbit burrows or other holes.
BEST PRACTICE
The production and use of nitrogen fertilizers results in greenhouse gas emissions, but with technological advancements and rational management of energy and other resources their volumes, and thus the carbon footprint, can be reduced. Examples of efforts aimed at limiting the carbon footprint of our products include the project ‘Support for Low-Carbon Agriculture Capable of Adapting to Climate Change Now and Within the 2030 and 2050 Timeframes (LCAgri)’, co-financed by the National Centre for Research and Development. Its purpose is to improve efficiency of resource utilisation by implementing innovative low-carbon agricultural solutions and promoting sustainable application of mineral fertilizers by Polish farmers.
The project is carried out by a consortium of Grupa Azoty Puławy, the Institute of Soil Science and Plant Cultivation, the Institute of Agrophysics at the Polish Academy of Sciences, and the Environmental Protection Institute.
BEST PRACTICE
Grupa Azoty Puławy monitors the volumes of gaseous pollutants and particulate matter emissions. The emissions are monitored on a 24/7 basis at three locations, allowing the company to assess the impact of pollutants generated during everyday operation of its units.
Grupa Azoty Puławy
Our investments:
- Modification of the power generating unit concept – instead of the previously planned combined cycle gas turbine (CCGT) unit, the company decided to build a coal-fired unit, which will produce lower CO2 emissions.
- Modernisation of catalytic and catchment gauzes helped reduce N2O emissions from nitric acid production. In 2016, the emission rate was 0.97 kg N2O per tonne of HNO3; after the modernisation in 2017 it was reduced to 0.68 kg per tonne of HNO3.
- Air emissions were also reduced in 2016 by replacing the ammonium carbamate condenser in the synthesis section of the urea II unit and heat exchangers in the ammonia 1 unit, installing new nitric acid circulation pumps in the K02 absorption column, new boiler feed water pumps in the nitric acid unit, and a 1,900 Nm3/h hydrogen compressor. In 2017, the structural filling of the cyclohexanone rectification column was replaced, the unit for CO2 absorption in potassium carbonate solutions on line 1 of the ammonia 1 unit was upgraded, and the burners in the reforming furnace of the ammonia 2 unit were replaced.
- The project ‘Wastewater Collection and Recirculation at Urea I Unit’.
- Modernisation of boiler no. 2 at the CHP plant, which is expected to support its efficient operation for the next 15 to 20 years with reduced nitrogen oxide emissions. The modernised boiler no. 2 and the previously upgraded boilers no. 4 and no. 5 will be the principal generating units of the CHP plant, with boiler no. 6 to be constructed at a later stage. Work on modernisation of boiler no. 2 is planned to continue until the end of 2018.
- Replacement of the TG-02 turbine generator set at the CHP plant.
- Reduction of the use of ground water and water from the Kurówka river thanks to the construction of a new, more efficient water demineralisation plant and closing of the 50-year-old, energy-intensive one.
- Modernisation of pumping station no. 3 that feeds surface water from the Vistula river to Grupa Azoty ZAP, consisting in replacement of old pumps with inverter pumps, which will contribute to reduced consumption of surface water from the Vistula river.
- Construction of a system for drainage of the decarbonisation sludge and recirculation of the drained water into the decarbonisation plant to reduce the consumption of water abstracted from the Kurówka river.
BEST PRACTICE
Tree for a Bottle’ is the company’s most popular project, initiated under the ‘Responsible Care’ programme and continued for 13 years now. The campaign combines environmental education with social activity and care for the natural environment and for people’s neighbourhoods. It is addressed to primary school and preschool children, who play in groups trying to collect as many empty plastic bottles as possible. The bottles are recycled, and trees received in return for the bottles are planted on the premises of the participating schools as reminders of the campaign. The winning groups receive financial and non-financial prizes. The project partners include the Municipal Services Company of Puławy and the Puławy County Governor Office. By 2016, in 12 editions of the ‘Tree for a Bottle’ campaign, the participants collected a total of 5,676,650 bottles and planted 3,354 trees in their local neighbourhoods. The 2017 edition attracted more than two thousand students of 26 educational institutions from all over the county (17 primary schools and 13 kindergartens). The participants collected a record number of more than one million plastic bottles.
MODERNISATION CHALLENGES – MAJOR ISSUES
In 2016–2017, Grupa Azoty Puławy faced sanctions for non-compliance of its operations with environmental laws and regulations, except for Grupa Azoty Puławy. In 2016, the company had to carry out necessary repairs that required shutting down the desulfurisation unit. As a result, the permitted level of sulfur dioxide emissions from the CHP plant was exceeded and a fine of PLN 227 thousand was imposed (decision of March 30th 2017). Similarly, in 2017 Grupa Azoty Puławy decided to stop its flue gas desulfurisation unit to remove defects inside the absorber and carry out an inspection of the booster fans. In order to minimise emission limit exceedance, only low-sulfur fuel was fed to the operating boilers. The unavoidable exceedance of the limits of sulfur dioxide and particulate matter emissions from the CHP plant resulted in the imposition of a fine of PLN 408 thousand on the company (decision of March 19th 2018).
Grupa Azoty S.A.
Our investment projects:
-
In 2017, work related to the launch of a new treatment plant for flue gas from the EC II CHP plant was nearing completion. This investment project, worth about PLN 90m, will have a positive effect on air quality in Tarnów and the Tarnów region. Concentrations of nitrogen dioxide and sulfur dioxide in exhaust gases will be reduced to less than 200 mg/Nm3, and particulate matter concentrations will drop to less than 20 mg/Nm3. Flue gas denitrification will be a two-stage process: the first stage will involve optimisation of the combustion process, and the second stage will consist in reducing nitric oxides content in flue gases using the NOx selective catalytic reduction (SCR) technology. The company has opted for the wet magnesium scrubbing method in the desulfuriation process because it produces magnesium sulfate, which is a valuable fertilizer. The project is co-financed under the Norwegian Financial Mechanism 2009–2014.
- In 2017, Grupa Azoty S.A. initiated a new project – ‘Collection of Slag from the EC II CHP Plant Boilers’; the slag may be then used to manufacture building materials, helping to reduce the amount of stored furnace waste.
- Projects to reduce consumption of energy carriers in production processes and ensuring more efficient use of available resources, including ‘Heat Recovery from the Beckmann Rearrangement Process – Phase 2’ and ‘Reduction of Steam Consumption in the Caprolactam Production Process’.
- Construction of a sanitary wastewater treatment system at the Dobrów chemical production plant.
BEST PRACTICE
Grupa Azoty S.A. monitors air quality at five sites across Tarnów on a continuous basis. The locations of the measurement sites have been selected so as to cover the wide area that may be affected by particulate matter and gas emissions from the plant.
Grupa Azoty Kędzierzyn
- In 2017, work continued on the second stage of upgrade of the central mechanical and biological wastewater treatment plant.
- The company reduced emissions from its TKV nitric acid production plant – the catalyst basket was repaired twice, a fresh catalyst for nitrous oxide reduction was provided, and gauzes were added. Also, the entire set of catalytic gauzes was replaced.
The activities conducted by the Grupa Azoty Group inherently involve consumption of natural resources, both for the purpose of generating energy for the organisation’s internal needs and for the core business purposes, that is production of fertilisers and chemical products.
Materials used by weight or volume
Energy
At Grupa Azoty S.A., the main source of heat and electricity for the production units is a coal-fired EC II CHP plant, which is planned to be gradually modernised. The scale and scope of any upgrade work will be adapted to the changing legal framework, including in particular regulations on environmental impacts, as well as changes in demand for energy carriers from the production units.
The plants of Grupa Azoty Kędzierzyn use energy carried by process steam with a pressure of 7 MPa, 1.5 MPa, 0.6 MPa and 0.15 MPa, generated in six fine coal-fired boilers. Part of the energy is generated in four turbine generator sets, while the balance is purchased from external sources.
The energy requirements of Grupa Azoty Police are partly satisfied with internal production: electricity from power generators at two CHP plants, and steam generated at the EC II CHP plant and in sulfur boilers at the sulfuric acid division. Energy is also purchased from external sources. The company’s fuel consumption reduction policy is based on an ISO 50001-compliant energy management system implemented in 2013.
Grupa Azoty Puławy consumes approximately 1.28 TWh of electricity and 14.1 PJ of heat per year. The company has its own CHP plant, which covers 100% of its heat needs and 46% of its electricity needs. The CHP plant is hard coal-fired. It generates the process utilities for the company’s production units, including process steam, electricity, demineralised water, decarbonised water, process heat and heat for heating purposes, which is also supplied to the town of Puławy.
BEST PRACTICE
A new CHP plant is planned to be built at Puławy. It is expected to produce lower emissions of carbon dioxide, while NOx emissions will be reduced by the use of a flue gas desulfurisation system. The entire energy generation system is to be better aligned with the company’s actual needs. It is anticipated that the project, with a budget of PLN 99m, will raise the efficiency of electricity and heat cogeneration through replacement of the 30 MWe TG-2 pass-out and condensing turbine with a new 37 MWe turbine as part of the power system upgrade. In addition, steam boiler no. 2 at the company’s CHP plant is to be modernised in order to reduce NOx emissions (project with a budget of PLN 70m). Once modernised, this boiler and boilers no. 4 and no. 5 will be the principal generating units for the company’s CHP plant.
Total electricity consumption at the Grupa Azoty Group:
All Group companies take various measures to reduce their energy consumption. In 2016-2017, the four largest companies of the Group implemented a number of projects for that purpose, including:
- heat recovery from the Beckmann rearrangement process – Phase 2 – annual savings estimated at PLN 2.55m,
- replacement of transformers in 6/0.4kV transformer stations (‘Młynownia’ and ‘Pompownia T’) – annual savings estimated at PLN 322 thousand,
- installation of a low-pressure turbine generator set at the EC II CHP plant – annual savings on lower purchases of electricity from external grid estimated at PLN 1.6m,
- upgrade of cold insulation – annual savings estimated at PLN 60 thousand,
- acquisition of white certificates – annual savings estimated at PLN 100 thousand.
| |
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| Year | 2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
| Total |
639,557.0 |
580,769.0 |
476,056.6 |
493,788.6 |
1,456,403.0 | 1,479,652.0 | 3,023,033.0 | 3,060,954.0 |
Energy consumption within the organisation, including information on the type of raw materials used
Fuels used to generate electricity by category of energy carrier (GJ)
| Category of energy carrier |
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| 2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
|
| Steam heat* |
374,800.00 |
1,322,900.00 |
458,584.00 |
443,996.00 |
0.00 |
0.00 |
0.00 |
0.00 |
| Process gas |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
4,400.00 |
0.00 |
| Natural gas |
0.00 |
0.00 |
0.00 |
0.00 |
5,102.00 |
1,700.00 |
1,309.00 |
0.00 |
| MEAK |
0.00 |
0.00 |
0.00 |
0.00 |
99,469.00 |
74,521.00 |
0.00 |
0.00 |
| Fuel-grade
MEK |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
16,645.00 |
0.00 |
| Fine coal and thermal
coal |
405,007.00 |
1,321,524.00 |
1,498,778.00 |
1,470,495.00 |
3,815,604.00 |
2,041,315.00 |
2,827,896.00 |
4,101,007.00 |
| Fuel oil |
484.00 |
1,556.00 |
1,818.00 |
2,643.00 |
0.00 |
0.00 |
14,197.00 |
20,151.00 |
| Total |
780,291.00 |
2,645,980.00 |
1,959,180.00 |
1,917,134.00 |
3,920,175.00 |
2,117,536.00 |
2,864,447.00 |
4,121,158.00 |
| |
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| 2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
|
| ELECTRICITY, HEAT, COOLING AND
STEAM PURCHASED FOR CONSUMPTION (GJ) |
1,271,909.17 |
1,032,142.47 |
1,473,830.30 |
1,552,182.19 |
3,680,128.00 |
4,325,221.00 |
667,197.00 |
596,869.00 |
| ELECTRICITY, HEAT, COOLING AND
STEAM GENERATED BY THE ORGANISATION (GJ) |
6,237,130.60 |
6,892,410.52 |
9,332,085.75 |
9,483,949.20 |
17,513,086.00 |
17,120 249.00 |
2,942,725.00 |
3,030,675.00 |
| ELECTRICITY, HEAT, COOLING AND
STEAM SOLD BY THE ORGANISATION (GJ) |
520,556.00 |
554,271.00 |
432,364.10 |
468,786.86 |
1,339,112.00 |
1,384,653.00 |
268,944.00 |
303,274.00 |
| TOTAL ENERGY CONSUMPTION WITHIN
THE ORGANISATION (GJ) |
6,988,483.77 |
7,370,281.99 |
10,373,551.95 |
10,567,344.53 |
19,854,102.00 |
20,060 817.00 |
3,340,978.00 |
3,324,270.00 |
| |
|
up
by approx. 1% on 2015 |
|
down
by approx. 6% on 2015 |
|
up
by approx. 2% on 2015 |
|
down
by approx. 17% on 2015 |
Total savings from reduced energy consumption and improved energy efficiency (PLN)
| |
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| Year |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
| Total |
12,451
,000.00 |
3,095,000.00 |
5,279,000.00 |
6,885,000.00 |
10,742,834.00 |
8,546,218.00 |
352,000.00 |
3,977,000.00 |
Total energy savings for the Grupa Azoty Group were as follows: PLN
28,824,834,00 in 2016 and PLN 22,503,218.00 in 2017.
Energy intensity ratio (EIR)
| |
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| Year |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
| Total |
27.99 |
39.27 |
28.59 |
50.82 |
41.22 |
42.00 |
57.61 |
44.44 |
| Relative to 2015 |
|
up by 6% |
|
up by 21% |
|
down
by 0.29% |
|
down
by approx. 20% |
Water
Water is used by our plants primarily for production purposes. Throughout the Group, we seek to reduce its consumption as far as practicable, and where possible we implement water recycling solutions.
At Grupa Azoty S.A., water taken from the industrial water system and used at the Luwy unit is then recirculated into three cooling circulation systems to compensate losses. Unused excess water is fed back to the industrial water system. Steam condensates are returned from the production units to the condensate processing facility, where they undergo the demineralisation process and then are fed back into the system for further use in the form of pre-processed water (demineralised water). This water is used in waste heat boilers. In addition, it is also used in the tarnoform unit start-up process and to compensate losses in the heating water network. Any excess is returned into the demineralised water system.
Grupa Azoty Kędzierzyn has a system in place whereby industrial water is produced from a mixture of treated industrial wastewater, storm water and spent cooling water.
At Puławy, a solution has been implemented which enables the company to reuse some of the spent cooling water – it is returned to the system that supplies the plant with surface water abstracted from the Vistula river.
At Police, process water is used to prepare water which is then used, for example, for cooling purposes.
Water withdrawal by source (m3)
| Water source |
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| 2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
|
| Municipal water supply system |
0.00 |
0.00 |
267,190.00 |
268,370.00 |
0.00 |
0.00 |
0.00 |
0.00 |
| Groundwater |
1,785,700.00 |
1,673,700.00 |
67.00 |
10.00 |
4,629,068.00 |
4,988,978.00 |
470,000.00 |
923,000.00 |
| Other |
1,882,700.00 |
1,839,600.00 |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
| Surface water |
4,883,893.00 |
4,134,331.00 |
170,796,025.00 |
167,961,447.00 |
92,999,549.00 |
88,286,936.00 |
11,273,000.00 |
11,880,000.00 |
| Total |
8,552,293.00 |
7,647,631.00 |
171,063,282.00 |
168,229,827.00 |
97,628,617.00 |
93,275,914.00 |
11,743,000.00 |
12,803,000.00 |
Percentage (%) of water reused or recycled
| |
2016 |
2017 |
|---|---|---|
| Grupa Azoty Kędzierzyn |
20.1 |
34.38 |
| Grupa Azoty Police |
9.67 |
10.44 |
| Grupa Azoty Puławy |
9.08 |
2.55 |
| Grupa Azoty S.A. |
16.52 |
14.76 |
The activities of any chemical company in the world involve environmental emissions. At the Grupa Azoty Group, we follow the latest emission reduction technologies developed globally. We implement such solutions at our plants, consistently lowering our emission ratios.
At Grupa Azoty S.A., in 2016 nitrous oxide emissions from the technical-grade nitric acid unit amounted to 363,476 Mg N2O, and the efficiency ratio was 1.2 (benchmark efficiency ratio: 1). In 2017, nitrous oxide emissions were 358,671 Mg N2O, and the efficiency ratio was 1.05 (benchmark efficiency ratio: 1).
Grupa Azoty Kędzierzyn operates modern nitric acid production units which meet BAT requirements and emit N2O volumes at benchmark level (2016). In 2017, emissions from the Kędzierzyn-based plant were 374.522 Mg N2O, while the plant produced 494.69 Mg of nitric acid – the emission ratio was therefore 0.76 kg N2O/t HNO3. A year earlier, the Kędzierzyn-based plant emitted 580.692 Mg N20, while the nitric acid production volume amounted to 504 Mg – therefore the emission ratio in 2016 was 1.15 kg N2O/t HNO3.
In recent years, also Grupa Azoty Puławy reduced its N2O emission ratios. In 2016, the company recorded an emission ratio of 0.97 kg N2O/t HNO3, while in 2017 the ratio was 0.68 kg N2O/t HNO3. The reduction was achieved by replacement of catalytic and catchment gauze sets. The ratios achieved in 2016 and 2017 were significantly lower than the BAT recommendations for existing medium pressure units (1.85 kg N2O/t HNO3) and close to the benchmark ratio (about 1 kg N2O/t HNO3) used to calculate free allocation of emission allowances under the ETS.
Grupa Azoty Police emits only negligible amounts of N2O.
BEST PRACTICE
Nitrogen oxide is much more toxic than carbon dioxide. For several years, Grupa Azoty Police and Grupa Azoty Kędzierzyn have been producing a water solution of urea, which is injected before the catalyst in the exhaust system in engines. Thanks to the reactions provoked by the substance, the engine emits nitrogen and water vapour, which are neutral to the environment. In the case of heavy vehicles running on diesel, the product – sold in Poland under the brand name NOXy® – is the only effective means allowing a vehicle to meet European emission standards.
Direct greenhouse gas (GHG) emissions
Volume expressed as CO2 equivalent, by GHG category (t)
|
|
Greenhouse gas category
|
2016
|
2017
|
|---|---|---|---|
|
Grupa Azoty Kędzierzyn
|
Carbon dioxide
|
1,111,065.0
|
1,172,569.0
|
|
Nitrous oxide
|
173,046.0
|
111,608.0
|
|
|
Grupa Azoty Police
|
Carbon dioxide
|
1,537,341
|
1,653,948
|
|
Nitrous oxide
|
0 |
0 |
|
| Grupa Azoty Puławy |
Carbon dioxide
|
1,946,484.0 |
3,273,991.0 |
|
Nitrous oxide
|
257,631.0 |
171,882.0 |
|
| Grupa Azoty S.A. |
Carbon dioxide
|
888,582.0 |
1,053,743.0 |
|
Nitrous oxide
|
108,316.0 |
106,884.0 |
Greenhouse gas (GHG) emissions intensity
CO2 emissions volume (t)
|
|
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
|
|
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
| CO2 EMISSIONS
INTENSITY RATIO [t CO2/t NH3] |
1.578 |
1.578 |
1.87 |
1.82 |
1.705 |
1.67 |
1.12 |
1.52 |
| N2O EMISSIONS INTENSITY RATIO [kg N2O/t
HNO3] |
1.15 |
0.76 |
Nd |
Nd |
1.00 |
0.64 |
1.20 |
1.05 |
Reduction of greenhouse gas (GHG) emissions (Mg CO2e)
|
|
2016 |
2017 |
|---|---|---|
| Grupa Azoty Kędzierzyn |
49 029,00 |
58 110,00 |
| Grupa Azoty Police |
0,00 |
26 300,00 |
| Grupa Azoty Puławy |
0,00 |
0,00 |
| Grupa Azoty S.A. |
10 103,00 |
11 535,00 |
| Total |
59 132,00 |
95 945,00 |
Nitrogen oxides (NOx), sulfur oxides (SOx), and other significant air emissions, by type of substance (Mg)
|
|
Grupa
Azoty Kędzierzyn |
Grupa
Azoty Police |
Grupa
Azoty Puławy |
Grupa
Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| 2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
|
| Ammonia (NH3) |
511.00 |
352.00 |
456.18 |
428.42 |
1,389.39 |
1,132.92 |
131.00 |
151.00 |
| Benzo(alpha)pyrene (C2OH12) |
0.0020 |
0.0025 |
0.0001 |
0.0001 |
0.0000 |
0.0100 |
0.0020 |
0.0030 |
| Sulfur dioxide (SO2) |
1836.00 |
1,272.00 |
3,152.97 |
2,795,.33 |
993.54 |
942.56 |
1,435.00 |
1,632.00 |
| Carbon dioxide (SO2) |
949,658.00 |
1,007,830.00 |
1,358,723.96 |
1,438,908.23 |
1,910,090.41 |
1,718,853.23 |
920,000.00 |
1,086,947.00 |
| Sulfuric acid (H2SO4) |
0.00 |
0.00 |
35.34 |
53.59 |
0.00 |
0.00 |
73.00 |
46.00 |
| Organic acids |
0.10 |
0.30 |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
0.00 |
| Volatile organic compounds (LZO) |
30.00 |
34.00 |
4.58 |
4.56 |
40.74 |
37.60 |
0.00 |
0.00 |
| Methane (CH4) |
6.00 |
119.00 |
0.00 |
0.00 |
4.78 |
11.25 |
21.00 |
30.00 |
| Nitrogen oxides (NOx) |
1,081.00 |
890.00 |
1,121.34 |
1,09.53 |
2,635,22 |
2,420.22 |
5,026.00 |
5,389.00 |
| Nitrous oxide (N2O) |
581.00 |
374.00 |
0.00 |
0.00 |
848.79 |
620.28 |
615.00 |
499.00 |
| Melamine dust |
0.00 |
0.00 |
0.00 |
0.00 |
12.54 |
11.13 |
0.00 |
0.00 |
| Urea dust |
59.00 |
35.00 |
58.43 |
117.75 |
26.81 |
28.92 |
0.00 |
0.00 |
| Ammonium nitrate dust |
91.00 |
76.00 |
0.00 |
0.00 |
391.46 |
387.58 |
174.00 |
172.00 |
| Ammonium sulfate dust |
0.00 |
0.00 |
3.74 |
3.75 |
224.29 |
198.23 |
0.00 |
0.00 |
| Particulate matter |
126.00 |
101.00 |
0.00 |
0.00 |
0.00 |
0.00 |
183.00 |
181.00 |
| Dust from fuel combustion |
61.00 |
54.00 |
94.77 |
83.85 |
79.02 |
111.99 |
64.00 |
61.00 |
| Carbon monoxide (CO) |
295.00 |
304.00 |
105.42 |
118.74 |
216.75 |
133.63 |
69.00 |
82.00 |
| Aliphatic hydrocarbons |
13.0000 |
14.0000 |
0.0188 |
0.0200 |
19.7400 |
10.6100 |
1.0000 |
0.0000 |
| Fluorine compounds |
0.01 |
25.00 |
5.20 |
4.41 |
0.44 |
13.75 |
0.00 |
0.00 |
| Other |
0.56 |
399 |
0.00 |
0.00 |
21.192 |
88.070 |
2.400 |
2.000 |
Effluents
Grupa Azoty S.A.’s operations generate three types of wastewater – process wastewater, sanitary sewage, and spent cooling water and stormwater. Depending on the type, the wastewater is transported using the industrial wastewater system for treatment at the central wastewater treatment plant or the biological wastewater treatment plant.
- Industrial wastewater and sanitary sewage undergo mechanical and chemical treatment at the central wastewater treatment plant, and the treated water is then discharged into the Biała Tarnowska river.
- Industrial wastewater containing biodegradable substances is directed via drains and trestle-supported sewer lines for treatment at the biological wastewater treatment plant; from there, it is streamed for additional treatment to the wastewater treatment facility operated by the Tarnów Water and Sewage Utility.
- Stormwater and spent cooling water from Grupa Azoty S.A.’s premises are transported by means of separate collectors via the retention pond, and then discharged through the Sutro weir into the Dunajec river. If a failure occurs and the wastewater contaminates the EF drain, the drain may be cut off completely and all of the wastewater may be pumped to the central wastewater treatment plant. It is also possible to direct the entire volume of wastewater generated by Grupa Azoty S.A. to the wastewater treatment facility operated by the Tarnów Water and Sewage Utility.
Wastewater by discharge point (m3)
|
|
Wastewater discharge point |
2016 |
2017 |
|---|---|---|---|
| Grupa Azoty Kędzierzyn |
Rivers (Odra River) |
5,379,796.00 |
5,563,175.00 |
| Grupa Azoty Police |
Rivers (Odra River) |
36,626,436.00 |
34,462,323.00 |
| Grupa Azoty Puławy |
Rivers (Wisła River) |
88,506,896.00 |
83,772,426.00 |
| Grupa Azoty S.A. |
Municipal wastewater treatment facilities |
1,399,000.00 |
1,422,000.00 |
| Rivers (Biała, Dunajec River) |
3,837,000.00 |
4,208,000.00 |
|
| Total |
135,749,128.00 |
129,427,924.00 |
|
Wastewater by treatment method (m3)
|
|
Wastewater treatment method |
2016 |
2017 |
|---|---|---|---|
| Grupa Azoty Kędzierzyn |
Biological treatment |
2,154,070.00 |
2,402,297.00 |
| Central wastewater treatment plant (mechanical and chemical
treatment) |
2,154,070.00 |
2,402,297.00 |
|
| Piskorzowiec |
5,379,796.00 |
5,563,175.00 |
|
| Wastewater treatment system |
0.00 |
0.00 |
|
| Grupa Azoty Police |
Mechanical and chemical wastewater treatment plant |
36,626,436.00 |
34,462,323.0 |
|
|
Biological industrial wastewater treatment plant |
1,655,940.00 |
1,728,030.00 |
| Grupa Azoty Puławy |
Central industrial wastewater treatment plant (mechanical
and chemical treatment) |
1,430,320.00 |
1,770,145.00 |
|
|
Dawidagi |
254,736.00 |
254,040.00 |
|
|
Blackwater industrial wastewater treatment plant
(biological treatment) |
114,530.00 |
136,680.00 |
| Grupa Azoty S.A. |
Biological treatment (3rd degree) |
88,506,896.00 |
83,772,426.00 |
|
|
Biological treatment |
1,399,000.00 |
1,422,000.00 |
|
|
Central wastewater treatment plant (mechanical and chemical
treatment) |
3,370,045.00 |
3,790,525.00 |
| Total |
142,745,839.00 |
137,703,938.00 |
|
Waste
Most of the waste is recycled by the Group companies internally or by external service providers. We follow closed-loop economy trends, analyse the life cycles of our products, and investigate what further steps can potentially be taken in this area.
Waste by disposal method (Mg)
|
|
Disposal method |
2016 |
2017 |
|---|---|---|---|
| Grupa
Azoty Kędzierzyn |
Storage |
16,998.00 |
16,985.00 |
| Recovery by external service
provider |
12,984.00 |
115,287.00 |
|
| On-site recovery |
80,810.00 |
0.00 |
|
| Transfer to third-party service providers |
13,274.00 |
115,471.00 |
|
| Storage |
2,465.00 |
0.00 |
|
| Neutralisation other than through storage
by a third-party service provide |
146.00 |
0.10 |
|
| Grupa
Azoty Police |
Storage |
1,113.76 |
1,205.39 |
| Recovery by external service provider. |
81,173.05 |
152,678.22 |
|
| On-site recovery |
329,300.82 |
419,988.76 |
|
| Transfer to third-party service providers |
81,325.47 |
152,936.09 | |
| Storage |
2,022,110.28 |
2,197,467.79 |
|
| Neutralisation other than through storage
by a third-party service provide |
152,41 |
257.87 |
|
| Neutralisation other than through on-site storage |
1,524,185.26 |
1,357,811.68 |
|
| Grupa
Azoty Puławy |
Storage |
308.30 |
265.31 |
| Recovery by external service provider |
97,867.56 |
81,597.02 |
|
| On-site recovery |
425.50 |
25.50 |
|
| Transfer to third-party service providers |
97,867.56 |
81,610.07 |
|
| Storage |
14,541.59 |
17,501.21 |
|
| Neutralisation other than through storage
by a third-party service provider |
0.00 |
13.05 |
|
| Neutralisation other than through on-site storage |
0.00 |
0.05 |
|
| Grupa
Azoty S.A. |
Recovery by external service provider |
55,378.20 |
49,682.96 |
| On-site recovery |
74.80 |
140.00 |
|
| Transfer to third-party service providers |
55,907.60 |
62,477.20 |
|
| Storage |
0.00 |
0.00 |
|
| Neutralisation other than through storage
by a third-party service provider |
529,40 |
464.00 |
|
| Total |
|
4,488,938.57 |
4,866,157.38 |
Percentage of reclaimed products and their packaging materials (by type of material)
|
|
Grupa Azoty Kędzierzyn |
Grupa Azoty Police |
Grupa Azoty Puławy |
Grupa Azoty S.A. |
||||
|---|---|---|---|---|---|---|---|---|
| 2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
2016 |
2017 |
|
| Wood |
16.00 |
16.00 |
16 |
16 |
16.00 |
16.00 |
16.00 |
16.00 |
| Paper and cardboard |
61.14 |
61.14 |
61 |
61 |
60.99 |
61.01 |
60.98 |
61.01 |
| Packaging that held hazardous substances |
|
|
20 |
30 |
20.17 |
30.09 |
20.55 |
29.93 |
| Steel and sheet steel |
51.01 |
50.90 |
51 |
51 |
|
51.02 |
51.28 |
51.11 |
| Plastic |
23.50 |
23.50 |
23.5 |
23.5 |
23.50 |
23.50 |
23.00 |
23.49 |
| Multi-material packaging |
|
|
|
|
|
|
25.08 |
20.00 |
Biodiversity
Because of the scale of their operations and the size of their plants, some of the Group entities are located adjacent to protected areas, or have such areas under their management. We want to minimise the effect of our activities on the neighbouring wildlife areas. Over the years, we have demonstrated our ability to conduct industrial operations in a responsible and environmentally friendly manner.
Grupa Azoty S.A. leases, from the Regional Water Management Authority in Kraków, an area of 7,849 m2 entirely covered by flowing water, which is necessary for the industrial infrastructure of a weir on the Dunajec River. The operations conducted in this area, which contains surface and underground water intake facilities, as well as reservoirs feeding water to an underground municipal water intake point, pose no threat to biodiversity. Abstraction of water is subject to relevant permits which set the maximum quantities of water that may be drawn.
Grupa Azoty Kędzierzyn and Grupa Azoty Puławy are not located in or adjacent to any areas created or established under the Nature Conservation Act of April 16th 2004.
Of the four largest companies of the Grupa Azoty Group, Grupa Azoty Police is the only one whose operations could have a potential impact on biodiversity, due to its emissions. Grupa Azoty Police conducts its operations on the basis of
