Initial situation Increased cost for raw materials and for landfilling have forced European steelmakers to look for new ways to […]
WEISS – Efficient operation of cooling water circuits by integrated desalination at the example of the steel industry
Initial situation
- Use of 2.3 billion m3 / a of water across industries for cooling purposes in Germany
- Salting due to evaporation / circulation in cooling circuits requires up to 200 m³ / h of blowdown to prevent corrosion
- No need-based dosing of cooling water treatment chemicals -> Increased operational costs
- Complex cooling water composition: biocides, anticorrosion agents, hardness stabilizers, flocculants, hardeners, turbidity / coloring as well as solids input (production-related), oil / grease from leaks
- Complex water cycles, especially in mature plants
Project objectives
- Halving of blow down water by removing salts and solids in the make-up water and appropriate chemical dosing (ATP measurement, solid state sensor)
- Water savings potential in an average steel plant up to 800,000 m³ / a
Innovative process approaches
- Desalination and softening by means of capacitive deionization (CDI)
- Development of anti-fouling coatings for reverse osmosis membranes
- High pressure reverse osmosis and evaporation for further narrowing of the concentrate (EVAP®) with patented polymer heat exchangers
- Modeling of cooling water circuits and mass flows to determine suitable process combinations / dosing quantities as well an economic-technical assessment by means of life cycle assessment
Current results (as of 11/2017)
- Solids separation before desalination process by means of magnetic separation or sand filter to fulfill the requirements possible
- Production of pure water fulfilling water quality requirements according company specifications by means of CDI (maximum separation grades achieved: chloride: 98%, sulfate: 72%, hardness: 84%, energy requirement: 0.8 – 1.3 kWh / m³) or by evaporation
- So far no disturbances of cooling water treatment chemicals on CDI, evaporation or reverse osmosis
Outlook
- Minimization of energy demand or increase in water yield of desalination
- Operational demonstration starting in I / 2018 at the production site of Deutsche Edelstahlwerk in Hagen
- Simulations and LCA based on data from the demonstration
Publications:
Hubrich, M., Kozariszczuk, M.:„Effiziente Kreislaufführung von Kühlwasser durch integrierte Entsalzung am Beispiel der Stahlindustrie. „IndustrieTage Wassertechnik, Dortmund, November 2017
Laghmari, S.; Ulbricht, M.Development and evaluation of an antifouling coating for reverse osmosis membranes which can be applied Jahrestreffen der ProcessNet-Fachgruppen für Fluidverfahrenstechnik, , Membrantechnik und Mischvorgänge, München27-28.02.18
Fitzke, B, Vu, D.: What´s up in Membrane Technology in Germany – Science and Innovation, DGMT IFAT 2018 Workshop 16.05.2018
Links:
Zukunftsfähige Technologien und Konzepte zur Erhöhung der Wasserverfügbarkeit durch Wasserwiederverwendung und Entsalzung (WavE)
Nachhaltiges Wassermanagement (NaWaM)
Projektträger Karlsruhe – PKTA – Bereich Wassertechnologie
Announcement: Meeting Process water treatment and concentrate handling in steel plants, Dec 12th, 2024
Contacts: |
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VDEh-Betriebsforschungsinstitut GmbH (Koordinator) Martin Hubrich Sohnstr. 65, 40237 Düsseldorf E-mail: martin.hubrich@bfi.de Tel:. +49-211-6707-34 |
SMS group GmbH Dr. Angela Ante Eduard-Schlömann-Str. 4, 40088 Düsseldorf E-mail: Angela.ante@sms-group.com Tel:. +49 2733- 29 3009 Mobil:+49 151-17141982 |
Technische Universität Berlin (TUB) Institut für Technischen Umweltschutz, FG Umweltverfahrenstechnik Prof. Sven Geißen Sekr. KF2, Straße des 17. Juni 135, 10623 Berlin E-mail: sven.geissen@tu-berlin.de Tel:. +49-30-314-22905 |
Universität Duisburg-Essen (UDE) Lehrstuhl für Technische Chemie II Prof. Matthias Ulbricht Universitätsstr. 7, 45141 Essen E-mail: mathias.ulbricht@uni-due.de Tel:. +49-0201-183-3151 |
Deutsche Edelstahlwerke Specialty Steel GmbH & Co. KG Ingo Robin Auestr. 4, 58452 Witten E-mail: Ingo.Robin@DEW-STAHL.COM Tel:. +49-22331-398-5216 |
WEHRLE Umwelt GmbH Dr. Bernd Fitzke Bismarckstr. 1-11, 79312 Emmendingen E-mail: fitzke@wehrle-umwelt.com Tel:. +49-7641-585-355 |
Institut für Automation und Kommunikation e.V Dr. Jens Alex Werner-Heisenberg-Str. 1; 39106 Magdeburg E-mail: jens.alex@ifak.eu Tel:. +49-391-990-1469 |
Fontaine Engineering und Maschinen GmbH Martin Sjöström Industriestr. 28, 40764 Langenfeld E-mail: martin.sjoestroem@foen-gmbh.de Tel:. +49 2173 270041 Mobil:+49 151 16773893 |