Innovative Water Supply Systems for Ferrous Metallurgy
1. EECCO-PROO-PROJJEСT Group of CompaniesEСT Group of Companies
YekaterinburgYekaterinburg
InnovativeInnovative Technologies of IndustrialTechnologies of Industrial
Water Supply SystemsWater Supply Systems fforor FFerrouserrous
MMetallurgicaletallurgical PPlantslants
2. 1993 – R&D Company ECO-PROJECT was founded as an institution intended to design
water treatment systems, especially for metallurgical industries. The company was
established by the leading experts from the Ural State Institute for Design of
Metallurgical Plants (Uralgipromez), Yekaterinburg
1995 – The first department for development of design documents for water treatment
systems was established
1996 – Production facilities were organized for manufacturing of highly efficient water
treatment systems
1997 – The department of process research and commissioning was established
As a result, a comprehensive engineering company has been created that isAs a result, a comprehensive engineering company has been created that is
specializedspecialized in designing and implementingin designing and implementing innovative water treatment processesinnovative water treatment processes asas
well as inwell as in engineering support of institutions acting as General Designers of ferrousengineering support of institutions acting as General Designers of ferrous
metallurgical industriesmetallurgical industries ((the Gipromez companies, etcthe Gipromez companies, etc)) in Russiain Russia andand UkraineUkraine..
WWater treatment processesater treatment processes ofof ECO-PROJECTECO-PROJECT also find a wide range of applications inalso find a wide range of applications in
non-ferrous metallurgynon-ferrous metallurgy,, machinery buildingmachinery building,, utility managementutility management and in otherand in other
branches of the national economybranches of the national economy
Historical Background of ECO-
PROJECT:
3. Structure of ECO-PROJECT:
Administrative
and technical
management
Department of
Engineering
Research and
Commissioning:
Porject
Department:
Department of
Equipment
Production:
- Establishment of
production of water
treatment systems
- Comprehensive
supply of the
equipment
- Supervision during
installation of the
equipment
Design
Department:
Back offices:
- General design
- Design of
engineering
facilities for water
treatment plants
- Design
supervision during
construction
- Engineering
research
- Development of
process regulations
for design work
- Commissioning
- Training of
operation personnel
of end users
- Technical support
and service of end
users
- Development of
design documents
for manufacturing of
water treatment
systems
- Quality assurance
during equipment
manufacturing
-Finance and
contract department
- Marketing and
technical
information
department
- Company
transport
department
Engineering personnel of
ECO-PROJECT – 60 persons
5. Our partners in ferrous metallurgy:
- - metallurgical plants
- general design institutions of ferrous metallurgy that make use of ECO-
PROJECT’s design products
6. The following facilities were put into operation onThe following facilities were put into operation on
the basis ofthe basis of ECO-PROJECTECO-PROJECT’s processes’s processes during theduring the
period of intensive technical modernizationperiod of intensive technical modernization ofof
ferrous metallurgical industriesferrous metallurgical industries
(mostly after the year of(mostly after the year of 20002000))::
А. Water treatment plants of water recirculating systems
- gas cleaning systems of blast furnaces - 2
- vacuum treatment plants of steel making shops - 2
- CCM - 12
- hot rolling mills and heat treatment plants - 23
В. Water treatment plants for various applications:
- make-up water preparation for recirculating systems,
- blowdown water for recirculating systems,
- waste emulsion treatment for expander systems,
- wastewater treatment for combined collection systems, etc - 19
С. Modernized industrial water supply system of Novolipetsk Steel:
- the CIS’ only system that is installed at the large metallurgical works and
is in compliance with ecological standards - 1
7. Examples ofExamples of water treatment systemswater treatment systems andand waterwater
treatment plantstreatment plants designed and implemented bydesigned and implemented by
ECO-PROJECTECO-PROJECT
8. Flocculator-clarifiers
(OF apparatuses)
* Used as primary units for
reactant and non-reactant
purification processes of natural
and technogenic water types
(recirculating, waste water, etc.).
As of 2012, over 150 units have
been put into operation with
max.rated capacity of 2,000
m3
/h (diameter – 12 m, height –
6.1 m). The max.capacity of
most units in use is 1,200 m3
/h
(diameter – 10 m, height – 5,6
m)
9. Advantages of flocculator-clarifiers:
Increased specific hydraulic load
* For purification of natural and waste water – 6 ÷ 9 m3
/(м2
·h)
* For water purification in recirculating systems – 13 ÷ 17 m3
/(m2
·h)
Increased water treatment efficiency – see the next slide
High reliability and easy operation
Reduced atmospheric pollution by water vapors and other pollutants
since the small diameter apparatus can be covered from top
Reduced construction period of water treatment plants thanks to
decreased volume of civil work
10. Quality requirements to recirculating water treatment in terms of
TDS and petrochemicals; treatment results achieved
at flocculator clarifiers
11. Novolipetsk Steel. Water recirculating system for the gas cleaning system
of the BF No.7:
1. Technical solutions of the Works’ project that was not implemented: three Ø 30 m radial clarifiers.
2. Technical solutions of the project implemented by ECO-PROJECT: three Ø 10 m flocculator-
clarifiers. Additionally, the following facilities were installed: two Ø 6 m sludge thickeners and the
building housing sludge lift pumps and reactant metering plant. Picture: see the next slide.
The construction cost was reduced by Euro 2.5 mln.
13. Novolipetsk Steel. Water recirculating system for the
gas cleaning system of the BF No.7
Layout of the water treatment plant designed by ECO-
PROJECT: flocculator-clarifiers (1) and sludge thickeners
(2) are located on the surface, while the sludge pumping
station and reactant handling system are partially buried (3)
14. Enakievo Iron and Steel Works,
Ukraine. Recirculating system of the
gas cleaning systems of the BF's
Nos.4 and 5
Thanks to compact design of flocculator-
clarifiers, it was possible to install the
water treatment plant at the overlapping of
the pumping station, within a limited area
near the gas cleaning systems. Owing to
that, there was no need to build a ramp for
water pipeline (€ 2.5 mln.); besides, power
consumption related to water circulation
was reduced by 0.9 mln. kW-hr per year.
The construction cost of the water
treatment system proper was reduced
considerably
15. Enakievo Iron and Steel Works, Ukraine. Recirculating system of the gas cleaning systems of the
BF's Nos.4 and 5. Flocculator-clarifiers, diameter 10 m
16. Seversky Tube Works,
Polevskoy
EAF Shop. Water recirculating
system in the secondary cooling
area of CCM ingots. Flocculator-
clarifier, diameter 6 m,
capacity – 400 m3
/h
19. Novolipetsk Steel (NLMK)
Process flow diagrams of recirculating water treatment of the vacuum treatment plant
in the BOF Shop No.2
I. Process according to the design developed by a foreign company that was never implemented: two-stage treatment by
means of 4 flocculator hydrocyclones (diameter 12 m) and 6 pressure filters
II. Process according to the design developed by ECO-PROJECT that was actually implemented: one-stage treatment by
means of 2 flocculator-clarifiers (diameter 12 m), capacity 1,700 m3
/h each (1 unit in use + 1 standby unit)
Construction cost reduced by € 6.3 mln.
20. Ural Steel, Novotroitsk, Orenburg Region
Water recirculating system of the vacuum treatment plant
22. Magnitogorsk Iron and Steel Works
Recirculating system of section mills.
Flocculator-clarifiers (diameter 10 m)
were installed in the vacated building
of the former blooming mill.
Since there was no filtering station for
after-purification of waste water,
construction cost was reduced
by € 7.5 mln.
23. Ural Steel
Water recirculating system of the hot rolling mill 2800 including Ø 10 m flocculator-clarifiers
Construction cost reduced thanks to exclusion of a filtering station
Construction cost reduced by € 6 mln.
24. Nizhneserginskiy Hardware-metallurgical Plant. Water recirculating system of the small section
mill 250/150. Time variation curve (t, h.) of TDS content in recirculating water after the inter-
shop scale pits (curves 4 and 5) and after flocculator-clarifiers (curves 1, 2, 3):
up to 0 hours – operation period without flocculent metering;
– operation period с with 0.05 mg/dm3
of flocculent; start of metering – 0 hours;
– same, 0.2 mg/dm3
; start of metering – 23 hours
25. Vyksa Steel Works
Pipe electric welding shop No.3. Recirculating water treatment plant
of the heat treatment section including Ø 10 m flocculator-clarifiers
26. Vyksa Steel Works. Pipe electric welding shop No.3
Building of the recirculating water treatment plant of the heat treatment section
27. Nizhneserginskiy Hardware-metallurgical Plant. Water recirculating system of the small section
mill 250/150. OKUD system for dewatering of sludge (fine grained oiled scale) pumped out from
flocculator-clarifiers
Such systems serve as an alternative to thickeners, centrifuges and press filters. The OKUD systems are more
efficient for reduction of sludge moisture (up to 15%, i.e., bulky condition; they feature a simple design, need
almost zero maintenance and consume no power for such key processes as thickening and dewatering
28. Nizhneserginskiy Hardware-metallurgical Plant
Water recirculating system of the small section mill 250/150
OKUD systems. Removal of filtered material after gravity dewatering of sludge
Interval between filter element replacement is minimum 5 years
30. Process flow diagrams of recirculating water treatment of CCM, hot rolling mills and heat
treatment plants for rolled stock:
А – conventional two-stage treatment;
В – conventional single-stage treatment;
С – based on developments of ECO-PROJECT including OF systems (19) and OKUD systems (21)
Notes:
- Number of treatment stages is related to external water treatment systems
- Legend – see the next slide
31. Inter-shop treatment systems: 1 – scale pit including scale dewatering silo; 2 - ditto, larger
in size (to enable water supply to filters); 3 – ditto; a compact design by ECO-PROJECT; 4 -
pumping station; 5 - grapple;
External treatment systems: 6 – secondary preliminary clarifier including overhead scraper
and oil skimmer; 7 – dewatering silo for scale and oil bearing sludge; 8 - грейфер; 9 -
pumping station для подачи воды на фильтрование; 10 – sand filters; 11 – cooling tower;
12 – flushing water tank including pumping station for filter flushing and end-user service;
13 - sludge pump; 14 – flush water thickener; 15 - pumping station for turbidity-free flushing
water; 16 – belt-type press filter or decanter (centrifuge); 17 - conveyor; 18 - conveyor for
scale and oil bearing sludge; 19 – flocculator-clarifier with oil skimmer; 20 - pumping
station for water supply to cooling tower and end-users; 21 – dewatering silo designed by
ECO-PROJECT including pumping station for supernatant water and filtered material;
I – polluted scale and oil bearing water from end-users; II – water supply to external
treatment systems; III – dewatered coarse-grained scales; IV - water supply from pumping
station of the CCM primary clarifier, pumping stations of laminar and intensive cooling of
rolled stock and from heat treatment sections; V – supply of clean and cooled water to end-
users; VI – filter flush water; VII - scale and oil bearing sludge for dewatering; VIII –
dewatered scale and oil bearing sludge; IX – petrochemicals; X – filtrate from press filter or
centrate from decanter (centrifuge); Р – reactants (not shown in the diagram)
Legend of the process flow diagrams of recirculating waterLegend of the process flow diagrams of recirculating water
treatmenttreatment forfor CCM, hot rolling millsCCM, hot rolling mills and heat treatment plantsand heat treatment plants::
32. Кe i = √ (Кс i ∙ Кq i) , Кс i = αс ∙ Сmin / Ci , Кq i = αq ∙ q v i /q v max ,
where αc and αq – weight ratios, Cmin – minimum component content in purified water within a group of appartuses, Сi - ditto for the apparatus
with an i-number, qv max – maximum specific hydraulic load, qv,i - ditto for the apparatus with an i-number.
Efficiency criterion for reactant treatment of
recirculating water for hot rolling mills
1 – Nizhniye Sergi Metalware & Metallurgical Works,
Ø 10 m flocculator-clarifier;
2 – two-stage process deigned by a German company
(settling + filtering - see Diagram A, Slide No.30);
3 – two-stage process deigned by an Italian company
(settling + filtering - see Diagram A, Slide No.30);
4 – radial clarifier including a Ø 30 m flocculation
chamber.
Efficiency criterion for reactant treatment
of recirculating water for the gas cleaning
systems of blast furnaces
1 – Yenakievo Iron and Steel Works, Ø 10 m
flocculator-clarifier;
2 – radial clarifier including a Ø 30 m flocculation
chamber;
3 – flocculator-hydrocyclone диаметром 12м.
Process efficiency criterionProcess efficiency criterion (К(Кe ie i))
of water treatment systems and their circuitsof water treatment systems and their circuits
33. An example of layout according to the process flow diagrams А and С for external water
treatment plants, capacity 12,000 m3
/h, for hot rolling mills
1 — cooling towers;
2 — pumping station;
3 — horizontal clarifiers;
4 — open platform for oiled scale dewatering;
5 — module for filtering, flushing water thickening
and oiled sludge dewatering;
6 — flocculator-clarifiers;
7 — OKUD system.
34. Economic efficiency ofEconomic efficiency of ECO-PROJECTECO-PROJECT’s innovative’s innovative
developmentsdevelopments
Thanks to application of ECO-PROJECT’s processes, it has been possible
to reduce 1.5 ÷2.5 times the area occupied by water treatment and sludge
dewatering plants within the recirculating water systemа, and to reduced 1.3 ÷2
times capital expenditures and running costs.
Power consumption related to recirculating water treatment and sludge
dewatering are as much as 5 times lower due to:
- switching ober from single-stage and two-stage filter based processes to
single-stage non-filtering ones;
- application of gravity based water treatment and sludge dewatering
processes;
- reduction of power consumption related to recirculating water circulation
thanks to positioning compact water treatment plants close to end-users;
- outdoor installation of main water treatment and dewatering systems
(flocculator-clarifiers and OKUD systems) under any climatic conditions.
35. Inter-shop primary clarifier (scale pit)
An example of comparison with conventional solutions:
Capcity of scale pit No.1 – 700 m3
/h, scale pit No.2 – 950 m3
/h
The following indicators have been improved as compared to the conventional solutions :
Scale pit No.1- reduction of area from 185 to 110 m2
, reduction of volume from 2,070 to 620 m3
Scale pit No.2- reduction of area from 180 to 85 m2
, reduction of volume from 2,660 to 700 m3
36. Vyksa Steel Works
Pipe electric welding shop. Pipe expanding section
Emulsion waste water treatment plant
37. Pipe electric welding shop. Pipe expanding section. Emulsion waste water treatment plant.
Emulsol Wedolit EP and emulsion waste water
38. Pipe electric welding shop. Pipe expanding section. Emulsion waste water treatment plant.
Purified emulsion waste water has a neutral PH value; its salt composition remains unchanged as
compared with the original composition
39. Pipe electric welding shop. Pipe expanding section. Emulsion waste water treatment plant.
Vacuum filter for dewatering of sludge resulting from treatment of emulsion waste water
41. Results of developmentResults of development andand implementation of theimplementation of the
Modernization programModernization program of industrial water supplyof industrial water supply
systemsystem atat Novolipetsk SteelNovolipetsk Steel
Item
No.
Indicators Before
modernization
After modernization – 2010
1 Consumption of fresh water from an
outside source, x 1,000 m3
/h
15 5 (summer)
2.5 (winter)
2 Disposal of industrial waste water,
x 1,000 m3
/h
8 0.4
3 Compliance with ecological standards No compliance The system complies with
ecological standards in terms of
combined waste water disposal from
the factory to the Voronezh River.
MAC’s for salt components (sulfates,
chlorides, etc.) are achieved via
mixing with purified waste water
from the sewage system of the city of
Lipetsk.
42. ECO-PROJECT offers
to carry out the following work:
Process development for industrial waste water treatment;
Preparation of design documents for construction of water treatment plants;
Development, production and supply of the above water treatment systems;
Construction supervision;
Commissioning of production process;
Service support
Proposal for cooperationProposal for cooperation::
Purpose of cooperation:
increasing competitiveness
Cooperation with ECO-PROJECT relies on innovations,
long experience, high competence, commitment and
mobility of the personnel as well as the impeccable
reputation of the company
43. ECO-PROJECT Group of CompaniesECO-PROJECT Group of Companies
YekaterinburgYekaterinburg, Russia, Russia
Office 900, 15 Pervomayskaya St.,Office 900, 15 Pervomayskaya St., YekaterinburgYekaterinburg,, 620062007575,, RussiaRussia
Mailing addressMailing address:: PO Box 163,PO Box 163, YekaterinburgYekaterinburg,, 620049620049
Phones:Phones: +7- (343) 283-01-04, 283-01-05, 283-01-06+7- (343) 283-01-04, 283-01-05, 283-01-06
CellCell: +7-912–22–47-303: +7-912–22–47-303
E-mail:E-mail: mail@eco-project.rumail@eco-project.ru
WEBWEB:: www.www.eco-project.rueco-project.ru
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