JSC NIUIF, starting from the year of foundation (1919), has always paid close attention to the environmental protection. During development and implementation of technological processes, the issues of raw materials consumption and handling of emissions, effluents and industrial wastes have always been put at the forefront.
Today, the main directions of the Institute's activities in the field of environmental protection are:
1. Technologies for processing of phosphorus-containing fertilizer production by-products and wastes.
1.1. Technology for processing fluorosilicic acid into aluminium fluoride and other fluoride salts.
Aluminium fluoride resource-saving technology allows you to get high-quality aluminium fluoride, used in the primary aluminum electrolysis.
Innovation allows the efficient use of energy. In particular, the JSC NIUIF aluminum fluoride technology, implemented in 2015 at the JSC PhosAgro-Cherepovets site, shows a fuel consumption rate of 30-40% lower compared to world analogues.
Figure 1. JSC PhosAgro-Cherepovets aluminium fluoride production (drying-calcining unit).
1.2. Neutralized phospho-gypsum stone technology from phospho-hemihydrate.
To use phosphogypsum stone in the cement industry, a method has been developed for neutralizing phospho-hemihydrate, which provides for intensive mixing of waste with lime, packing of the obtained material and its aging on a specially organized site.
2. Technologies for recycling, utilization and waste processing of phosphorus-containing fertilizer production.
2.1. Phosphogypsum recycling in the phosphorus-containing mineral fertilizer production.
The use of phosphogypsum as an inert additive in the production of phosphorus-containing mineral fertilizers makes it possible to obtain specific balanced grades using a cheap inert additive.
2.2. The use of phospho-hemihydrate in the road construction.
Developments in the field of road construction using phospho-hemihydrate in the construction of pavement foundations provide the possibility of utilizing fresh phospho-hemihydrate.
2.3. Preparation of phosphogypsum for the construction industry.
Research and practical developments of the Institute allow to obtain industrial gypsum for various uses, including construction industry.
Figure 2. Preparation of agglomerated phosphogypsum for construction industry
3. Optimization of enterprises’ water consumption and water disposal systems.
3.1. Technology for processing fluorine and phosphorus-containing wastewaters to produce concentrated phosphate-containing sludge and purified cooling water.
The solution to such a resource-saving task as processing fluorine and phosphorus-containing wastewater leads to an increase in the utilization rate of non-renewable phosphate resources due to the extraction of phosphorus compounds from effluents.
JSC NIUIF engineering solutions for wastewater management make it possible to solve the abovementioned problem and to obtain concentrated phosphate-containing sludge (32-38% P2O5) and purified cooling water.
3.2. Inspection and optimization of water consumption and disposal systems.
Optimization of water consumption and disposal systems makes it possible to maximize the use of enterprises’ cooling water and significantly reduce wastewater discharges to wastewater treatment facilities.
4. Ensuring safe and efficient operation of waste disposal facilities.
Long-term cooperation with leading research organizations in Russia has made it possible to achieve great results in ensuring the safety and efficient operation of waste disposal facilities (in particular phosphogypsum), which, due to their technogenic origin, cause keen interest both from the public and from the oversight bodies.
Figure 3. Phosphogypsum dump at JSC Apatit Balakovo branch
5. Development of recommendations for waste disposal facilities remediation.
An effective way to minimize waste disposal facilities impact on atmospheric air and soil is biological remediation, which allows to secure the dump mass slopes by stabilizing their surface with various technical means and plants to reduce the erosion of rocks forming slopes.
Figure 4. Technical remediation results of the phosphogypsum dump at JSC Apatit Balakovo branch
6. Waste classification, waste management enterprises’ regulatory and technical documentation improvement.
JSC NIUIF employees have accumulated great experience in improving the regulatory and technical documentation of mineral fertilizer production enterprises in terms of waste management.