The permission to use the appropriate data needed to complete this project was given by the Managing Director of MSP. Unit in Krako´w.

5.2Characterisation of Waste Management in the Discussed Facilities

5.2.1The Coke Production Facility: Coke Plant

The Coke Production Department includes: a coal processing plant, two coke ovens, a dry coke quenching facility, a boiler house facility, a coke sorting plant, central dust removal machines along with dust monitoring stations, and cokequenching towers.

The Coke Plant generates the following types of waste: acid tars, liquid waste containing phenols, quick coke from decanters, a mixture of molecular salts and autoclaving condensate, tar deposits from tank cleaning (the above types of waste in the past were treated as waste – they are included in the analysis nonetheless – now they are treated as by-products), sorbents, filtering media, wiping cloths, protective suits, rubber, canvas covers, ink, toners, cases, oven linings and refractory materials from metallurgical processes, concrete waste and concrete waste from demolitions and repairs, mixed waste from concrete, crushed bricks, waste ceramic materials and equipment elements, wood, copper, bronze, brass, iron and steel, mixtures of metals, insulating materials, sludge from biological treatment of industrial sewage, waste that undergoes biodegradation, unsegregated (mixed) solid municipal waste, as well as waste generated during street and site cleaning.

The waste produced in the Coke Plant is re-used, by the Plant itself, whenever possible, in MSP facilities. If however, MSP is unable to recycle waste, it is then forwarded to external buyers (for recycling or neutralisation) or neutralised by depositing it in a landfill.

5.2.2The Ore Sintering Facility: Sintering Plant

The Sintering Plant produces blast furnace and converter sinters and utilises ferruginous waste generated by the other departments within the Plant.

The following types of waste are produced in the Sintering Plant: solid waste from smelter gases cleaning, sludge and filter cake from smelter gases cleaning, sorbents, filtering media, wiping cloths, protective suits, rubber, canvas covers, worn out devices containing hazardous substances (devices containing mercury, used lamps, fluorescent lamps, sodium-mercury discharge lamps), ink, toners, cases, copper, bronze, brass, aluminium, iron and steel, cables, and unsegregated (mixed) solid municipal waste.

The waste produced in the Sintering Plant is re-used, by the Plant itself, whenever possible, in MSP facilities. If however, MSP is unable to recycle waste, it is then forwarded to external buyers (for recycling or neutralisation) or neutralised by depositing it in a landfill.

5.2.3The Pig Iron Melting Facility: Blast Furnaces

The pig iron melting facility is part of the Steel Plant – Blast Furnaces Department. The main task of the Blast Furnaces Department is to prepare blast-furnace charges, to produce pig iron in blast furnaces, and to transfer pig iron to the Converter Plant.

Slag is the by-product of blast-furnace processes, which is converted into a granulated product and sold to external buyers. Here, however, it is classified as waste for it received such a classification in the source materials.

The following types of waste are produced in the discussed Department: slag from iron-making processes, solid waste from smelter gases cleaning, sludge and filter cake from smelter gases cleaning, melting losses from ferrous metallurgy, production scrap, engine, gear, and lubricating oils, sorbents, filtering media, wiping cloths, protective suits, rubber, canvas covers, worn out devices containing hazardous substances (devices containing mercury, used lamps, fluorescent lamps, sodium-mercury discharge lamps), oven linings and refractory materials from metallurgical processes, concrete waste and concrete waste from demolitions and repairs, mixed waste from concrete, crushed bricks, waste ceramic materials and equipment elements, copper, bronze, brass, iron and steel, mixtures of metals, insulating materials, and unsegregated (mixed) solid municipal waste.

The waste produced in the pig iron melting facility is re-used, by the Plant itself, whenever possible, in MSP facilities. If however, MSP is unable to recycle waste, it is then forwarded to external buyers (for recycling or neutralisation) or neutralised by depositing it in a landfill.

5.2.4The Steel Melting Facility: Converter Plant

The steel melting facility is part of the Steel Plant – Steel Converter Plant Department and its aim is to produce liquid steel and ingot steel. The activity of the Converter Plant consists of the following: accepting and storage of charge materials, preparing the charges for converters, production of liquid steel in the converter, casting the steel into ingot moulds or transferring it to the Continuous Steel Casting Department (CSC).

The following types of waste are produced in the Converter Plant: slag from steel-melting processes, unprocessed slag from other processes, solid waste from smelter gases cleaning, sludge and filter cake from smelter gases cleaning, melting losses from ferrous metallurgy, production scrap, engine, gear, and

lubricating oils, sorbents, filtering media, wiping cloths, protective suits, rubber, canvas covers, worn out devices containing hazardous substances (devices containing mercury, used lamps, fluorescent lamps, sodium-mercury discharge lamps), lead-acid accumulators and batteries, oven linings and refractory materials from metallurgical processes, mixed waste from concrete, crushed bricks, waste ceramic materials and equipment elements, copper, bronze, brass, aluminium, iron and steel, cables, biodegradable waste, unsegregated (mixed) solid municipal waste, and other unmentioned waste.

The waste produced in the Converter Plant is re-used, by the Plant itself, whenever possible, in MSP facilities. If however, MSP is unable to recycle waste, it is then forwarded to external buyers (for recycling or neutralisation) or neutralised by depositing it in a landfill.

5.2.5The Continuous Steel Casting Facility: CSC

The Continuous Steel Casting facility is part of the Steel Plant – Continuous Steel Casting Department and its aim is to produce slabs. The facility uses liquid steel from the Steel Converter Plant Department as its resource, and slabs are its final products.

The following types of waste are produced in the discussed Department: melting losses from ferrous metallurgy, paper packaging, plastic boards, sorbents, filtering media, wiping cloths, protective suits, oven linings and refractory materials from metallurgical processes, copper, bronze, brass, iron and steel, and other unmentioned waste.

The waste produced in the Continuous Steel Casting facility is re-used, by the Plant itself, whenever possible, in MSP facilities. If however, MSP is unable to recycle waste, it is then forwarded to external buyers (for recycling or neutralisation) or neutralised by depositing it in a landfill.

5.2.6The Facility for Hot Rolling of Ferrous Metals: Hot Strip Mill

The facility for hot rolling of ferrous metals – Hot Strip Mill is used to produce hotrolled steel sheets:

•Sheets made of carbon constructional steel,

•Formed sheets designed for further cold rolling,

•Shipborne sheets,

•Sheets made of low-alloyed constructional steel with microadditives,

•Sheets made of silicon steel (transformer and dynamo).

The following types of waste are produced in the Hot Strip Mill: mill scale and silt, production scrap, sludge from metalworking, grinding waste, engine, gear, and lubricating oils, mineral oils and liquids used as electric insulators and heat carriers, sorbents, filtering media, wiping cloths, protective suits, rubber, canvas covers, worn out devices containing hazardous substances (devices containing mercury, used lamps, fluorescent lamps, sodium-mercury discharge lamps), worn out electronic and electric devices, engine scrap, ink, toners, cases, lead-acid accumulators and batteries, oven linings and refractory materials from metallurgical processes, concrete waste and concrete waste from demolitions and repairs, mixed waste from concrete, crushed bricks, waste ceramic materials and equipment elements, wood, glass, and plastic waste, tar paper waste, copper, bronze, brass, aluminium, iron and steel, mixtures of metals, cables, biodegradable waste, and unsegregated (mixed) solid municipal waste.

The waste produced in the Hot Strip Mill is re-used, by the Plant itself, whenever possible, in MSP facilities. If however, MSP is unable to recycle waste, it is then forwarded to external buyers (for recycling or neutralisation) or neutralised by depositing it in a landfill.

In this project’s LCA research, the characterisation and balance data used (for the year 2005), come from the old Hot Strip Mill. Currently, production processes are carried out in the new Hot Strip Mill.

5.2.7The Fuel Combustion Facility: Thermal-Electric Power Station (Power Plant)

The main purpose of the Power Plant is the production of electric energy, blast furnace wind, process steam (1.6 and 0.8 MPa), heat in heating water, as well as the production of gas-free heated softened water, and heated demineralised water. These products are mostly used to cover the own needs of Mittal Steel Poland S.A.

The following types of waste are produced in the Power Plant: coal fly-ash, slagash mixtures from liquid drainage of furnace waste, sludge and preventive sediments, engine, gear, and lubricating oils, mineral oils and liquids used as electric insulators and heat carriers, worn out devices containing hazardous substances (devices containing mercury, used lamps, fluorescent lamps, sodiummercury discharge lamps), worn out electronic and electric devices, engine scrap, ink, toners, cases, lead-acid accumulators and batteries, copper, bronze, brass, aluminium, cables, insulating materials, water decarbonisation sediments, solutions and sludge from the regeneration of ion-exchange units, and unsegregated (mixed) solid municipal waste.

The waste produced in the Power Plant is re-used, by the Plant itself, whenever possible, in MSP facilities. If however, MSP is unable to recycle waste, it is then forwarded to external buyers (for recycling or neutralisation) or neutralised by