1.
INTRODUCTION
Exports
have been the great lever of domestic production of iron ore in Brazil. The
main reason is the Chinese imports that have become the major importer of
Brazilian iron ore since 2002. China, that in 2001 bought 20.3 million tons
(megatons), started buying in 2007 a total of 89.0 Mt, an increase of 338% in
these amazing 6 years (BRAZIL, 2009).
The
steel industry in China continued to grow and the country increased by 11%
imports of iron ore and concentrates. Diversification of Chinese imports, with
the encouragement of South Africa, did not alter the dependence this country
has of its major suppliers, Australia and Brazil. China imported from these
countries in 2011, 64% of its iron ore needs, without significant variation in
the previous year (SAMARCO, 2012).
Brazilian
exports of primary goods Iron in 2010 reached 311 million tons (IBRAM, 2011).
But
along with economic growth there it is necessary to think about how to ensure
the current production with a look at future needs, and most importantly, how
to do this taking into account the social and environmental aspects, such as
establishing the doctrine of sustainability.
Being
the mining activity one of the most polluting in the world, what one intends in
this work is offering opportunities to minimize environmental impacts, through
proposals for a production scheduling-oriented concept of Cleaner Production,
which finds backed on Material Flow Analysis, to facilitate its implementation.
Thus,
based on this objective, the section 2 presents the methodological aspects that
contributed to arrive to search results; then in section 3 is presented a
survey of the relevant literature to the concepts of Cleaner Production and in
section 4, the Flow Analysis Material; in section 5 is shown the contribution
of this research, the case study, and also to characterize the activity of the
company under review; in section 6 is explored the Material Flow Analysis from
the perspective of Cleaner Production; in section 7 is made to interpret the
data obtained and the conclusions of the research, and finally section 8
presents the conclusions.
2.
METHOD
2.1.
Subjects or Participants
The
object of this paper is devoted to an industrial unit of pelletizing iron ore
in Brazil, identified here with fictitious name Iron SA, and the methodological
procedures used were based on the constraints of the research of an exploratory
nature, as Gil (1999) defines its presence when it is developed in order to
provide an overview about the fact determined.
The
private company is a joint venture between two big international companies,
operates an integrated project comprising mining, beneficiation and
concentration of iron ore of low grade, as well as movement of the ore
concentrate by pipeline, linking the two operating units of the Company. In
industrial unit under review, pelletizing processes occur - processing the ore
concentrate into pellets, its flagship product, and production flow for marine
terminal itself.
With
an installed production capacity of around 22.5 million tons, the production is
substantially sold in foreign markets. In 2011, Iron SA sold 99% of steel
production for 19 countries in the Americas, Asia, Africa and Europe. Although
the Chinese market still represents a large part of sales of Iron SA, the trend
is the increased presence of its products in the Americas, the Middle East and
North Africa.
2.2. Apparatus
The
case study is highlighted in this work, considering that the focus of research
interest is focused on current phenomena, analyzed within the context of real
business object of the study. For Gil (1999), the case study involves the
profound and exhaustive study of one or a few objects in a way that allows its
broad and detailed knowledge.
Exploratory
research is supported by field research, the importance of which is defended by
Dane (1990), whereby it is as a label that can be assigned to a collection of
research methods involving direct observation of occurrences of natural events.
Because this was an exploratory study, the function of your goal is to generate
knowledge and practical application directed to the solution of specific
problems (CERVO; BERVIAN, 2002). Andrade (2002) also highlights some of the
primary exploratory research purposes, such as providing more information on
the subject that will investigate, facilitate the delineation of research
topic, guide the setting of objectives and the formulation of hypotheses, or
discover a new type of focus on the subject.
2.3. Procedure
A
qualitative descriptive study was done through literature that, according to
Lakatos and Marconi (1991), seeks to explain a problem from theoretical
references in published documents. The literature search to identify and
analyze the existing cultural or scientific contributions on a particular
subject, theme or issue. It covers all the literature ever published on the
topic of study, and the main sources of quantitative data were obtained from
the Annual Sustainability Report and Management Report and Financial Statements
of the company.
Aiming
which demonstrate the company's practices regarding pollution prevention, data
collection was done through direct observation during field visits to the
company's industrial unit. From here it was possible to establish a proposal
for implementation of the program of Cleaner Production in the process of
pelletizing iron ore for export, backed environmental tool in the Material Flow
Analysis.
2.4. Cleaner Production
Program
The
need to reduce production costs, increase efficiency and competitiveness of
these companies is in line with the adoption and deployment of Cleaner
Production, which also contributes to the reduction of fines and penalties for
pollution; facilitates access to lines credit; improves the health and safety
of the worker; improves the company's image with consumers, suppliers and
government; improves relationships with environmental agencies and the
community, in addition to providing greater customer satisfaction (UNEP, 2002).
The
practice of using cleaner production leads to the development and deployment of
Clean Technologies in production processes. To introduce cleaner production
techniques in a production process can be used several strategies in order
targets environmental, economic and technological.
The
National Center for Clean Technologies (CNTL), the office in Brazil resulting
of joint efforts of the United Nations Industrial Development Organization
(UNIDO) and the United Nations Environment Programme (UNEP), the prioritization
of these goals is set in each company, through its employees and its
policy-based management. Thus, depending on the case, you can have the economic
point of awareness as to the definition and evaluation of adaptation of a
production process and minimization of environmental impacts going to be a
consequence, or conversely, environmental factors and aspects will be priority
economic will become result (CNTL, 2002).
According
to the booklet of CNTL (2002), the priority of Cleaner Production (Figure 1) is
at the top (left) Flowchart: avoid the generation of waste and emissions (level
1). Waste that can not be avoided should preferably be reintegrated into the
production process of the company (level 2). In their absence, recycling
measures outside the company can be used (level 3).
Figure 1. Escope of work of Cleaner Production. Data from CNTL (2012).
Domingues
and Paulino (2009) define as housekeeping changes to internal processes using
creativity, at low cost, without requiring significant technological changes
and practices that address the prevention or minimization of waste, effluents
and emissions; proper operation of equipment and better internal organization.
Costa
(2002) points out that the basic idea of the Cleaner Production is based on the
recognition that the control of pollutants after they have been generated, a
technique known as end-of-pipe, is more expensive than pollution prevention.
The control end-of-pipe means the installation of equipment such as filters,
precipitators, scrubbers, for the case of atmospheric emissions as collect and
clean the exhaust gases at various stages of the steelmaking process, but then
require treatment of wastewater from the "washing" of the equipment,
as well as the proper disposal of solid waste.
Costa
(2002) explains that the control-end tube one polluting substance (such as
powders exhaust emissions, for example) having been generated may result in a
change from one substance to another half, without, however, eliminate the
problem (liquid effluent generated from the gas washing controlled). Therefore,
the fact that the control will not be fully effective, besides involving
equipment and high cost operations led to the shift in focus to combat
pollution. The important thing is to find ways to prevent or minimize the
generation of polluting substance.
The
rising cost of production inputs, the tightening of environmental regulations
regarding waste disposal and environmental awareness of citizens are factors
that lead industries to seek strategies for pollution prevention.
But
the productive organizations face difficulties in maintenance and use of
equipment and it is not always economically viable to purchase raw materials
and supplies best quality, to meet the established principles of Cleaner
Production.
According
to research conducted by Costa (2002), technologies for abatement of air
pollutants are classified into two major groups: Control of Pollution (CP) and
Pollution Prevention (PP). The technologies consist primarily of CP system
control atmospheric emissions, and techniques are based on end-of-pipe, will
not be treated here.
In the case of PP technologies, Costa (2002) lists a number available for all
production steps and can be classified as:
· Changes in technology, including new equipment, automation and layout change;
· Change or reduction of inputs, including materials and energy (energy efficiency measures);
· Operational procedures and maintenance;
· Recycling internal.
Thus,
Oliveira Filho (2001) defines Cleaner Production as a technology strategy that
requires permanent and continuous actions to conserve energy and integrated
feedstock, replacing non-renewable resources with renewable and eliminate toxic
substances, reducing waste and pollution resulting products and production
processes.
2.5. The Analysis Flow
Material
According
Bartelmus (2002), Material Flow Analysis (MFA) was developed initially for
specific commodities, the U.S. Bureau of Mines in the 70s, and generalized
nationally by American Wuppertal Institute for Climate, Environment and Energy,
as a tool to evaluate the environmental sustainability of growth and
development of an economy.
The purpose of a Material Flow Analysis is to monitor and quantify the flow of
materials in a defined situation and for a defined period of time (BARRET et
al, 2002).
For
Bringezu and Moriguchi (2002), AFM is based on the paradigm of common
industrial metabolism, concept firstly proposed by Ayres (1992) as the
integrated set of physical processes that convert raw materials, energy and
labor into finished products, energy and waste. Yet for Bringezu and Moriguchi
(2002), the vision paradigm of a sustainable industrial system is characterized
by physical exchanges minimized and consistent between human society and the
environment, with the cycles of material internal flows driven by renewable
energy.
Yet according to the authors above, the
materials that are extracted by economic activities, but who do not normally
serve as input for the production or consumption activities (such as the mining
of mining) are called hidden flows or "ecological rucksacks".
Bartelmus (2002) uses the AFM with the objective to evaluate the use and
movement of materials through a key indicator, the Total Material Required
(TMR) and various derivatives indicators, such as the Direct Material Input
(DMI), measures the input of materials used in the economy, economic value and
used for production and consumption activities (equals domestic extraction plus
imports), the Domestic Processed Outputs (DPOs) or domestic processed outputs
(own translation), representing the total mass of material which has been used
in the domestic economy before flowing into the environment, and Total Domestic
Output (TDO) equals the sum of DPO and disposal of unused domestic extraction.
The schematic flow of material in a large savings can be seen in Figure 2,
below.
Figure 2. Flow materials of a
broad economy. Based on BRINGEZU and MORIGUCHI, 2002.
Also
according Bartelmus, the TMR reflects the total use of materials as a ratio of
income through the economy, including its "ecological rucksacks". The
scope of sustainability with such yield economic performance must occur at a
level compatible with the "ecological balance" in the long run the
planet.
To
Bringezu and Moriguchi (2002), the services provided or the economic
performance (in terms of value added or GDP) may be related to both indicators
of input or output to provide efficiency measures. For example, the ratio of
GDP by DMI indicates the productivity of direct materials. The GDP measures the
TDO by economic performance in relation to significant losses to the
environment. Set the value in relation to the inputs and outputs provides
important information about the eco-efficiency of an economy. The
interpretation of these measures should always consider the trends of absolute
parameters. The latter are usually also provided on a per capita basis to
support international comparisons.The representation of the mass balance in the
production process of an ore (generic) is shown in Figure 3.
In
industrial ecology, the Life Cycle Assessment
(LCA) has been used as a tool responsible for review and compilation of
inputs, outputs and potential environmental impacts of a product during its
life cycle (SUH; HUPPES, 2005).
According
to Hinz (2007), LCA is concerned with environmental preservation coupled with
technological development and its function is to transform the material flows
cyclically and ecological, which encompasses the process from capture of
natural resources to final disposal, also considering aspects such as:
recycling and reuse.
Figure 3 Generic mass balance of the ore. Data from Brazil, 2009.
The
LCA tool is standardized and structured by the international standard of the
International Organization for Standardization (ISO) ISO 14000, environmental
management standards ISO 14040 specifically: LCA, Principles and Structure and
ISO 14044: ACV, Requirements and Guidelines. Its structure consists of four
interdependent steps, one of the Life Cycle Inventory, which estimates the
resource consumption and the amount of waste streams and emissions caused by or
attributable to the life cycle of a product (ROJAS, 2010).
The
Life Cycle Inventory, one of steps of LCA, keeps more similarities with the
Material Flow Analysis, which appears most appropriate tool for the type of
study to which this work is dedicated.
3.
CASE STUDY: EXPLORING THE MATERIAL FLOW ANALYSIS FROM THE
PERSPECTIVE OF CLEANER PRODUCTION
After
the ore is mined, processed and concentrated, it is mixed with water and
transported in the form of pulp by two pipelines, approximately 400 miles long
each, up pelletizing plants, in the industrial unit under study, where the pulp
is received and subjected to a process for separating solid what is and what is
water.
The
solid fraction is directed to the production process, where the iron ore concentrate
is converted into pellets, of sizes between 8 and 16 mm in diameter. These
undergo a heat treatment in acquiring desirable characteristics to the steel
industry is in the process of blast furnace or direct reduction to.
The
surplus production of iron ore concentrate, pellets out of specification, known
as thin (sinter feed and pellet feed), are also sold. Thus, only pelletizing
iron ore belongs to the scope of this work.
As
in Material Flow Analysis, the inputs and outputs in the production process
must be qualified and quantified to support the evaluation of Cleaner
Production. This is the first step to implement a program of P + L, according
to the CNTL (2003), after a detailed analysis of the flowchart allows
visualization and definition of qualitative flow of raw materials, water and
energy in the production process, visualization waste generation during the
process, thus acting as a tool to obtain data required for the formation of a
strategy of minimizing the generation of waste, effluents and emissions.
The
next step for implementing P + L, according to the CNTL (2003), is drawing up
the material balance, where indicators are set forth and identified the cause
of the generation of waste, i.e. exactly equal to that followed in the Flow
Material Analysis to be made then the identification of options Cleaner Production.
After
lifting the flowchart of the production process of the company, the survey is
made of the quantitative data of existing environmental and production using
available sources, as can be seen in Figure 4, for the case of the production
process of the company under study.
Figure 4
Qualitative and quantitative analysis of inputs and outputs of the production
process of the Iron SA. Base on CNTL, 2003.
The
annual analysis of qualitative and quantitative inputs and outputs of the
production process of Ferro SA (above) have elaborated the tables below,
necessary to compose the environmental diagnosis.
In
Table 1, the cost presented related to raw materials, it was considered the value
(most significant) to acquire iron ore from third parties, since the company
has its own operating mine ore, and the purchase takes place in casual
occasions . The cost of the water is unknown due to not declared in any of the
reports of the company that served of basis for this research.
Table 1 Table of raw materials, inputs and auxiliary. Base on CNTL, 2003
|
|
Quantity |
Cost |
|
Energy |
1,946
GWh |
|
|
Feedstock |
751.254
t |
US$
121,7 millions |
|
Water |
16.357.971
m³ |
unknow |
|
Auxiliary |
304,04M
m³/3.475t |
US$ 1.360.610 |
Still on the data in Table 1, the
cost related to "auxiliary" was considered the total of raw
materials, consumables and changes in finished goods and work in process
inventories recognized in cost of sales of the Company.
Among
the auxiliary materials, for purposes of calculating the total natural gas
defendant appealed to the given volume traded in the year 2011 of exercise Iron
SA, which was a total of 22.506 tons of dried metric (tdm) of iron ore. Thus,
based on qualitative and quantitative analysis of inputs and outputs of the
production process of the company (Figure 4), we arrived at a total of 288.3
million cubic meters of natural gas required in the pelletizing operation. This
value combined with the diesel fuel used in the production (constant in Figure
3) gives the amount of volume at 304.04 M inputs in m³ (the amount of fuel oil
is provided beside in the table).
In
Table 2, the cost of products (sinter feed and pellet feed) is not considered,
since they are sold as surplus production (which is essentially based on
pellets) and are reversed in profit for the Company. In the amount of effluent,
approximately 2.9 million cubic meters, it is being considered only the
effluents from the pelletizing operation (one cannot ignore the importance of
wastewater generation during beneficiation of iron ore, but this phase does not
belong to the scope of this work).
Table 2 Table of byproducts, waste, effluents and
emissions. Base on CNTL, 2003
|
|
Quantity |
Cost |
|
Byproduct |
1.771M
tdm |
Not
present |
|
Waste |
19.138,12t |
Σ
= US$ 175 millions |
|
Effluents |
2.876.197,64M
m³ |
|
|
Emissions |
1.841.164t
in CO2 eq* |
Even
with regard to Table 2, the cost that relates to waste, effluents and
emissions, is considered in the budget of the total investment planned for the
year 2012 exercise in the treatment of these components, as presented in the
Management Report and Financial Statements of Iron SA.
4.
RESULTS
With
the information from the environmental diagnosis, the next step to implement a
program of Cleaner Production, according to the CNTL (2003), is to select among
all the activities and operations of the focus work. This information is
analyzed considering the legal regulations, the amount of waste generated, the
toxicity of the waste, and the costs involved.
As
an approach in this work, it was decided to focus on issues that relate to air
emissions at the plant of S. Ferro A. in particular the emission of greenhouse
gases, the ability to cause warming of the globe, which implies several
consequences harmful to the planet, especially the occurrence of climate
change.
The
Brazilian Law, CONAMA Resolution n. 436/2011, Annex XIII establishes emission
limits for air pollutants generated in the pelletizing plant iron ore, whose
kiln exhaust system is touted as emission source punctual, being allowed up to
70 mg/Nm3 for Particulate Matter, 700 mg/Nm3 for SO2 and 700 mg/Nm3 for NOx
(MMA, 2011).
Seeking to meet the demands that the previous law, the main type measure
Pollution Prevention (PP), to reduce greenhouse gas emissions, the Iron S. A.
promoted the substitution of fuel oil by natural gas as an energy source in
pelletizing furnaces, the initiative also resulted in cost savings (CEPEMAR,
2009).
Even
with regard to atmospheric emissions, is accented generation of particulate
matter, as can be confirmed by qualitative and quantitative analysis of inputs
and outputs of the production process of pelletizing the company in question
(Figure 4). However, in this regard, are observed more actions for the Control
of Pollution (CP), one of them is the
________________________________________________________________________________________________
*It
is a metric measure used to compare the emissions from various greenhouse gases
(GHGs) based on global warming potential of each. Represents the result of
multiplying the tons of GHG emitted by its global warming potential. For
example, the global warming potential of methane gas is 21 times higher than
the potential of CO2. So, tell us that the CO2 equivalent of methane equals 21
(IPAM, 2013).
wind fence (about wind, our translation), a structure about 30 meters high
which acts as a screen that involves all the stockyard. This device reduces the
incidence of wind, minimizing the susceptibility of Entrainment of particles
that may be emitted to the environment.
Figure
5 Wind fence (photo of the
author's field visit)
Another
measure adopted as CP to improve the environmental quality of the site is the
enclosure of the towers of transfers in the courtyard of pellets (Figure 6), because
detachment of dust kicks in (transfer between conveyor belts).
Figure 6 Cloistered tower of Transferring (photo of the author's field visit)
The
dust collector, venturi-type, is also a dust collecting device installed in the
towers
transfer, which are the places where there are drop pellets in
transposing the direction of flow of the product. There are suction points in
kicks (where there is detachment of powder pellets), and the air with airborne
dust is collected and is directed to the gas scrubber, which sprinkles water
for cleaning. The powder is then separated from the wastewater system and that
subsequently goes to the clarifier.
Figure 7 Dust
collector (photo of
the author's field visit)
As
for technology shares under the Control of Pollution, the Iron S. A. invested
with the installation of Electrostatic Precipitators, equal to that shown in
Figure 8, with the aim of reducing particulate emissions from pellet plants, so
that they reach an adequate performance to environmental requirements.
Figure 8 Electrostatic
Precipitator in Iron SA (photo of the
author's field visit)
Another
technological resource control air pollution caused by the dispersion of
particulate matter in the air bag filters are used in other areas of the
production process of the Iron S. A. but in a smaller dimension, which
mechanism is explained by Cavalcanti (2012) which consists in that particles
are separated from the exhaust gas through a porous material, allowing high
removal efficiencies, its power consumption is high and can operate only a
limited range of temperature and humidity of the gases.
Finally,
when iron ore, in pellets form, are arranged in stacks in the yard ore, and it
is the applicated a polymer, the suppressor powder diluted in water adheres to
the surface of the pellet forming a film that prevents dust particles from
detaching and issued the environment by wind.
5.
DISCUSSION
The
main results were obtained from analysis of company reports available to the
public via the world wide web. Based on them we observe that the company Ferro
S. A., guided by economic strategy applies, even if informally, some of the
recommendations of the Cleaner Production program to promote technological
change, change or reduction of inputs and internal recycling, especially as it
is for the reuse of water in your production process.
However,
it is possible to verify that there is still waste in the utilization of iron
ore mainly in powder form during the production process and the emphasis is
still in control, and not for the prevention of pollution. In an attempt to
solve the problem, most investments, seen in section 7, is still done in the
control end of pipe, one conducted after the waste is generated.
However,
what is observed is that most of these investments would be better spent if it
were based on a more detailed analysis of the Material Flow of the process
under study. Thus follows the line of recommendation Brigenzu and Moriguchi
(2002) when they say that this analysis is increasingly used to provide the
basis for measures of political, strategic and environmental, and evaluate the
effectiveness of such measures.
It
is noteworthy that the inferences developed in this work were based on data
provided exclusively through the company's own statements, contained in its
reports for accountability to society, and that lack of a more detailed
quantification of data, rendering it impossible to check these values, as
observed in the preparation of Table 1, which showed no data regarding the
acquisition cost of the water required to feed the production process.
Despite
the field visit, it is understood that a closer relationship with the company
could bring more information that is not found in reports, thus enabling the
application of tools to analyze environmental management as coherently as possible
with the reality of industrial dynamics studied.
Another
factor that makes the limited studies and applications of these tools coincides
with the line of reasoning of Rojas (2010), states that it is unknown when the
publication of a database containing information of emissions, pollutants and /
or waste generated in different industrial activities in Brazil.
Finally,
it is believed that the Cleaner Production program when integrated with Industrial
Ecology, allow to achieve the purpose of monitoring progress towards
sustainability can be improved continuously.
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