Installing equipment that aligns with the best global practices and enables the production of consumer-driven products while minimizing energy and resource consumption is one of the most effective ways to reduce the environmental impact of an enterprise. Upgrading our facilities with advanced purification equipment and implementing automatic emissions monitoring systems are equally vital and effective measures for fostering sustainable development. This is precisely the approach we follow.

In 2021, we introduced a new carbon re-burning furnace installation, provided by a leading global manufacturer of industrial furnaces for the electrode industry. The installation also includes modern equipment for the thermal purification of exhaust gases, ensuring compliance with EU standards.

In 2021, UKRGRAFIT successfully implemented an innovative regenerative-thermal oxidation (RTO) system, which has proven to be an optimal solution for treating off-gases from calciners in compliance with the EU Best Available Techniques Reference Document for the Non-Ferrous Metal Industries. This state-of-the-art gas cleaning equipment effectively reduces the levels of tar and carbon monoxide in exhaust gases.

The project was executed by a renowned global leader specializing in turnkey RTO systems for the electrode and cathode industries.

The regenerative-thermal oxidation plant comprises four sections filled with ceramic elements and a valve system that redistributes the gas flow among the sections. This design ensures a balanced and cyclical utilization of all sections of the RTO. The equipment operates by facilitating the hydrocarbon oxidation process at extremely high temperatures ranging from 800 to 1100 °C. In this controlled environment, the harmful hydrocarbon components react with oxygen to produce harmless compounds, namely carbon dioxide and water vapor. These byproducts are non-toxic and odorless.

Furthermore, the equipment can operate without the need for natural gas, offering additional efficiency and cost-saving benefits.

One of the crucial and highly energy-intensive stages in the production of graphite products is the graphitization process. Artificial graphite is formed when exposed to temperatures above 2500°C.

Previously, Acheson electric furnaces were utilized for graphitizing products. This method involved heating the bulk material, which in turn heated the graphite blanks. Consequently, it resulted in increased energy costs of production, lengthy graphitization cycles, and the emission of substantial amounts of carbon monoxide, originating from the bulk material.

In 2019, we successfully completed a project to establish a complex of 11 lengthwise graphitization furnaces. This endeavor spanned over three years and received financial support from the European Bank for Reconstruction and Development.

The newly created furnace complex is unparalleled in Ukraine, with virtually every component being unique. The movable feeding module for lengthwise graphitization furnaces, developed and manufactured as part of this project, was the outcome of collaborative efforts between scientists, designers, and our specialists. The implementation of this modern graphitization system has significantly shortened the technological cycle from a week to nearly a day.

UKRGRAFIT has traditionally relied on a neighboring facility’s boiler to supply steam for equipment heating. However, when we learned about its planned shutdown, we faced a crucial decision with two options on the table. The first option was the easiest and most cost-effective: renting an existing but outdated boiler. The second option involved constructing a brand-new boiler from scratch, requiring substantial investments. However, it promised significant ecological benefits and energy savings. After careful consideration, we decided to choose the latter path.

To meet our specific requirements, we designed our own custom waste utilization boiler. This advanced boiler features three parallel sleeve filters, ensuring the effective purification of exhaust gases. As a result, we can now utilize heat from technological off-gases and gases, along with carbonaceous byproducts from our production process, in addition to natural gas as fuel.

This innovative approach has proven to be a great success, providing ample steam for our plant’s technological needs while significantly reducing our reliance on natural gas. Thanks to harnessing waste gases from the annealing furnaces, our gas consumption has been nearly eliminated for specific carbon product annealing processes.

Moreover, our efforts have led to remarkable environmental improvements, reducing solid substance emissions by 4 times and carbon monoxide emissions by 5 times.

The total investment in this project amounted to UAH 83 million, and we can proudly say that it has been worth every penny.