This facility uses world-class, best-of-breed patented Tenova technology, who pride themselves in the advancement of their green technologies in this sector utilized across the globe. This aligns well with Petmin USA’s own environmental stewardship.
Following an extremely thorough permitting process by the Ohio EPA, that entailed detailed design enquiries and clarifications to confirm conformance with local air quality standards, the Ohio EPA issued the required air permit that allows Petmin USA to begin construction of its Nodular Pig Iron (NPI) facility in Ashtabula. The project has also received comprehensive reviews from multiple different local, state and federal agencies, including the US EPA, U.S. Army Corps of Engineers, and the City of Ashtabula, among others.
Best-In-Class Lowest Greenhouse Gas Emissions
While any heavy industry and iron smelting process entails the release of greenhouse gas emissions, Petmin is projected to set the industry standard for CO2 emissions at less than 0.8 tonnes CO2 per tonne product. Petmin’s best-in-class margin widens even further as result of the CO2 recovery plant that Petmin remains committed to including at its Ashtabula project site.
Coal Replaced By Natural Gas
Although this NPI facility was originally intended to be a coal-based process, it has over the years evolved into a gas-based process, utilizing environmentally conscious Tenova technology. The emissions levels for a gas-based process (less than 0.8 tonnes C02 per tonne product) are approximately 40% to 50% lower compared to a coal-based process (about 1.5 tonnes CO2 per tonne product). The new Tenova gas-based technology used will be globally superior to other gas-based technology processes currently available.
Energiron is the state-of-the-art technology for the production of premium quality DRI that is designed to convert iron ore pellets into metallic iron using reducing gases in a solids/gas moving bed shaft furnace. Petmin will use a HYL Zero Reformer (ZR) configuration, which is the most advanced and eco-friendly method, to reduce gas that is generated through in-situ reforming of natural gas inside the shaft furnace. The electric arc furnace (EAF) is continuously directly fed with hot DRI pellets from the Energiron DRI shaft at ~700*C to the electric arc furnace. This results in substantial energy savings (reduction in power requirements).
Recycling of Unconverted Gas in the Direct Reduced Iron (DRI) Shaft Reduces Energy Requirements Further
Unconverted gas in the Energiron DR Shaft is recycled, and includes heat recovery, for use in other parts of the plant. This results in a reduction of total gas and power (i.e. energy) required per ton of product produced, further contributing to process efficiencies.
Reduction in Solid Waste Through Recycling or Sale of By-Products
The baghouse filters included in this facility will have efficiencies of 99.99%, well within Ohio EPA requirements. The fine dust particles collected at the baghouse can be sold and recycled. Petmin plans to install a briquetting plant that will enable Petmin to briquette this material and re-use in its process.
Petmin will seek out recycling opportunities, which currently include briquetting of iron ore pellet fines for recycling, as well as sale of its slag by-product, which will be granulated for use in cement, road base course material, civil engineering works and raw material for fertilizer.
We are aware of the impact of past industries on the Ashtabula river system, and efforts made by the community to clean up the river system. We also share in the intent to protect this scarce commodity.
Petmin will be using raw water from the Ashtabula Port Authority’s existing water system. All discharge wastewater will be directed to the City of Ashtabula’s wastewater treatment plant located adjacent to the Petmin site.
The Petmin facility will also have its own wastewater treatment plant, thus ensuring water that is discharged to the Ashtabula water treatment facility meets required criteria.
Most importantly, Petmin’s own wastewater treatment plant will facilitate the internal recycling of water resulting in a substantial savings - a two-thirds reduction - in its water usage.
Note that no wastewater will be discharged into any river or lake system. All discharge water will be directed via pipeline to the City of Ashtabula's wastewater treatment plant, located immediately adjacent to the Petmin site.
Other Facility Green Initiatives
All electrical motors for all equipment have been specified to be high energy-efficiency motors. All motors shall be designed in accordance with National Electrical Manufacturers Association (NEMA) MG-1 Motors. The necessary additional upfront capital cost is offset by long-term cost savings.
All workshop and warehouse facilities exterior cladding will have strategically placed transparent panels allowing natural light to penetrate the buildings, thus reducing artificial lighting requirements. Office area architectural designs will optimize use of natural lighting during daylight hours. All light bulbs will either be CFL or LED lights which consume less energy. Where practically possible laptops will be utilized, which typically consume 80% less energy than desktops. All hot water systems for offices, control rooms and change rooms will be solar powered.