WEISS_4PN - Integrative application of innovations and digital cooling capacity management to reduce water consumption in steel production – Sub-project 2: Forecast of operational scenarios of cooling circuits due to climate-related bottlenecks and determination of disturbing influences when using the Capacitive Deionization (MCDI)

Initial situation:

Ongoing climate change and the associated extreme weather events result in increasing water stress, leading to limited or insufficient water availability. This has a negative impact on production processes in the steel industry, e.g. increased corrosion in piping systems due to sharp increases in dissolved salts (including chloride). The iron and steel industry is significantly dependent on the availability of water. There is no or only very limited reuse of wastewater due to strongly fluctuating levels of salts, hardness constituents and organic substances. Lack of information on flow rates, compositions and complex water systems hinder effective water management. Available recovery technologies must first be adapted to complex water matrices in the iron and steel industry.

Project targets:

  • Development of suitable processes for tapping wastewater as alternative water sources to secure the water supply
  • Digital mapping and simulation of the overall water management of an integrated steelworks in SIMBA# software system
  • Development of a forecasting model for critical low water levels in rivers as a service water source for industrial water supply

Innovative approaches:

  • Consideration of water streams from wastewater treatment plants as an alternative source of cooling and process water after desalination by MCDI (membrane-based capacitive dionization)
  • Production of a sulphate-containing monoconcentrate and a chloride-containing permeate from MCDI mixed concentrates by means of selective nanofiltration for subsequent utilization, e.g. electrolytic biocide-production
  • Using the potential of digitalization and simulation to link production with water supply processes

Benefits for the industry:

  • Recycling wastewater as an alternative water source through innovative treatment technologies
  • Reducing dependence on external fresh water supply
  • Reduction in the discharge of wastewater into public systems and compliance with legal requirements
  • Possibility of valorization of concentrates from desalination plants
  • Reduction of corrosion and sedimentation effects in piping and plant systems
  • Increased planning reliability thanks to the availability of digital forecasting tools for predicting upcoming bottlenecks in water supply and wastewater treatment

About the project:

Project duration: 04/2021 – 10/2024
Project Management Agency: Projektträger Karlsruhe (PTKA)
Funding provider: Federal Ministry of Education and Research

back