Reducing of the water losses in Kremikovtzi, Ltd through closing of the water cycle in order to miti

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Reducing of the water losses in Kremikovtzi, Ltd
through closing of the water cycle in order to
mitigate the water stress
Eng. Nikolay Savov
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REPORT ABOUT KREMIKOVTZI CORPORATION

• Kremicovtzi Corporation is the biggest
  metallurgical plant in Bulgaria. The corporation
  has founded since 1964.
• The corporation is available with units,
  equipments and technologicals for full
  metallurgical cycle from iron ore production to
  the final product.The company is produced
  hot-rolled products andcold-rolled products,
  coke, chemical and other products.

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THE USE OF WATER INMETALLURGICAL PROCESS

• The industrial water-supply of Kremikovtzi
  was built in the baseof a large numbers
  recycles.
• The water is used for cooling for each
  units, but an under certain conditions and for
  all group of units.

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CLEAN RECYCLE

• The processing cycle is called Clean when
  cools engine rooms and units, and the water in
  it has to required to high rates of quality and
  physic-chemical properties.
• In these recycles the water is only cools
  in cooling towers, after that the water
  is fed by pumps to the units.

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DIRTY RECYCLE
The water of the dirty recycle is used
for cooling of the metallurgical gase and hot
metal . In this process of treating of
gasesand hot metal in the water are separated
polluting parts and slime.
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MOTION OF THE WATER
For each one of the both type of recycles
there are constructed clearning equipment,
radials and horizontal settling tanks, where the
settled slime by means of pumps is thrown out to
the settled lake Sgurootval. The
purified water is entranced into the
coressponding pump station and after that is
delivered into the cooling towers. Then the water
is cleared and cooled, the water is fed again to
the coressponding units and equipments. And
so is achieved closed system.
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SUPPLIED RECYCLE WATER
According to done calculations and plannings in
the recent years are being observed relatively
permanently rate of the quantity of supplied
recycle water to the units. In annual aspect it
is about 600 million m3 per year or little more
than capacity of the dam lake Iskar.
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USE OF A FRESH INDUSTRAL WATER
For complement of the technological and failure
losses in the each one of the recycles is used
a fresh industrial water. The water-supply with
a fresh industrial water is realized from the
lake in Botunetz, which is a balancer with
capacity 1 million m3. The additional quantities
a fresh water entrancing in Kremikovtzi are from
a few watersources with different quality and
physic-chemical properties.
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DESIGNING AND ALTERNATIVE SOURCES
Metallurgical plant ?remikovtzi was designed
to be power-supplied with water only from
Pancharevo lake. According to the project for
full load of powers was provided maximum rate of
consumption of water 110 million ?3 per
year. With a coming of the water crisis in
1980-1985 were built alternative water
sources - Pump Station (PS) Lesnovska, PS
Kazichane1,PS Kazi-chane 2, PS Dolni
Bogrov, ballasts.
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CLOSING RECYCLE OF THE WATER
Before the water crisis happened during
1995-1996 Kremikovtzi Corporation used water in
capacity about 90 million ?3/year. Closing
recycle of the water and reduction of the
pollutions have been achieved after the
undertaken rates for optimization of the used
water in operating process. In this way the
quantity of the necessary fresh industrial water
was decreased to 50-60 milllion ?3/year during
1997-2002.
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THE STATE OF THE WATER-SUPPLY SYSTEM
In the recent years have been worked for a
decrease of the technological and breakdown
losses by the water net. In the result of this,
for concerved capacity of the recycle water, the
consumption of a fresh industrial water suddenly
is decreased. The coefficient of the cycle in
2000 is 91,4 , while in the last 2004 it was
95,2 . These percents are equaled of 22,8
million ?3 saved water.
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THE STATE OF THE WATER-SUPPLY
SYSTEM
Even so the necessity of ?remikovtzi of a
fresh industrial water is still strong. In the
corporation was introduced a new technology for a
continuous caster of a steel which reflect and in
less capacity of the consumed water. Built and
put into operation is a pipeline for assimilation
of the backwash waters of the Power Plant in
Blast Furnace Plant, which lead to one more
saving of 1,2 million ?3/year.
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THE STATE OF THE WATER-SUPPLY SYSTEM
Kremikovtzi kept the equipments of the dam
lake Ognianovo, which is alternative source of a
water-supply of the corporation. In the recent
years have been invested a great amount of money
for it. The experiments to put the blame on the
dam lake Ognianovo as a main reason for the
floodings in Elin Pelin area do not reply to the
truth.
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THE STATE OF THE WATER-SUPPLY SYSTEM
In the period 4 - 8 August, as a result of the
fallen heavily rains and broken river dikes, the
corporation sustained huge losses, stay isolated
from the capital and of the rest part of the
country. The delivery of a raw materials was
stopped. The workmen were blocked in their
places.
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THE STATE OF THE WATER-SUPPLY SYSTEM
If the floodings were caused of the dam lake
?gnianovo, would be affected the most seriously
villages ?gnianovo, Doganovo, Lesnovo. They are
disposed along to the river Lesnovska, by which
the waters flow out of the dam lake. It is with
cappacity of 32,6 million ?3, but in the four
days mentioned above it in run out about 90
million ?3 water - nearly 2,5 more than its
capacity.
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THE STATE OF THE WATER-SUPPLY SYSTEM
The proof that ?gnianovo is not the reason of
the floodings, is the fact that among the most
affected areas is Golema Rakovitza, which is
placed above the dam lake, and the populated
areas, which are placed after the flowing of the
rivers Gabra, Azmaka and Matitza.
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THE STATE OF THE WATER-SUPPLY SYSTEM
The control of the watersources and the
equipments to them is being done according to the
Ministry of environment and water control
requirements. The department exercised strict
control of the execution. In this case
?remikovtzi has followed the actions,which have
described in the Failure plan for work in a
similar cases.
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A RATES FOR A SAVING OF WATER IN ?REMIKOVTZI

• The corporation foresee erection of the local
  water-purification work for the separated phenol
  waters from Coke Plant, after that these waters
  will be returned into cycle.
• This will decrease the consumption of fresh
  industial water in the Plant.

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A RATES FOR A SAVING OF WATER IN ?REMIKOVTZI

• Putting into operation of installation for
  dewater of the wasted slimes, separated of the
  radial settling tanks of the dirty recycle in
  Blast Furnace Plant and Steel Making Plant. The
  separated slime will use as a raw material in
  Sinter Plant.

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A RATES FOR A SAVING OF WATER IN ?REMIKOVTZI
This project will lead to decrease of the used
quantity fresh industrial water with about
2 million ?3/year. Except to the water
saving that will lead to a closing of the
Purificate equipment Sgurootval, which will
have a great ecological effect the villages in
the area.
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A RATES FOR A SAVING OF WATER IN ?REMIKOVTZI

• Additional criterions are foreseen as a passing
  of Hidrosbiva of Hot Streep Mill from clean
  to dirty recycle, which will lead to saving of
  a fresh water from about 4,3 million ?3/year.
• These projects are connected with serious
  investments.