INSPIREWATER – Innovative Solutions in the Process Industry for next generation Resource Efficient Water management

Initial situation

• Process related intake of scale, formation of hardness and salting (rolling mill cooling water) or metals in pickling acids/rinsing water avoiding/limiting internal reuse
• High fouling potential of effluent of water treatment plants avoiding internal reuse (zero liquid discharge)
• Implementation of alternative heat sources for separation by using waste heat

Project objectives of the steel case

• Reduction of water consumption and waste water production about 30 %
• Energy saving of 15 % by including use of waste heat
• 20 % validated increased recovery of materials (metals and phosphorous)

Innovative approaches

• Establishment of an Holistic water and resource management system
• Systemic configuration and  technology adaptation
• Demonstration of new technologies and combinations for sustainable water treatment (e.g. magnetic separator and electro-precipitation for softening with simulations disinfection)
• Economic assessment, exploitation

Current results (as of 11/2017)

• Determination of optimum combination of flocculent – coagulant as well as parameter for magnetic separator operation including cleaning in lab trials
• Selection of a suitable RO-Membrane and IX resins materials based on lab trial
• Chosen combination for demonstration considering technical and economic aspects: 3layer filtration or magnetic separator followed by RO
• Magnetic separator operation at a cooling water circuit since 09/2017 (treated flow: 20.000 m³, outlet solid content generally < 10 mg/L to 20 mg/L) parallel to operational sand filter and a 3layer filtration

Outlook

• Continuing of demonstration including testing of BFI online solid measurement for tailored magnet cleaning and set ups for enhanced sludge dewatering
• Preparation of a Life Cycle Assessment

• Cooling water
• desalting
• magnetic separation
• online solid measurement
• scale removal