ISCOR Steel Profile Products, Newcastle Works Republic of South Africa

 

The Client

ISCOR Steel Profile Products contracted N.A. Water Systems to study water use at the plant and to make recommendations for optimal treatment strategies that would meet the requirements of the South Africa Department of Water Affairs and Forestry's (DWAF) new Water Bill.

The Client's Needs

According to the new Water Bill, industrial facilities must maximize the reuse of water and minimize discharges to waterways.

The study involved all production areas of the facility, including the Coke Plant, Blast Furnace, BOF, Casters, Hot Mills, and Utilities. Strategies for reducing the wastewater flows on a facility-wide basis were identified.

In addition, a strategy for treating the contaminated process effluents was developed, as well as recommendations for improving the facility's utility services.

Our solution

The study involved :

  • Developing a water balance study, recommendations, and programs for cost-effective water management
  • Minimizing the intake of river water, maximizing the reuse of water, and minimizing discharges of wastewater
  • Determining design parameters and programs for implementation of intermediate optimization projects within budgets.
  • Assisting with DWAF approval of all proposals/recommendations.
  • Benchmarking proposals and recommendations in accordance with international practice in the iron and steel industry.
  • Estimating the capital expenditure required for implementation of the recommendations/proposals.
  • Estimating the annual operational cost of implementing the recommendations/proposals.Strategies that were developed included:

Strategies that were developed included :

  • Process modifications to reduce wastewater discharges.
  • Two biological treatment alternatives to replace the existing Coke Plant wastewater system.
  • A TDS treatment system to enable recycle within the facility.
  • Options for disposal of concentrated brine from the TDS treatment system.
  • Recommendations for upgrading the facility's water utility services.

Benefits

Implementation of the recommendations contained in the Water Audit would reduce the facility's water usage by an estimated 60 percent from the present levels and would ensure compliance with the Department of Water Affairs and Forestry's new Water Bill. These proposed modifications would also make our client one of the lowest consumers of water per ton of steel produced for a fully integrated mill.