Mobile magnetic separator (50 m³/h) at a field trial

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

Gallery

Recommendation

INTEGA – Thermoelectric generators (TEG) for high temperature

Situation: In the iron and steel industry, large amounts of heat are lost as radiation. One possibility for the use […]

HEROLL – Prevention of hydrogen embrittlement of cold rolling rolls by improved work roll material and lubricant configuration

Situation: Increasing number of cold rolling work rolls failures, induced through hydrogen. Damages and/or failures can also cause dangerous explosions […]

DynStir – Dynamic stirring in secondary metallurgy

Initial situation: Stirring is often carried out on the basis of static pre-set parameters, without regard to the changing metallurgical […]

TopTemp – Shaft furnace analysis with acoustic gas temperature measurement

Initial situation: Shaft furnaces such as blast furnaces for pig iron production are highly effective aggregates, but very complex physico-chemical […]