PB-250 435
POLLUTION CONTROL OF BLAST FURNACE PLANT GAS
SCRUBBERS THROUGH RECIRCULATION
Robert E. Touzalin
Interlake, Incorporated
Prepared for:
Environmental Protection Agency
July 1974
¦*>
DISTRIBUTED BY:
National Technical Information Service
U. S. DEPARTMENT OF COMMERCE
-------
ATTENTION
AS NOTED IN THE NTIS ANNOUNCEMENT,
PORTIONS OF THIS REPORT ARE NOT LEGIBLE,
HOWEVER, IT IS THE BEST REPRODUCTION
AVAILABLE FROM THE COPY SENT TO NTIS.
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BIBLIOGRAPHIC DATA
SHEET"
1. Report No.
3, Recipient's Accession No.
4. Title and Subtitle
Pollution Control of Blost Furnace Plant Gas Scrubbers
Through Recirculation
5, Report Dare
July 197^
7. Author(s)
Touzalin, R. E.
8. Performing Organization Rept.
No,
9. Performing Organization Name and Address
Interloke, Inc., Chicago, Illinois 6o6(A
10. Project/Task/l'ork Unit No.
12010 DRE
11, Contract/Grant No.
12010 DRE
12, Sponsoring Organization Name and Address
U, S. Environmental Protection Agency, Office of Research
and Development, Washington, D. C. 20k60
13. Type of Report & Period
Covered
14,
15. Supplementary Notes
16, Abstracts A system was developed and facilities were installed at Interlake, Inc., Chico
go Plant, to treat, clarify, cool, and recirculate blast furnace and sinter plant vet
scrubber effluents in one unified.system, in order to effectively reuse these waters and
liminate their discharge into the Calumet River. Prior to recirculation of scrubber va
ters, the concentration, of contaminants in effluents consistently exceeded Illinois code
limitations with gros^s contaminant discharges totaling stout 1*,100 tons per year. The
ontaminant intake from the river was about 2,900 tons per year, so net contaminant dis-
charge to the river was 1200 tons per year. After the recycle system started operating,
gross contaminant discharge 'became a negative quantity. The construction cost of the
unified recirculating system vas $1,109,^00 for this plant producing about 3,200 tons of
hot metal and 3,?00 tons of sinter per day. Operating costs are about $285,000 per year
higher than the costs of operating the old "once-through" water system. Elimination of
iredging costs, and increased iron recovery produce savings of about $10,000 per year, sc
the net increase in plant operating costs is about $275,00 per vear, or -kOOOl per gallor
17. Key Words and Document Analysis. 17o. Descriptors of throughput
3hemicel Control, contaminants, flocculntion, recirculated water, water clarification,
acidity, alkalinity, ammonia, anion exchange, cation exchange, cooling tower, corrosion,
osts, efficiencies, hydraulic design, hydrogen ion concentration, iron, phenols, pollu-
tion abatement, polyelectrolytes, polymers, scaling, sedimentation, separated sewers, su:
pended solids, temperature, water quality standards.
blow-down, corrosi've-scaling conditions, hydraulic balance, stability index, blast furnacj
hemlcnl stability, clarifier, conservative substances, cyanide, dust collector, gas
leaner, gas cooler, gas scrubber, high-energy gas scrubber, hydraulic load, mate-up,
Salco Aquagraph, non-conservr.tive substances, particulate, Eyznnr Stability Index, scale
formation, secondary clarifier, sinter plant, spray tower, water separator.
17b. Identifiers/Open-Ended Terms
17c. COSATI Field/Group
18. Availability Statement
Available from KTIS
19..Security Class (This
Report)
, WCl.ASSlFlEn,
20. Security Class (This
Page
'ge
UNC
LASS1FIED
21. No, of Pages
IWl).
22, Prk;
c«
1RM NTts-as IBEV. 10-731 ENDORSED BY ANSI AND UNESCO. | THIS FORM MAY BE REPRODUCED uscomm.oc »s«a-P7*
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SELECTED WATER
RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
POLLUTION CONTROL OF BLAST FURNACE PLANT
GAS SCRUBBERS THROUGH RECIRCULATION
Touzalin, R.E.
9. Organization
Interlake, Incorporated
12. ¦ •-. • f>sr'i!ic:.iin:5 Environmental Protection Agency
Environmental Protection Agency report
number EPA-660/2-74-051, July 1974 (r> , J)
A system was developed and facilities were installed at Interlake, Inc., Chicago
Plant, to treat, clarify, cool, and recirculate Mast furnace and sinter plant wet
scrubber effluents in one unified system, in order to effectively reuse these waters
and eliminate their discharge into the Calumet River.
Prior to recirculation of scrubber waters, the concentration of contaminants in
effluents consistently exceeded Illinois code limitations with gross contaminant
discharges totaling about 4,100 tons per year. The contaminant Intake from the
river was about 2,900 tons per year, so net contaminant discharge to the river was
1,200 tons per year.
After the recycle system started operating, gross contaminant discharge decreased to
1,900 tons per year, and net discharge became a negative quantity.
The construction cost of the unified recirculating system was $1,109,400 for this
plant producing about 3,200 tons of hot metal and 3,300 tons of sinter per day.
Operating costs are about $285,000 per year higher than the costs of operating the old
"once-through" water system. Elimination of dredging costs, and increased iron
recovery produce savings of about $10,000 per year, so the net increase in plant
operating costs is about $275,000 per year, or $.0001 per gallon of throughput.
*Chemical Control, ^Contaminants, *Flocculation, *Recirculated Water,
*Water Clarification, Acidity, Alkalinity, Ammonia, Anion Exchange, Cation Exchange,
Cooling Tower, Corrosion, Costs, Efficiencies, Hydraulic Design, Hydrogen Ion
Concentration, Iron, Phenols, Pollution Abatement, Polyelectrolytes, Polymers,
Scaling, Sedimentation, Separated Sewers, Suspended Solids, Temperature, Water
Quality Standards.
*Blow-down, *Corrosive-Scaling Conditions, *Hydraullc Balance, *Stability Index,
Blast Furnace, Chemical Stability, Clarifier, Conservative Substances, Cyanide, Dust
Collector, Gas Cleaner, Gas Cooler, Gas Scrubber, High-Energy Gas Scrubber, Hydraulic
Load, Make-up, Nalco Aquagraph, Non-conservative Substances, Particulate, Ry2nar
Stability Index, Scale Formation, Secondary Clarifier, Sinter Plant, Spray Tower,
Water Separator.
05C, 0JD
'• , ' •/*
. f H • I
s . - • '
>
Send To;
WATER RESOURCES SCIENTIFIC INFORMATION CENTER
UJ. DEPARTMENT OF THE INTERIOR
WASHINGTON. DJC. 202*0
R. E. Touzalin
Tp"
250415
H. IVru-nphr-' O.'ui'nLut:r»n
12010 DRE
12010 DRE
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POLLUTION CONTROL OF
BLAST FURNACE PLANT GAS SCRUBBERS
THROUGH RECIRCULATION
by
Robert E. Touzalin
Interlake, Inc.
Chicago, Illinois 60604
Project 12010 DRE
Program Element 1BB036
Project Officer
Clifford Risley, Jr.
Office of Research and Development
Region V
Chicago, Illinois 60606
Prepared for
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
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EPA REVIEW NOTICE
This report has been reviewed by the Office of Research
and Monitoring, Environmental Protection Agency and
approved for publication. Approval does not signify
that the contents necessarily reflect the views and
policies of the Environmental Protection Agency, nor
does mention of trade names or commercial products
constitute endorsement or recommendation for use.
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ABSTRACT
A system was developed and facilities were installed at
Interlake, Inc., Chicago Blast Furnace Plant, to treat,
clarify, cool, and recirculate the blast furnace and
sinter plant wet scrubber effluents in one unified system,
in order to effectively re-use these waters and eliminate
their discharge into the Calumet River.
Prior to recirculation of scrubber waters, the concentration
of contaminants (specifically suspended solids, hexane
solubles, ammonia nitrogen, cyanide and iron) in effluent
waters consistently exceeded the Illinois code limitations
with gross contaminant discharges totaling about 4,100 tons
per year. The contaminant intake from the river was about
2,900 tons per year, so the net contaminant discharge to
the river was 1,200 tons per year or about 2 pounds per ton
of hot metal produced.
After the recycle system was placed in operation, the gross
contaminant discharge decreased to 1,900 tons per year, and
the net discharge became a negative quantity.
The construction cost of the unified blast-furnace and
sinter plant recirculating system was $1,109,400 for this
2-furnace plant producing about 3,200 tons of hot metal and
3,300 tons of sinter per day. Operating costs are about
$285,000 per year higher than the costs of operating the old
"once-through" water system. Elimination of dredging costs,
and increased iron recovery produce savings of about $10,000
per year, so the net increase in plant operating costs is
about $275,000 per year. This amounts to about $.0001 per
gallon of throughput.
This report was submitted in fulfillment of Program
No. 12010 DRE between the Federal Water Pollution Control
Administration and Interlake, Inc.
iii
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CONTENTS
Section Page
I CONCLUSIONS 1
II RECOMMENDATIONS 9
III PRODUCTION PROCESSES 13
IV PRELIMINARY STUDY OF POLLUTION
ABATEMENT MEASURES 31
V DESIGN OF RECIRCULATING SYSTEM ^5
VI SYSTEM OPERATION -START-UP AND
REFINEMENT 53
1. Hydraulic Balance 55
2. Sludge Concentrator 56
3. Coarse Particulates 58
4. Pump and Valve Maintenance 61
5. Control of Chemical Stability -
Blast Furnace System 63
6. Control of Chemical Stability -
Sinter Plant System 69
VII ANALYSIS OF PERFORMANCE 73
Control of Cyanides and
Suspended Solids 73
Control of System Water
Temperatures 80
Cost Analysis 83
VIII ACKNOWLEDGEMENTS 87
IX REFERENCES 89
X PUBLICATIONS 91
XI APPENDICES 93
Appendix A - Processes for
Effluent Treatment 93
v
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Appendix B - Cyanide Treatment
in a Cooling Tower
97
Appendix C - Scale Formation and
Control (Stability Index) 99
Appendix D - Notes on Recycle
Objectives and Procedures for
a Combined Blast Furnace and
Sinter Plant Gas Cleaning System
for Interlake Steel Corporation 107
Appendix E - Data Tabulation 115
Appendix F - Modifications of
the Recirculation System 149
vi
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FIGURES
Page
1. Chicago Plant Map 14
2. Blast Furnace Plant 17
3. Blast Furnace A & B Working Dimensions 22
4. Chicago "A" Furnace Material Flow
Diagram 24
5. Chicago "B" Furnace Material Flow
Diagram 25
6. Blast Furnace and Sinter Plant Scrubber
Water System - Before Recycle 32
7. Recirculation Without Cooling Tower,
In Winter J/
8. Recirculation Without Cooling Tower,
In Summer 38
9. Recycle System Flow Schematic, Drawing
CA-3253 49
10. Blast Furnace and Sinter Plant Scrubber
Water Recycle Systems - As Initially
Installed 50
11. Blast Furnace and Sinter Plant Scrubber
Water Recycle Systems - Modified to
Discharge Blow-down into Sanitary Sewer 54
12. Blast Furnace and Sinter Plant Scrubber
Water Recycle Systems - Modified to
Permit Make-up and Blow-down Either Before
or After Cooling Towers 57
13. Blast Furnace and Sinter Plant Scrubber Water
Recycle Systems - Modified to Reduce Load
on Sludge Concentrator 59
vii
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14
15
16
17
18
19
20
21
22
23
24
25
60
62
64
65
66
67
68
69
71
72
101
105
Blast Furnace and Sinter Plant Scrubber
Water Recycle Systems - Modified to
Eliminate Flow to Sludge Concentrator
Blast Furnace and Sinter Plant Scrubber
Water Recycle Systems - Modified with
Stand-by Clarifier
Blast Furnace Water System Stability
During Initial Operation with 50 Percent
Blowdown Rate
Effect of Reduction of Blast Furnace
Water System Blowdown Rate from
50 Percent to 10 Percent
Effects of Periodic Purging on Blast
Furnace Water System Stability
Blast Furnace Water System Stability
Under Scaling Conditions Prior to
Acid Addition
Effect of Continuous Acid Addition on
Blast Furnace Water System Stability
Sinter Plant Water System Stability
During Initial Operation with 25 Percent
Blowdown Rate and Intermittent Acid
Additions
Effect of Increase of Sinter Plant Water
System Blowdown Rate from 25 Percent to
50 Percent
Sinter Plant Water System Stability with
50 Percent Blowdown Rate
Temperature Effect on Saturation pH (pHs)
Use of Nalco Aquagraph
viii
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1
2
3
4
5
6
7
8
9
10
11.
12,
13,
14,
15,
16,
TABLES
Page
Blast Furnace Scrubber Water
Recirculating System - Balanced
Condition Parameters 2
Sinter Plant Scrubber Water
Recirculating System - Balanced
Condition Parameters 4
Cyanide Concentration - Before and
After Recycle System 6
Mass Intake and Discharge of Pollutants
from Chicago Plant 8
Blast Furnace Plant Raw Materials 18
Particle Size of Blast Furnace Dust 30
Typical Analysis Prior to Recycle 34
Material Balance Prior to Recycle 74
Recycle System Chemical Balance 76
Recycle System Mass Balance 78
Water Quality Changes in Blast Furnace
Scrubber Water System 79
Mass Discharge of Pollutants from Chicago
Plant 81
Recycle System Water Temperatures 82
Cost of Recirculating System 84
Operating Cost of Recirculation System 85
Analyses of the Waters from the Marley Cooling
Towers at the Toledo and Chicago Coke Plants 98
ix
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SECTION I
CONCLUSIONS
The operating experience gained during the first 22 months
of operation of the Blast Furnace and Sinter Plant recircu-
lation systems lead to the conclusions listed below.
Stability and Blow-Down
1. The Ryznar Stability Index, an indicator which relates
calcium ion concentration, total alkalinity, dissolved
solids, temperature and ph, is a dependable measure for
control of the corrosive-scaling condition of a water
system. (Appendix C)
The Interlake blast-furnace scrubber water system is
regulated by monitoring the stability index and
attempting to control it to a value between 5 and 6.
(Page 68 )
2. The Interlake blast-furnace scrubber water system
stability index is controlled by acid addition and
rate of blow-down. (Page 68) Presently, 200 gallons
per day of sulphuric acid are added on a continuous
basis, to the cooling tower basin.
Blow-down from the blast-furnace system to the plant
sanitary sewers is maintained at about 10%; it can be
extracted from either the hot-well or cold-well pump
discharge lines, but is normally extracted from the hot-
well pump discharge line.
Table 1, shows the salient parameters of final,
stabilized operation of the blast furnace system.
3. The Interlake sinter-plant scrubber water system
stability index is controlled by the rate of blow-down.
(Page 70 ) At the sinter plant, blow-down extracted
from either the hot-well or cold-well pump discharge
lines, is directed to plant sanitary sewers. When blow-
down is maintained at about 50%, the stability index
fluctuates in a range generally between a value of 4
and 7. (Page 72 ) jn the early days of system
1
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TABLE 1
BLAST FURNACE SCRUBBER HATER RECIRCULATING SYSTEM
BALANCED CONDITION PARAMETERS
Suspended
Ammonia
Solids
Nitrogen
Cyanide
Phenol
Iron
Flow
Lbs./Ton of
Lbs./Ton of
Lbs./Ton of
Lbs./Ton of
Lbs./Ton of
Location
(GFM)
Iron Produced
Iron Produced
Iron Produced
Iron Produced
Iron Produced
£H
Make-up Water
650
.15
.0072
.00003
.00003
.0046
8.1
Clarifier Influent
4,500
17.3
1.06
.125
.0017
7.9
8.2
Clarifier Effluent
4,300
.70
1.02
.074
.0004
.16
8.3
Clarifier Underflow
130
16.6
.031
.051
.0013
7.7
8.5
Blow-Down
450
.07
.106
.0075
.00004
.018
8.3
Evaporation Loss
70
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operation, control of the stability index through
manual acid additions in the clarifier overflow basin
was attempted, but the extent of swings in index
(+9 to -3) and the slow response time (3 to 4 days per
cycle) resulted in such unsatisfactory control that
this practice was abandoned. (Page 70 )
Reliable instrumentation for automatic regulation of
the stability index is not presently available, so a
manual method which has proved to be effective in
inhibiting scaling formation in the piping is presently
in use at the sinter plant system. When the sinter
plant is operating, no acid additions are made. On
the plant shut-down shifts (usually one shift per week),
acid is added and the system pH is controlled between
3-5 in order to remove scale and clean out the piping
system. This method has been very effective.
Significant flow and chemical parameters of final
stabilized operation are shown in Table 2.
There is only a minor interaction between the blast-
furnace and sinter-plant systems. The only inter-
connections which remain are the underflow lines from
the blast-furnace clarifier to the sinter-plant clarifier,
and this is a relatively minor flow, under 200 gallons
per minute. Not only does the underflow serve as a blow-
down of the blast furnace system, but the unused under-
flow line can be used for pumping of blow-down from
either system to the other.
Solids Removal
4. When operated on a once-through basis without addition
of flocculants, the blast-furnace clarifier was about
95% efficient in removing solid particulates, and the
sinter-plant clarifier was about 98% efficient. In
the recycle systems, with polyelectrolyte additions to
the clarifier feed, about 96% efficiency is being
obtained at the blast-furnace clarifier, and 98%
efficiency has been retained at the sinter-plant.
3
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TABLE 2
SINTER PLANT SCRUBBER WATER RECIRCULATING SYSTEM
BALANCED CONDITION PARAMETERS
Suspended
Ammonia
Solids
Nitrogen
Cyanide
Phenol
Iron
Flow
Lbs./Ton of
Lbs./Ton of
Lbs./Ton of
Lbs./Ton of
Lbs./Ton of
Location
(GPM)
Iron Produced
Iron Produced
Iron Produced
Iron Produced
Iron Produced
£H
Make-up Water
360
.086
.004
.00002
.000018
.0025
8.1
Clarifier Influent
690
38.3
.106
.085
.0027
14.4
10.5
Clarifier Effluent
630
.93
.071
.022
.00005
.084
11.0
Clarifier Underflow
50
37.4
.004
.063
.0026
14.3
11.2
Blow-Down
300
.44
.035
.011
.000022
.04
11.0
Evaporation Loss
10
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At the blast-furnace clarifier we are presently feeding
a cationic polymer, Nalco 610, in an amount of .05
parts per million, allowing it to mix, and are then
introducing an anionic polyelectrolyte, Nalco 676, in
an amount of one part per million.
5. There is no tendency for recirculating solids to cause
plugging of sprays or other portions of the piping
systems. This is logical in consideration of the fact
that the clarifiers are at least as efficient as they
were formerly, and the recirculated water is normally
lower in coarse solids content than intake water from
the river has been in the past.
Cyanide Control
6. Particulate compounds of cyanide can be removed by
settling. In both a blast-furnace operation and a
sinter-plant operation, a portion of the cyanide bearing
components are in settleable forms. (Page 42 )
7. Simple cyanides can effectively be oxidized by aeration
in a cooling tower. This aeration does not result in
the release of hydrogen cyanide gas to the atmosphere.
(Page 75) As shown in table 3 below, the concentration
of cyanide in the recycle system is higher than in a
once-through system. (Page 77 )
5
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TABLE 3
CYANIDE CONCENTRATION - BEFORE AMD AFTER RECYCLE SYSTEM
CYANIDE CONCENTRATION (ppm)
Once-Through Recycle
System System
Water Intake ,050 .014
Blast Furnace Clarifler Influent 1.7 7.53
Blast Furnace Clarifler Effluent .26 4.64
Blast Furnace Clarifler Underflow 41. 107.
*Sinter Plant Clarifler Influent 8.0 16.3
Sinter Plant Clarifler Effluent 2.0 9.40
Sinter Plant Clarifler Underflow 170. 340.
* Does not include Underflow from Blast Furnace Clarifier
In neither the once-through systems nor the recycle
systems are the effluents suitable for discharge to
the river. When an acceptably stable operation is
reached in the recirculation systems, the residual
amounts of cyanide, averaging about 5 ppm in the blast
furnace system and 10 ppm in the sinter-plant system,
far exceed the allowable .025 ppm. The cyanide con-
tent of the combined blow-downs from the recirculating
systems is, however, within the 10 ppm limitation of
the sanitary sewer code, and these effluents can be
discharged to the sanitary sewer for subsequent
treatment. Additional dilution by non-cyanide
effluents from other sources within the Chicago Plant
reduces the cyanide concentration in the sanitary
sewer to 2.68 ppm, about % the allowable concentration.
6
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Construction and Operating Costs
8. The construction cost of the recirculating system
was $1,109,400 for the 2-furnace plant producing 3200
tons of hot metal and 3300 tons of sinter per day.
Operating costs are about $285,000 per year higher
than the cost of operating the once-through water
system. Economies, which should result from elimina-
tion of dredging cost payments to the Corps of
Engineers and the reclamation value of salvaged iron
units, will total about $10,000 per year. Thus the
net cost of operating the system is $275,000 per year.
General
The mass discharge of contaminants from the Interlake
recirculation system was substantially reduced from that of
the once-through system. Table 4, which is a compilation of
the various pollutant discharges under both schemes of
operation, indicates the reduction in mass discharge,
which is achieved in the recirculating system. A net
reduction of 2300 tons per year of contaminants discharged
to the Calumet River has been effected, and a reduction of
1900 tons per year of total discharge to the river and to
sanitary sewers has been achieved.
It should be noted that the net contaminant discharge to
the Calumet River, with the recycle system operating, has
now assumed a negative quantity. In other words, the Chicago
Plant is discharging a lower tonnage of contaminants
than are in the intake waters.
One bad side effect of recirculating the blast furnace
scrubbing water is a decrease in the efficiency of blast
furnace gas cleaning. With a once-through scrubber water
system, gas was cleaned to a dust content of about .02
grains per cubic foot of gas. Since the recycle system
has gone into operation, average dust content of the gas
has been 1% to 3 times as high as during once-through
operation. Increased dust content of blast furnace gas
results in increased residue being deposited in hot-blast
stove checkers and in the boiler burners. The cause of
decreased gas-cleaning efficiency is still being investi-
gated.
7
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TABLE 4
MASS INTAKE AND DISCHARGE OF POLLUTANTS FROM CHICAGO PLANT
Once-Through System -
A. Intake from Calumet River
B. Discharges to Calumet River
(CO-1, 2, 3, 4)
C. Net Discharge to River
Recycle System
A. Intake from Calumet River
B. Discharges to Calumet River
C. Net Discharge to River
Reduction in Discharge of
Contaminants to Calumet River
Blowdowns to Sanitary Sewer
Suspended
Solids
(lb./roin.)
10.5
15.1
4.6
11.3
7.0
4.3
8.9
1.15
Hexane
Solubles
(lb./min.)
3.7
3.'42
- .28
1.4
1.41
.01
- .29
.05
Ammonia
Nitrogen
(lb./min.)
1.0
1.02
.02
.52
.40
- .12
.14
.32
Cyanide
(lb./min.)
.010
.082
.072
.002
.002
.072
.041
Phenol
(lb./min.)
.0018
.0091
.0073
.0024
.0014
.0010
.0087
.00015
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SECTION II
RECOMMENDATIONS
1. A cooling tower should be provided in any blast furnace
gas scrubber water recirculating system in which the
volume of blow-down is constrained. Water used for
blast-furnace gas scrubbing and cooling should be
under 110°F., and the recirculating system cooling
tower should be designed to remove from the gas clean-
ing water about 200,000 BTUs per ton of iron produced
at the furnaces. A cooling tower is not required in
all sinter plant dust collector water recirculating
systems, and thorough testing of the sinter plant
scrubber system should be conducted to ascertain the
water cooling needs and blow-down limitations prior to
the design of the recirculating system. (Page 82 )
2. Equipment for acid addition should be provided in any
blast furnace or sinter plant recycle system, in order
to minimize permanent scale formation. This equipment
should include complete monitoring instrumentation and
automatic controls which will regulate chemical
stability and permit the lowest possible blow-down rate
while minimizing scale formation. (Page 64) No
such controls are presently available, and it is
strongly recommended that efforts be made to develop
these controls.
3. A dual polyelectrolyte feed system should be provided
in order to obtain the most effective solids removal
possible. (Page 75)
4. Horizontal pumps should be used wherever possible.
Vertical pumps constitute a potential source of high
maintenance costs and undependable operation. (Page 61)
9
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5. Wherever waste is not or may not, in the future, be
acceptable for discharge to sanitary sewers, treat-
ment facilities must be designed for the processing
of all system blow-down. The recirculating system
covered by this report was not limited as far as
quality of discharge of effluent to sanitary sewers
was concerned, so no design of a treatment plant was
contemplated other than in the conceptual stages of
system design. (Page 35)
6. Every effort should be made to reduce the hydraulic
load on a recirculating system. All non-contact
waters should be separated from the system and dis-
charged into other channels. The age of a plant may
complicate the separation of waters, due to unavail-
ability of dependable piping drawings and the
existence of unknown connections and cross-connections.
(Page 55 )
7. Although it was not included in the design of the
system covered by this report, it might be desirable,
in future blast furnace scrubber water systems, to
separate gas cooler effluent from gas scrubber
effluent. Whereas the gas scrubber effluent has a
normal dust loading of about 2,000 ppm, the gas cooler
effluent averages only about 300 ppm. Gas cooler dis-
charge water could be recirculated in a separate system
with blow-down to the more heavily loaded gas scrubber
system. (Page 45)
8. There are, to the extent of our present knowledge, no
advantages associated with the combining of a blast
furnace gas scrubber water system with a sinter plant
dust collecting water system. The initial thinking
was that a chemical balance of the systems would be
made easier if the systems were combined. Blow-down
of one system to the other was considered to be a
potential advantage in reducing total blow-down and
obtaining hydraulic balance. It was also thought that
the blending of blow-down might make the effluent more
acceptable to the river or the sanitary sewer. These
advantages did not materialize, and combining of the
10
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systems is not recommended, but is certainly acceptable
if no substantial extra cost is involved.
11
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SECTION III
PRODUCTION PROCESSES
Interlake's Chicago Plant includes 4 separate parcels of
land totaling about 500 acres. Generally, the plant is
located on the Calumet River, with iron-making facilities
on the east side of the river and coke-making facilities
on the west side, A high-level suspension bridge carrying
a coke conveyor and gas and steam mains connects the two
plant areas. The plant map, Figure 1, shows the facilities
and their relative locations.
Coke Plant
The coke plant consists of coal unloading and storage
facilities, two batteries of 50 Wilputte underjet ovens
each and a by-product plant.
The coal mix for coke making includes 3 main coals normally
proportioned as follows:
25% Pocahontas Low-Volatile Coal
60% Illinois Coal
15% Pond Creek Coal
Coal is delivered to the coke plant in unit trains of 100
cars. It is unloaded by car dumper and delivered by
conveyors to the storage area. Here the stocking system is
served by 3 Euclid Twin-Scraper units which handle coal into
or out of stock as received or required. The normal coal
storage capacity of 150,000 tons can be readily expanded, if
necessary.
Coal going to the ovens is reclaimed from the storage area
and conveyor fed to a pulverizer and then the mixer
building bins. Next it is blended in the desired propor-
tions and conveyed to the oven storage bins. From these
bins it is drawn, as required, into the coke-oven larry car
or charging car. The larry car, which is designed to hold
the amount of coal needed for charging one oven, runs on
Preceding page blank 13
-------
LAKE CALUMET
gawf KlMS h&
¦AXaXXlj^QBSXy jut mm*
mmm.w. taut rijHT
y»»..aLniii
Fig. 1 Interlake, Inc. - Chicago Plant 2lap
14
-------
tracks supported on top of the batteries of ovens. Coal
is charged into each oven through three holes, which are
immediately sealed when the charging operation is completed.
As the coal is heated in the oven, it becomes plastic at
660 to 890°F, forming a fused mass irrespective of its
form when charged. Through this range of temperature,
volatile matter is given off, rapidly at first, then more
slowly up to about 1740°F.
The volatile matters evolved are a combination of gases
and vapors. Gases include hydrogen, methane, ethane,
carbon monoxide, carbon dioxide and unsaturated hydro-
carbons such as ethylene, propylene, butylene and acetylene.
Other gaseous compounds present are hydrogen sulphide,
ammonia, oxygen and nitrogen. The vaporized liquids in the
gases exiting from the ovens include a multitude of hydro-
carbons which are generally grouped into three categories,
ammonia liquor, tar and light oil.
A good metallurgical coke will retain very little volatile
matter — not over 2 percent — and will contain 85 to 90
percent fixed carbon. The remainder is ash, sulphur, and
phosphorus.
A typical analysis of metallurgical coke would be:
Fixed carbon - 90.0%
Volatile matter - 1.3%
Phosphorus - .005%
Sulphur - .75%
Other ash materials - 7.945%
At the Interlake Coke Plant, the two batteries of ovens,
built in 1956 and 1957, are of relatively modern design.
They are operating presently on a continuous 16-hour cycle
basis. Each oven is designed to receive a charge of 17.4
tons of coal. In 16 hours, 11.6 tons of coke are produced
per oven. This results in a yearly coal consumption of
900,000 tons and yearly coke production of 620,000 tons,
including 575,000 tons of metallurgical coke suitable for
blast furnace use.
15
-------
Coke discharged from the ovens is quenched at a water spray
type quench tower which uses river water as a make-up
source, and which recirculates the quenching water. There
is no blow-down from this system. Coke is then conveyed
over a series of belt conveyors to a screening station at
the southwest corner of the blast furnace plant. Chemicals
volatilized during the coking process are piped to the by-
product plant where ammonium sulphate, tar, pitch, and light
oil are removed from the coke-oven gas.
There are no special provisions for sulphur removal in the
coke plant gas system; the gas leaving the plant has a
sulphur content of from 1 to 2 grains per cubic foot.
Sulphur is in die form of I^S.
Blast-Furnace Plant
In the ironmaking area, east of the Calumet River, there
are two blast furnaces, ore unloading and storage facilities,
a coke-screening station, a sinter plant, a boiler-house,
two 2-strand pig machines, a pig storage yard, and
miscellaneous supporting facilities.
Raw Materials
The map of the Chicago Blast Furnace Plant, Figure 2, shows
that raw material unloading, storage, processing, and
handling are major considerations in a blast-furnace plant.
In 1970, the Chicago Plant consumed the quantities of raw
materials shown in Table 5.
16
-------
SLAC l>NK
i< »i ¦¦nw —— Hint mi
PI6 I » Jh- t T 0 » > (ht y * R o
{'""¦lit.
Fig. 2 Incedake, Inc. - Blast Furnace Plant !!ap
-------
Table 5
Blast Furnace Plant Raw Materials
Coke
680,000
tons
Coke Breeze (Fines)
60,000
tons
Limestone (Coarse and Fine)
120,000
tons
Dolomite (Coarse and Fine)
160,000
tons
Iron Ore (55% Fe)
320,000
tons
Pellets (62% Fe)
1,250,000
tons
Sinter (53% Fe)
500,000
tons
Scrap
60,000
tons
Miscellaneous Iron-bearing Materials
250,000
tons
Inasmuch as the quantities of raw materials handled are
so large and deliveries to the plant may be seasonal,
control of raw material movement is of utmost importance.
The raw material storage capacities are limited, and the
optimum quantities of some materials are somewhat un-
predictable, due to changes in iron analysis and in raw
material prices and availability.
Ore, sinter, pellet and flux (limestone and dolomite)
storage is provided in 3 storage yards: the north dock
storage, 780 feet long by 210 feet wide; the south dock
storage, 650 feet long by 350 feet wide; and the south
storage yard, 497 feet long by 390 feet wide. The north
and south docks will each accommodate a lake carrier of the
longest type. Materials are unloaded from carriers by
means of an ore unloading tower and unloading bridges with
lifting aprons. Two 5-ton bridges serve the north dock,
while the south dock is served by one 10-ton bridge and
a 20-ton unloading tower. The south storage yard is
served by a 20-ton bridge. A conveyor system serving the
entire length of the south dock will accept material from
either unloader along this dock and deliver it to a trough
under the bridge serving the south storage yard.
18
-------
Two 50-ton transfer cars operate on a continuous highline
track which runs the entire length of each storage yard.
A second highline track at the blast furnace stockhouses
is used in supplying some coke and most miscellaneous
materials to the furnace.
Access to the two highline tracks has previously been
provided by a highline approach at the north end of the
plant. Now, production facility expansion has necessitated
the abandonment of this approach, and an approach connect-
ing into the highline opposite the south storage yard has
recently been placed in service.
Sinter Plant
The sinter plant produces an excellent iron-bearing raw
material using partly waste materials from Interlake's
and other area plants, as well as lower-price fine iron
ores which would be impractical to use in their natural
condition. The charge material produced, sinter, is also
more reducible than ore in the blast furnace and is a
desirable furnace burden material in producing even gas
flow within the furnace stack and a smoother operating
furnace. Alkaline additives to the sinter produce a
furnace feed material which can be self-fluxing or even
higher in basicity than required for the sinter alone.
The Chicago sinter plant, which is of Dravo-Lurgi design,
has a production capacity of 3300 tons per day. The plant
does not always operate on a 3-shift, 24-hour basis, and
some of its production is sold to other steel companies, so
the yearly sinter consumption figure can not be correlated
with sinter plant capacity. The plant is of modern design
although it was first put into operation in 1960.
Fuel for the sintering operation is brought into the plant,
in the form of breeze and fines, by conveyor from the
adjacent coke screening station or from ground-level track
hoppers. If required, it is ground to the required
fineness in a rod mill and then conveyed to a large storage
bin. Other raw materials, fine iron ores, flue dust,
dolomite and limestone, are brought in through a system of
track hoppers and conveyors, screened and stored in large
bins. These materials are fed, in closely controlled
19
-------
proportions, onto a system of conveyor belts which carry
them to the sinter machine. Flue dust from the blast
furnaces, varying from 0 to 10% of the feed, is pugged,
or moistened, and also introduced into the system. Filter
cake from the slurries collected at the sinter plant
clarifier is fed directly onto the sinter feed belt.
Fairly recent additions to sinter plant feed materials
include pellet fines, roll scale and several other steel
plant offal materials. The proportions of various iron-
bearing, flux and fuel materials which are fed to the
machine vary over a fairly wide range, depending on the
cost and availability of materials, basicity of sinter being
produced, and other factors.
The mix is placed on the traveling grates of the sinter
machine, where it first passes under an ignition furnace
which ignites the coke and other combustibles. An induced
draft fan of 290,000 cfm capacity, driven by a 2500 horse-
power motor, pulls air down through the bed of material as
the grates travel the length of the machine. When the bed
reaches the end of the machine, it has been sintered, or
burned, to a hard, homogeneous clinker. After discharge,
from the machine, the sinter passes through a breaker to
reduce it to usable sized pieces. At this point, it is
hot-screened and the proper sized portion is carried on the
sinter cooler to the load-out tower. The sinter is cooled
by having air drawn through the bed of material. At the
load-out tower, the sinter product is cold-screened, and
material of blast furnace size (+ 1/4") is loaded into a
transfer car for transportation to the blast furnace bins,
or is conveyed to a storage pile. The -3/8" material
separated by hot screens after the sinter breaker, and the
-1/4" fines separated at the cold screens after the cooler
are recirculated and reintroduced into the mix feed system.
Some of the intermediate size material (+3/8"-l") separated
at the cold screens, is recirculated as a hearth layer on
the sinter grates, to reduce the amount of dust passing
into the exhaust system.
20
-------
Dust produced in the sintering process is drawn down
through the wind boxes beneath the traveling grates into the
gas main, where the larger particles drop out into a series
of dust hoppers. Sinter particles are carried on with the
gas and are removed in a series of sixteen parallel high-
efficiency cyclone collectors before the gas is emitted
from the stack. All dust removed to this point, amounting
to about 120 tons per day or over 98% of the total gas
solids, is collected on a conveyor and reintroduced into
the system. This amounts to about 3% of the raw feed to
the sinter machine.
There are in the plant a total of 34 belt conveyors handling
raw material and finished product. In order to control the
dust generated at the various exchange points and other
areas, including the sinter machine discharge, two dedusting
systems are operated. System "A" collects air at the sinter
machine discharge, hot sinter feeder and screens and other
points on the hot and cold fines system. System "B" pickup
points are in the cold-screening and load-out building.
Both systems utilize wet scrubbers, with the resulting
slurry being discharged to the sinter plant clarifier. The
dedusting systems exhaust to atmosphere. A more detailed
description of these systems is given in Section V.
Blast Furnaces
The focal points of the South Chicago Plant are the two
blast furnaces. These furnaces produce the molten iron
required by the basic oxygen steelmaking shop at the
Riverdale Plant and by the Microdot ingot mould facility
located adjacent to the Blast Furnace Plant. The furnaces
also produce some iron which is pigged and sold as merchant
grades of pig iron. Total iron production of the two
furnaces is 1,100,000 tons per year.
Figure 3 is a diagrammatic cross-section of a typical blast
furnace, identifying the principal elements of construction
and indicating the flow of gases through the material
burden within the furnace. The working dimensions of the
Interlake Chicago furnaces are shown on this cross-section.
21
-------
EMERGENCY VENT
VALVE
B-55-0
SMALL
BELL
LARGE BtU
DIA. A-15-0'
3. 12-9* I
STOCK LINF DIA
300 F
OVERALL
a-2ii-th; .
_B_-l58-7>/2
TO DUST
CATCHER
A-72-4*
B-62-51/^*
TOP OF BOjSH^
DIA. A.-30-0
B-25
BUSTLE
PIPF
BOSH A-12-8*
B-12-11
HOT BLAST
MOLTEN SLAG
TAPPING HOI E
COLUMN
30Q0T
HEARTH
fcVfcg*'
HEARTS DJft
.A.-25-3
.B.-I9-8*
CINDER
NOTCH
11 FURNACE
Fig. 3 - Blast Furnaces A fi B Working Dimensions
22
-------
Essentially, the blast furnace process consists of charging
iron-bearing materials (ore, sinter, and pellets), fuel
(coke) and flux (limestone and dolomite) into the top of
the furnace and blowing heated air into the bottom of the
furnace. The furnace is a huge steel shell lined with
carbon and ceramic refractories. Once started, it runs
continuously until all or part of the lining needs renewal,
or until demand for the iron drops. Iron-bearing materials,
coke and fluxes in alternate layers work their way down
from the top, becoming hotter as they sink. In the upper
portions of the furnace, reducing gases from the coke and
from gaseous or liquid fuels injected with the air blast
at the tuyeres react with oxygen released from the heated
ore and other iron oxide materials. Midway down the furnace
stack, fluxes begin to react with the impurities in the
burden to form slag. Next, the iron becomes a porous mass
as the burden moves down the stack progressively yielding
molten metal which drips down through the burden and
collects in the hearth of the furnace. Ash from the coke
is absorbed by the slag which drips down to form a pool of
molten slag on top of the iron pool. Coke reaches the
region of the tuyeres in a white hot condition and reacts
vigorously with the oxygen in the hot air blast to produce
the heat needed for the blast furnace process, and to form
the reducing gases used in the upper portions of the stack.
Periodically (from 5 to 9 times a day) the furnace is
tapped, and iron and slag are withdrawn. Iron is conveyed
to hot metal cars in which it is transported to the
Riverdale BOF shop, the Microdot mould facility or to the
pig machine located within the South Chicago Plant.
Figures 4 and 5 are line diagrams of solid material flows
at each of Interlake's two Chicago blast furnaces. Material
flows shown are based on representative figures for pro-
duction rates and raw material consumption.
23
-------
MATEWtAL FLOW FIGURES GIVEN ABE NET TONS Pfft DAY
10 NT. DUST
-¦*'>10000 fPU fL FAMfiAC
¦I N.T.DUST
PUS I
£.<&££&!
flkiSI
umyxs.
i7.« Kt oust rwpM "a'rct.
•T, O.AST riWfUCE j
£icyi
61 ¦ HX OUST
27 NT. DUST
rmm
I Q*MF
Itumm
f n?™-
I1 HEARfH
-HQI V
W£tttCAR
.200NX cas
SLAG RT — • -•->
CA£*XiTf.£*54- t±*LE
-gqqoN^jro mvErajALE,
MtcgoooiLfoukePXOR
PIG CASTING UMCUMZ
«—«EC1RCUL*11N0 -SttTCM,
&*S_5l,tiNs£j&!5kB
Fig. 4 - Chicago "A" Furnace Material Flou Oiagraia
-------
ORE INCLUDES
VWBUSH PELLET!
EPIC fCLLETt —
IINTEW
aON.T. FLUX
'i>N-T. SCRy
rSON.T. COKE
MATERIAL FLOW FIGURES GIVEN ARE NET TOWS PCB PAY
glfc' CSMMCTt tUARIFIEff fOf?
V WI1 blast ruiwti
'iWCFM.CLEW OS
¦ l N.T. DUST
15- i1
OIA.
v.9Nj. our.T from "a'fce,
a.AST FURNACEj
61 N.T. OUST
27 UT. DUST
3SON.T. SLAG
HEARTH
SLAG PIT -
CAPAoir.EAia.
ijSONT. TO RtvEROALE.
HtCROOOT_FOUMDKTLOR
PIG CASTING IUCWINE
^¦T. SCRAP
—?EClRCUL#IIMCuarSJEIL
GAS CLEANING WATER
SLAG >:
Fig. 5 - Chicago "B" Furnace Material Flou Diagram
-------
The blast furnace plant blowing facilities include 3 turbo-
blowers, each rated 70,000 C.F.M. at 25 p.s.i.g. The
blowers are equipped with parallel-blowing and split-wind
control, so that the combined capacity of either two or
three blowers can be split as required between the two
furnaces.
It is interesting to note the changes in pollution and
pollution control techniques which have occurred within the
past 15 years. 15 years ago, over 100 tons of flue dust
per day were discharged in the gases passing from the tops
of the two blast furnaces. After cleaning of the gas and
settling of solids from the wash water, approximately 7,400
tons of solids per year were discharged to the Calumet
River. Through design improvements, refinement in operation,
and beneficiation of raw materials, it has been possible to
reduce the dust rate (pounds of flue dust discharged, per
ton of iron produced) from about 150 pounds per ton to the
present 25 pounds per ton. The recirculating water systems
have been effective in not only eliminating the solids
discharged to the river from the gas cleaning systems, but
actually brought about, in 1970, a negative net solids
discharge. That is, the water returned to the river was,
on the average, cleaner than that taken in and used by the
plant. This was accomplished at production rates almost
exactly twice as high as those existing 15 years ago.
A high percentage (actually about 99 percent) of the solid
materials escaping from the blast furnace in its exhaust
gases is captured by the gas cleaning system and reclaimed
for use as charge material. This is accomplished by a
3-stage cleaning system including a conventional dry dust-
catcher, a high-energy wet scrubber and a counter-current
spray tower which acts as a combination gas cooler-
moisture eliminator.
The dry dustcatcher dust is taken by railroad car to the
sinter plant, where it is conveyed to feed bins and
eventually fed into the sinter machine mix. Wetted dust
from the high-energy scrubber and gas cooler is pumped,
with the discharge water, to a water treatment system.
The dust in the form of a thickened slurry is then pumped
to two disc-type sludge filters located at the sinter
plant. The filter cake feeds directly to the sinter
machine feed conveyor.
26
-------
Blast furnace gas is used as a fuel in the blast furnace
stoves and the boilers. The more critical requirements
for clean and dry gas exist at the stoves, where
maintenance of checkerwork cleanliness is an important
factor. Gas which contains more than .01 grain of dust
per cubic foot is not desirable for use in the small-hole
(2-inch square or smaller) checker tile of a modern stove.
Excessive moisture in the gas not only depresses the thermal
value of the gas but produces a sloppy condition at the
stove burners.
Iron Production Wastes
Based on the variety of constituents in iron ores, fuels
and fluxes, and on the temperatures and pressures which
exist in an operating furnace, the chemical reactions which
are carried out in a blast furnace are multitudinous and to
some degree indeterminate.
The reduction of iron oxides to metallic iron proceeds in
accordance with a dozen or more reactions involving C, CO,
CO2, Fe203, Fe304, FeO and Fe. These reactions have been
the subject of many comprehensive studies, but they are not
germane to the subject of formation of contaminants in the
blast furnace gas.
The significant pollutants in blast furnace gas scrubber
water are cyanide, phenols, ammonia, suspended solids,
temperature and pH. The source of these pollutants is as
follows:
Cyanide
The hot blast of air blown into the furnace at the
tuyeres has the usual proportions of 02 and N2• The
action of the nitrogen of the blast upon the hot
carbon in the hearth results in the formation of
small quantities of cyanide. Cyanide has a strong
affinity for the sodium and potassium present in
the fuel ash, and as a result, cyanides of the
alkali metals are present in the gases leaving the
hearth zone. Typically, this reaction proceeds as
27
-------
shown. (4).
K2 C03 + 4C + N2 - 2KCN + 3CO
The cyanide, which is a powerful reducing agent
reacts:
KCN + FeO = Fe + KCNO
The resulting potassium cyanate passes upward in
the gases and is decomposed by CO2 into carbonates
with the liberation of nitrogen, thus:
2KCN0 + C02 = K2 CO3 + CO + N2, or
KCN + KCNO + C02 = K2 CO3 + 2CN
The potassium carbonate is largely deposited in
the cooler parts of the furnace and carried down-
ward by the descending materials to the hearth,
where it can again act as a base for cyanide
formation.
The precise mechanism of formation and circulation
of cyanides within the furnace is open to speculation,
however, it is a fact that a quantity of cyanides
escapes from the furnace in the outlet gas and in
the flue dust. This is the quantity which pollutes
the gas scrubber water.
The discharge of cyanide from a blast furnace occurs
in an irregular pattern of flow, and a chemical
treatment of the gas is therefore rendered more
difficult. It is possible that these variations in
cyanide evolution may be a result of channeling of
gases through the burden in the furnace stack.
This is a factor which cannot be effectively
controlled in present-day normal blast furnace
practice.
28
-------
Phenol
The entire list of sources of phenols is not pin-
pointed but it is apparent that much of these
originate in the volatile residue in the coke, or
possibly in other organic gangue constituents of
the furnace raw materials.
At some coke plants, a potential source of phenol
is introduced by the technique of quenching coke
with waters which contain phenolic wastes from
coke gas by-product plant operations. Interlake does
not use such waters for quenching, but employs a
separate recirculating quench water system with
river water provided as make-up. Whatever the
exact source, some phenols are picked up in the
gas scrubber water and carried into the blast
furnace recycle system.
Suspended Solids
Fine particles which enter or are formed in the
top of the furnace are picked up by the high gas
velocities existing in the furnace stack and are
conveyed through the raw gas system.
The nature of particulate matter escaping from the
stack will vary from furnace to furnace, depending
on the composition of the raw materials, furnace
operating techniques and other variables. Some
of the constituents which are carried over with
the gas are FexOy, CaC03, CaS, MgC03, SiC>2, CaO,
MgO, KCN, and Carbon. In regard to particle
size, one sample of particulate matter analyzed
as shown in Table 6.
29
-------
Table 6
Particle Size of Blast Furnace Dust
Particle size + 635 microns - 11%
635 - 423 microns - 13
423 - 317 microns - 8
317 - 254 microns - 7
254 - 169 microns - 7
169 - 127 microns - 6
127 - 102 microns - 3
102 - 94 microns - 5
94 - 78 microns - 2
smaller than 78 microns - 38
100%
In the Xnterlake gas systems, as in most blast furnace
gas systems, the dustcatchers collect from 25% to 75%
of the particulate matter. About 99% of the particulates
which are not captured in the dustcatchers are collected in
the gas scrubbing water and processed in the recycle system.
Temperature
As is the case with many blast furnace operating conditions,
the top temperature is a function of many factors, and may
vary from over 1000° F. (with abnormal furnace filling)
to under 212° F. A more normal range for top temperature
is between 250 and 400° F. As discussed in more detail in
Section IV, it is desirable, in the gas cleaning system,
to cool the gas to a temperature which inhibits the vapor
content of the gas. Most of the thermal energy removed
from the gas is transferred to the scrubbing water, with
the resultant thermal pollution of this water.
2H
The alkaline condition of the gas cleaning water is a
result of a predominance of alkaline minerals and chemicals
in the fumes and dust emitted in the furnace top gases„
The turbulent contact between gases and waters in the
scrubbing and cooling units promotes an effective absorption
and pick-up, by the water, of these alkaline constituents.
30
-------
SECTION IV
PRELIMINARY STUDY OF POLLUTION
ABATEMENT MEASURES
History
Historically the cleaning of blast-furnace gas was originally
undertaken, not on a pollution abatement basis, but rather
as a requirement to prepare the gas for combustion in
various auxiliaries of the furnace. Blast-furnace gas-
fired boilers became more sophisticated; hot-blast stoves
were designed with smaller checker openings in order to
acquire more heating surface; cleanliness requirements for
coke-oven underfiring became more stringent; in short, the
fine cleaning of gas became a necessity. This cleaning was
accomplished in wet scrubbers and wet electrostatic
precipitators, with the effluent slurries being treated in
a clarifier or settling basin before discharge to the
waterways.
Original Water System Design
The gas-cleaning water system at Interlake's Chicago plant
was somewhat unusual, in that the slurry underflow from a
primary clarifier at the blast furnaces was pumped to a
secondary clarifier located adjacent to the sinter plant.
The secondary unit clarified the effluent water from two
sintering plant environmental control systems, as well as
the blast furnace clarifier underflow.
A diagram of this system is shown in Figure 6. The system
had the advantage of consolidating all solids-containing
wastes at one location, where the solids could be recovered
and fed directly to the sinter plant raw material feed
conveyor.
31
-------
24 400 CPM
emeu. A1 INC
PUMPS
WTER
SCRUBBERS
SUMP
J 690 GPW
-SCRVCE WATER
PUMPS
TUR0O-6UOWER
COKXhSERS
•rmxc
SO*>
<
JL
•—(5)
wtn
watch
NON-CONTACT
WATERS
V CONVEYOR TO
0 \ SINTER PLANT
EVAPORATION-70 CPM
BLAST FURNACE
CLAAIfiCR
M90CPM
TO RIVCR
CO I
uqcpu
VACUUM
FILTER
m
*-riLTRATC
R.R.CAR
SmTEfl
PLANT
OUST
POUCLECTROUfE
&60CPM
LOCATION OF SAMPUNS POINTS
«. tmouGh TO m.*ST ru«H*ct cuwpikii
*, 5rtB»\ow n»o*i itoT nj*Mce
%, MAKt-UP Wl¥l* INAttft
?. UNSCffTL^*, S.*1T ru*ll*Ct
i. t*guc* ra smtt* (vw a.**'**
». owia*. sihich i»i>ni u>*>mR
<2.U«(eC*n.O*.3iMTtft Pt*Nt
EVAPORATION-1Q CPU-
~30 CPM
TO RIVER
Fig. 6 - Mast Furnace & Sinter Plant Scrubber Water System Before Recycle
-------
The first effluent clarity controls imposed on Interlake
were a result of agreements with the U. S. Corps of
Engineers. Starting in the year 1954, Interlake commenced
continuous sampling of all effluents from the Chicago Blast
Furnace and Coke plants. Agreements were reached, in
accordance with which Interlake paid the Corps of Engineers
for dredging of the Calumet Eiver on a basis commensurate
with the measured discharge of solids from the plants.
However, it became obvious, even prior to Federal, State,
and Metropolitan Sanitary District moves into environmental
control, that limitations on discharges into waterways were
imminent, and efforts towards better clarification of the
effluents were instituted by Interlake. These efforts
took the form of increased usage of the blast furnace
clarifier, and measured additions of flocculents to improve
the efficiency of the sinter plant clarifier.
Interlake1s responsible and successful efforts to satisfy
the Corps of Engineers, resulted in an early appreciation
of the need for water pollution abatement. The problems
related to water supply, treatment, distribution, and
pollution control became apparent. In 1963 the firm of
Stanley Consultants was retained to perform a complete
water inventory of the Chicago Plant. This survey served as
a basis for efforts to improve water distribution and
pollution control.
During the period prior to 1967, a state of limbo existed
in the field of pollution abatement, because of the lack of
any definite direction by the various governing agencies.
A need existed for viable criteria on which design of
abatement systems could be based. This void was filled by
SWB-15, a law adopted June 28, 1967, by the Illinois State
Water Board, which established standards for the constituents
and properties of all effluents. Based on these standards,
Interlake instituted a study of the Chicago Plant effluents
and the need for treatment of these effluents. Table 7
records the pertinent criteria set in SWB-15 and typical
analyses of Chicago Blast Furnace Plant intake and outfalls,
prior to the installation of the recirculating systems
(Flow as diagrammed in Figure 6). The data in Table 7
generally represent the average values of a number of grab
sample analyses. Not all analyses were performed on each
33
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TABLE 7
TYPICAL ANALYSIS PRIOR TO RECYCLE
Suspended
Hexane
Ammonia
Flow
Solids
Solubles
Nitrogen
Cyanide
Phenol
Iron
Location
(GPM)
(ppra)
(ppra)
(ppm)
(ppo)
(ppb)
(ppm)
eIL
Intake
24,400
51.5
18.
5.0
0.050
9.0
3.3
7.7
North Sewer (CO-2)
11,300
80.6
18.
5.3
0.40
47.0
5.9
8.3
South Sewer (C0-3)
7,220
77.2
25.
1.4
0.41
13.0
2.5
8.1
Blast Furnace Clarifler
Influent
3,690
928.
8.0
16.
1.7
171.
371.
8.4
Blast Furnace Clarifier
Effluent (CO-1)
3,490
44.6
6.0
10.
.26
80.0
11.5
8.4
Blast Furnace Clarifier
Underflow
130
25,200
74.
10.
41.
2760.
10,200
8.6
iSinter Plant Clarifier
Influent
560
9,240
12.
35.
8.0
400.
2,770
10.3
Sinter Plant Clarifier)
Effluent )
Sinter Plant Outfall )
630
305
10.
27.
2.0
298.
35.1
10.3
CCO-4) I
Sinter Plant Clarifier
Underflow
50
165,000
210.
27.
170
7900.
57,100
10.3
Steam & Evaporation
Loss
1,760
-
-
-
-
-
-
-
Code, SWB-15
-
25
15.
2.5
.030
200.
10.0
6—1C
*Does not include Underflow from Blast Furnace Clarifler
-------
sample, but it is believed that the tabulated figures are
representative of the system water quality and quantity.
With the exception of tests for iron, analytical procedures
used to determine concentrations as shown on Table 7 were
performed in accordance with "Standard Methods for the
Examination of Water and Waste Water", 12th Edition, 1965.
Iron analyses were performed by atomic absorption
spectrophotometry.
Table 7 indicates that the effluents were not in compliance
relative to allowable discharge of suspended solids,
ammonia, cyanide, phenols, iron, and pH.
Studies were promptly instituted to investigate the most
practical method for control of the polluting constituents.
First efforts were directed towards treatment of the
effluents to allow continued discharge to the Calumet River.
Numerous treatment processes were considered and evaluated
in this study. See appendix A for details of some processes
which were evaluated. It was eventually decided that the
volume of water requiring treatment, the state of develop-
ment of the systems, the possibility of changing standards
for pollution abatement and the limited area for facilities
were going to result in a capital expenditure of prohibitive
proportions and a system of questionable effectiveness.
It appeared, therefore, that the logical approach to
Interlake's problem was a recirculating system, in which
the effluent from the two clarifiers would be recycled for
use in the various gas scrubbing units. Some blast furnace
plants had used, and still use, such a system, but none had
incorporated sinter plant wet scrubbers into an integral
recycling system with blast furnace gas-cleaning units.
In considering the feasibility of a recirculating system,
several important questions had to be answered and deter-
minations made. These were:
1. Are cooling towers required?
2. What water stability problems would be encountered,
and how could these be solved?
35
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3. At what level of concentration would the various
contaminating constituents stabilize?
4. What effects would flocculents have in the system?
The study of these questions proceeded with the following
considerations and decisions.
1. Are cooling towers required? Blast furnace gas
leaving a wet scrubber will be saturated with
moisture. The temperature of the gas at this point,
therefore, determines the amount of moisture (in
vapor form) that will be contained in the gas. This
amount varies drastically with relatively small
differences in temperature. For example, gas at
100°F. will carry 20 grains per cubic foot, while
gas at 120°F. will carry over 34 grains per cubic
foot, a 72% increase.
Excessive moisture in the gas not only decreases the
effective calorific value, but it results in heavy
condensation in gas mains, burners, etc. It is,
therefore, desirable to cool the gas to a fairly low
temperature in the wet scrubbers or gas coolers
following these scrubbers, and this is accomplished
by maintaining a low temperature in the water going
to scrubbers and gas coolers. Water temperature is
also one of the variables which effects chemical
stability, so it is an important factor in scale
deposition. At the Chicago Plant, a water temperature
of under 110°F. is believed to be desirable.
Thermal balances were prepared in an investigation of
the amount of blow-down required to maintain the
desired operating temperatures, when using the clarifier
as the only means of heat transfer. From the thermal
balances, a family of curves, shown in Figures 7 and
8, were developed. These curves indicate that a
blow-down rate of 25-40% during the summer months,
would have to be maintained in order to reduce the
water temperature as required. Because of the limitations
in allowable quality of flow of effluent to the river
and the limited hydraulic capacity of sanitary sewers,
36
-------
AIR TEMPERATURE=40°F
RELATIVE HUMIDITY **SG%
RECIRCULATION RATE =4500G.PM.
MAKE-UP WATER TEMPERATURE=60
BLOW-DOWN
Bate
CYCLES
A 5 6 7
5.31 7.06 a©5 10.62 12.39
* TIME FROM S TART—UP (HRSi)
Fig. 7 - Recirculation Without Cooling Tower in Winter
-------
AIR TEMPERATURE=80»F
RELATIVE HMMID1TY=50%
RECIRCULATION RATE =4500 Q.PM
MAKE-UP WATER TEMP=70°F ^
8
3 4 5 6 7
5.31 108 6.65 fO.62 12.39
* TIME FROM START-UP (HRS!) —
Fig. 8 - Recirculation Without Cooling Tower in Sumner
-------
we could not tolerate a blow-down of this magnitude,
so a cooling tower was included in the blast furnace
recycle system.
The sinter plant dust collector water temperature can
vary over a fairly wide range, as the conditions at
collection points change or the distribution of
collected air is changed.
A need for low water temperature at the dust collectors,
in order to reduce the air temperature leaving the
collectors, does not exist, as this air is merely
exhausted to atmosphere through a fan. There is,
however, another reason for maintaining a low water
temperature, the desirability of minimizing the build-
up of alkali deposits within the recycle system. The
water temperature is inter-related with water stability.
Biijed on a combination of measured and assumed
operating information, it was concluded that the sinter
plant scrubber water system also required a cooling
tower to maintain desirable temperatures in the system.
2. What water stability problems would be encountered and
how could these be solved? As stated earlier, the
purpose of the gas scrubbers and counter-current spray
towers is to cool the gas and to remove suspended
particulate matter so that the blast furnace gas is a
suitable fuel for blast furnace stoves, boilers, and
other auxiliaries. In achieving these results gas
cleaning water also picks up dissolved inorganic and
organic materials.
Many of these materials are considered pollutants to
receiving waters. To reduce the level of pollutant
discharges in the clarifier overflow, a scheme of
operation in which a large proportion of the overflow
is fed back to gas cleaning units is employed. The
principal questions to be discussed pertain to
materials, picked up by the washer water, that limit
the level of reuse or recycle of the water. No gas
cleaning system can operate on complete recycle;
39
-------
material balances must be satisfied. The water has
a finite transport capacity for suspended and dissolved
material and for heat. In order to maintain its
ability to clean the gas, the gas cleaning water must be
processed in such a way that incremental amounts of
suspended and dissolved materials and heat are removed
from the water. If the transport capacity of the
water is exceeded, the gas cleaning operation will fail.
It was an objective of preliminary studies to point
out the limiting factors that control the gas cleaning
operation and to achieve operating conditions in which
materials in excess of those which can be carried by
the washer water are removed in the treatment device
and not at indeterminate points in the system. Two
contrasting waste treatment problems exist. In the
once-through operation, a high-volume-low concentration
stream must be treated. A recycle operation will need
some type of treatment for the main water stream but,
in addition, will have a blowdown stream which is a
low volume-high concentration stream. The character
of this blow-down stream is influenced by two not
necessarily compatible factors, namely, the concentration
and treatability of the pollutants in the stream and
the concentration and transport limiting character-
istics of control materials in the main gas cleaning
water. In the Interlake recirculating system, the
latter was the governing factor.
The chemical and physical contaminant parameters of the
water system can lie classified as conservative and non-
conservative. Conservative substances, such as sodium
and chloride, are added to the water by the gas
cleaning process and generally tend to build up in
concentration with time. By the means of blowing down,
or discharging from the system a portion of the gas
cleaning water, the concentration of the conservative
substances can be held nearly constant. Theoretical
analysis of conservative substance control is detailed
by McMichael, et al (1). Non-conservative substances
are also added to the water by the gas cleaning process.
40
-------
These substances may undergo chemical reaction and
be precipitated, volatilized, or otherwise lost from
the system, Their behavior is not readily predictable.
Included in the non-conservative or interacting para-
meters are calcium, alkalinity, pH, ionic strength,
ammonia, phenol, cyanide, and temperature. These non-
conservative materials are also effected by, and can
be partially controlled by, blow-down. It is necessary,
for operational control, to determine the response of
the water recycle system with regard to the non-
conservative substances. Broadly, some non-conservative
substances may change concentration by large amounts,
reach saturation levels, precipitate, and entirely
change the chemical composition of the recycle water
stream. The prediction and control of this chemical
system is the principal problem of the recycle opera-
tion. Ideally, this system should be controlled with
a minimum of outside activity.
It was hoped that control of the non-conservative sub-
stances could be managed by the same technique as used
for control of conservative substances, that is, blow-
down from the system.
Observations of blast furnace gas cleaning systems on
recycle show that the principal failures are due to
the plugging of spray nozzles, deposits in venturi or
orifice throats, and the closing of transport pipes by
precipitated materials (1). Chemical analyses of such
materials show they are mainly calcium carbonate.
Suspended material does not seem to be a controlling
factor. Carbon dioxide and calcium oxide in the gas
react with the wash water to change the calcium
carbonate equilibrium. Other materials in the gas add
incrementally to the total dissolved solids.
Measurable amounts of iron, sodium, potassium,
magnesium, chloride, sulfate, and ammonia are found in
addition to other constituents previously mentioned.
The different levels of these materials depend on the
furnace burden and method of operation.
41
-------
Many arbitrary rules of operation exist within the
steel industry regarding recycle operation (1). Some
general statements indicate that systems on 80 percent
recycle (or 20 percent blow-down) generally perform
like once-through operations. Tighter systems require
more care than once-through operations. Some companies
control their recycle system through blow-down and
make-up water, keeping the total dissolved solids (or
electrical conductivity) below an empirically determined
value. Other companies operate similarly but monitor
total alkalinity. One successful recycle operation
controls its system by acid addition to keep the pH
below an empirically determined level. Each of these
systems has had its failures, and by one mechanism or
another has wandered to an apparently satisfactory
working level.
3. At what level of concentration would the various
contaminating constituents stabilize in the blast
furnace recycle system? Our primary concern, at the
outset of our studies of a recycle system was the
build-up of cyanide.
Cyanide in blast furnace waters exists in three com-
plex forms; (1) as an organic amino compound, (2) a
non-metallic salt, and (3) a metallic salt. It was
believed that a reduction in cyanide content would be
accomplished by the treatment of the scrubber water
with polyelectrolytes and subsequent settling of the
metallic and non-metallic cyanide salts in the
clarifier. Originally it was intended that an anionic
polyeleetrolyte be added ahead of the clarifier;
cationic particles such as iron would be agglomerated,
thereby improving the collection efficiency by 60-70%.
A product made by Nalco Chemical Company, Nalco #673
was selected for this service and bench tests were
conducted to determine the effectiveness of the pro-
posed additions. This product, by itself, improved
the suspended solids removal as anticipated, but the
tests showed that further improvement was needed in
order to bring the cyanide and suspended solids levels
down even further.
42
-------
Experimentation showed that we could improve the
efficiency of the suspended solids removal, and hence
the removal of the cyanide, by first introducing a
cationic, low molecular weight polymer, NaLco 610, and
following with an anionic polyelectrolyte, Nalco 676.
An improved efficiency of solids removal of over 95%
was believed to be possible, and such efficiency was
actually reached in later full scale operation.
The Interlake Research Department undertook another
program in which they studied the means by which cyanide
could be treated by oxidation. In full scale research
performed at Interlake's Toledo Plant, it was found
that the free falling of water through an air current
resulted in an effective reduction in the cyanide
concentration. We do not have definitive results of
these earlier tests, however parallel tests of a
quantitative type were conducted at the Chicago and
Toledo Coke plants in July, 1971. Results of these
tests are tabulated in Appendix B. Although the
effectiveness of this aeration treatment was erratic,
it appeared that about 45 percent of the cyanide could
be removed from coke plant waters.
The design of the Chicago recirculating system was
based on bringing the scrubber water to a clarifier,
flocculation with a polyelectrolyte, settling of the
solids and passage of the overflow through a cooling
tower. This practice promised to effectively suppress
the build-up of cyanide concentration in the recycle
system.
4. What effect would polyelectrolytes have in improving
sedimentation efficiency in the clarifiers?
It would be logical to expect that the level of suspended
solids in the clarifier effluent would build up
gradually on a recycle type operation. This idea is
based on the principle that finer sized particles would
not be captured in the clarifier. Such particles would
theoretically not have enough time to settle in the
clarifier and would pass into the overflow effluent.
On each pass through the gas cleaner, more small
43
-------
particles would be added to the wash water, and the
concentration of particles would steadily increase.
It is probable that such a small particle build-up
would be encountered, if steps were not taken to in-
duce optimum floeculation of these particles. It is
suspected that the particles undergo some type of
self-floeculation at higher concentration, and thus
the small particle solids removal capability of a
clarifier is increased on recycle. In addition to the
above mentioned "self-floceulation", it is desirable
that solids be encouraged to precipitate to the
maximum degree possible, in order to reduce the
possibility of plugging or pipe restriction anywhere
in the system, and to minimize the loss of suspended
solids in the blow-down. Improved sedimentation
efficiency is important to the success of the recycle
system and the effectiveness of polyelectrolytes for
this service was hopefully expected, but unknown. This
factor was, therefore, one of the questionable features
of the recirculation system.
44
-------
SECTION V
DESIGN OF RECIRCULATING SYSTEM
The arrangement of the original Chicago Plant Blast Furnace
gas cleaning system, Sinter Plant fume collecting system
and the associated waste water handling systems has been
briefly mentioned in earlier sections of this report, but
it is appropriate, before launching into a description of
the redesign of this system, to describe in some detail,
the system as it existed before the recirculating system
was built. A simplified schematic diagram of the system
was shown in Figure 6.
Secondary cleaning of blast furnace gas from both "A" and
I'B" furnaces is performed in high-energy wet scrubbers,
"A" furnace is equipped with a Research Cottrell Louver-
type variable-orifice scrubber, a unit which was designed
to meet Interlake's specifications and which has been
extremely successful in reducing maintenance of the gas-
cleaning system. "B" furnace uses a variable-throat
venturi scrubber as manufactured by Chemico, At each
furnace, the high-energy scrubber is followed by a Chemico
centrifugal water separator, and then by a counter-current
spray tower or gas cooler. The spray tower's principal
function is cooling of the gas. The "A11 furnace gas
system also includes a moisture eliminator mounted at
the top of the spray tower, to minimize entrainment of
moisture in the gas. The "B" furnace gas system has no
moisture eliminator.
Gas scrubbing water was withdrawn from the plant water
system, with booster pumps for that portion which was fed
to high pressure sprays. Discharge water from the scrubbers
was collected in the centrifugal separators and fed to the
90-foot diameter primary clarifier located in the vicinity
of the blast furnaces. Effluent water from the spray tower
was originally, because of its relative cleanliness,
discharged directly to the Calumet River, thus reducing the
hydraulic load on the clarifier. Studies of gas cleaning
system discharge waters, with measurements taken daily over
a period of more than 10 years, indicated that the average
dust loading of the spray tower discharge water was less
45
-------
than one tenth that of the scrubber water.
As furnace production was increased and as the need for
cleaner effluents to the river became evident, the spray
tower effluents, even though relatively clean, were also
directed to the clarifier.
Before construction of the new sinter plant at the south
end of the Chicago Plant, disc-type Oliver filters,
located in the old sinter plant adjacent to the primary
clarifier, produced a filter cake from the clarifier under-
flow. When the new sinter plant was built in 1960, it was
decided that it would be advantageous to consolidate the
filtering equipment at the new sinter plant. Under-flow
from the blast-furnace clarifier was pumped at a relatively
low solids content (5 to 10% solids) to a 40-foot diameter
sinter plant clarifier. During the past eleven years, the
blast furnace flue dust production has been drastically
reduced and, as shown in the figures of Table 7, the
suspended solids content in the blast furnace clarifier
underflow has correspondingly been reduced from the original
5 - 10% solids.
The sinter plant and its auxiliaries are provided with two
dust collecting systems. System "A" is ducted to pick up
fines and fumes at the following points in or near the main
building of the sinter plant:
Sinter Machine Discharge Hood
Hot Sinter Feeder
Hot Sinter Screen
Hot Fines Feeder
Hot Fines Surge Bin
Cold Fines Feeder
Hot Fines Conveyor
Various Conveyor Transfer Points
Capacity of the "A" system fan is 90,000 C.F.M.
46
-------
System "B" picks up from the following points in the vicinity
of the sinter screening station:
Sinter Cooler Discharge Hood
Primary Sinter Screens
Secondary Sinter Screens
Conveyor Loading Points and Discharges
Capacity of the "B" system fan is 53,000 C.F.M.
Each system includes ducts, dampers for system balance, a
wet scrubber and a fan. Although the scrubbers were
originally equipped with Peabody impingement trays, continual
plugging of the cleaning elements occurred, and the scrubbers
were eventually converted to spray towers. Sludge draining
from the "A" and "B" system scrubbers flowed by gravity to
the sinter plant clarifier.
The sinter plant clarifier received the effluent from the
sinter plant dedusting systems as well as the underflow
from the blast furnace clarifier. Underflow from the sinter
plant clarifier was pumped to the disc-type filters located
within the sinter plant. The filter cake produced here
dropped onto a belt conveyor which could feed the cake
directly to the sinter machine feed conveyor or to a rail-
road car for alternate disposal at a storage area.
Design of the recirculating system was initiated in 1968.
In view of their knowledge of our Chicago Plant feed water
and waste water systems, and their reputation for expertise
in the field of waste treatment, Stanley Consultants were
retained to assist Interlake in the engineering of the blast
furnace and sinter plant gas cleaning and dust collecting
water recycling system.
Several differences do exist between the blast furnace and
sinter plant systems. The blast furnace system is not
equipped with a filter for removal of solids from the
primary clarifier underflow. Instead, that underflow is
pumped to a sludge thickener or concentrator at the sinter
plant. As stated earlier in this report, this consolidates
the filtering equipment at a location convenient to the
processing of the solids. As a result of a cooperative
47
-------
study, Flow Schematic CA-3253, shown in Figure 9 was
developed. This diagram shows both the blast furnace and
the sinter plant systems and their interconnections. Note
that each system performs the same basic functions. The
process water becomes dust laden and warm in the gas
cleaning units. The dirty, heated water is then cleaned
through the settling action in a separator and is aerated
and cooled in a cooling tower. The treated water is then
re-used in the wet scrubber units.
Duplicate underflow lines are provided from the blast
furnace system to the sinter plant system. One of these
lines is available as a stand-by underflow line, but it was
also intended to serve as a means of taking blowdown from
the sinter plant system for disposal in the blast furnace
area. One possibility considered was the disposal of blow-
down as slag quenching water at the "A" and "B" furnace
slag pits.
The existing secondary clarifier at the sinter plant was
changed to perform only as a primary clarifying unit with
underflow being pumped to the sludge thickener. The sludge
thickener concentrated the slurries received from the blast
furnace and sinter plant clarifiers and pumped a high solids
content sludge to the disc filters.
In order to portray the recycle systems in the various
stages of change and development which occurred during
start-up, debugging and refinement of the systems, a
series of simplified flow diagrams, Figure 10 through 15
has been prepared. Duplicate pumping, piping, and valving
equipment has been omitted from these diagrams, for ease
of explanation and understanding.
Figure 10 diagrams the recycle systems as they were
initially installed. Dark lines outline all new equipment
and piping. Changes from the systems as originally
developed in conjunction with Stanley Consultants included
the following items.
Blast Furnace Clarifier drains to the sewer or
river were eliminated.
Stove cooling water and condensate drains to
48
-------
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-------
Che recycle system were disconnected. Water
from these sources was redirected to sewers.
Overflow to the north sewer, CO-2, of untreated
gas cleaning water was eliminated. This overflow
had taken place from a manhole connected to the
trench carrying dirty water to the gas washer
pump house (shown on figure 9).
Polyelectrolyte additive system was added at
blast furnace clarifier.
Blowdown from the sinter plant recycle system
which was first shown as discharging into the
north sewer, CO-2, was redirected to the blast
furnace clarifier.
51
-------
SECTION VI
SYSTEM OPERATION - START-UP AND REFINEMENT
The blast furnace recycle system as shown in Figure 10 went
into operation on October 31, 1969. The sinter plant system
started a few days later.
The first seven days were spent phasing the systems in,
one section at a time. During this period, there was 24-
hour supervision by Engineering and Environmental Control
representatives. The time was also used to train plant
operating personnel.
Neither recycle system was introduced into the production
cycle until it had been run under operating conditions.
This was accomplished by maintaining a supply of mill
water to the blast furnace gas cleaning and sinter plant
dust collection systems, and running the effluent directly
to the river (equivalent to 100 percent blow-down). This
allowed the testing of all equipment and balancing of the
system, without interruption of blast furnace and sinter
plant production. All piping tie-ins had been completed
during the construction phase, using scheduled maintenance
shutdowns at the blast furnace and sinter plant. There
were no curtailments nor reduced production periods associated
with the phase-in of the recycle system.
In adopting the use of recycle systems, the primary objec-
tive was to achieve conformity with established effluent
standards. The ultimate goal was complete elimination of
all effluents to the Calumet River. When the recycle systems
were designed, it was thought that effluent standards could
be met by reducing the effluent to only a small flow of
blow-down (approximately 2%). Due to the high concentration
of contaminants in the system, the blow-down quality could
not be tolerated in the river and it was decided that blow-
down from the systems should normally be discharged to a
sanitary sewer instead of the river. Emergency overflows
to the river were sealed off. These piping revisions were
made, and system operation changed as shown in Figure 11.
Preceding page blank 53
-------
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RIVER REVOVEDi
Fig. 11 - Blast Furnace G Sinter Plant Scrubber Water Recycle Systems -
Modified to Discharge Blowdown into Sanitary Sewers
-------
Once the system achieved the designed operating status,
six major problems developed. These problems occurred and
corrective measures were taken as described in the
following paragraphs:
1. Hydraulic Balance
It became evident that unaccounted for water was
infiltrating the system, making it impossible for
the sanitary sewer to accommodate all blow-down,
and requiring some blow-down to the river. Each
time the blow-down to the river was shut off there
would be a constant pick-up of water level in the blast
furnace system, and after 6 to 8 hours time lag, the
high-water alarm would go off. Then the blow-down
had to be reopened to the river. When the system was
designed, it was thought that all major heat-exchange
water systems were divorced from the system, leaving
only process contaminated water going to the recycle
systems. With the recycle system integrated with
the old effluent system, small amounts of water were
evidently being discharged from a number of sources
which did not show on current plant drawings. It is
estimated that 800 to 1000 GPM of water were in-
filtrating the system. Because of the underground
location of these infiltration points, it was difficult
and time-consuming to identify and eliminate them.
The sources which were discovered included stove valve
cooling water, unknown water supply cross-connections,
pump gland water and water from shut-off valves. By
March, 1970, the system was isolated from exterior
water sources, blow-down to the river was shut off
and the systems were in balance. There has been no
need to blow-down to the river, to relieve high water
situations, since that time.
Although the original scheme was to blow-down the
blast furnace recycle system after the water had
passed through the cooling tower, in order to send
minimal cyanide content to the sanitary sewer, this
pattern of flow did not produce good hydraulic
55
-------
balance, in that water needed for gas cleaning and
cooling was being taken from the scrubber water supply
system.
The systems were therefore modified, as shown in
Figure 12, to allow blow-down from either the hot-
well or cold-well pumps. Provisions were also made
to add make-up water in both hot wells and cold wells.
With the modified piping, the normal mode of operation
called for blow-down from the hot well (the clarifier
overflow basin at the sinter plant) and make-up in the
cold well. These changes relieved the load on both
cooling towers and resulted in satisfactory hydraulic
balance in the system.
As mentioned earlier, one possibility originally
considered was the disposal of blow-down as slag
quenching water at the "A" and "B" furnace slag pits.
Due to the intermittent nature and high requirements
of this usage, approximately 1500 G.P.M. for 4 hours,
3 times a week, this method of disposal was never
attempted for fear of throwing the system out of balance.
2. Sludge Concentrator
The sludge concentrator had been designed to concen-
trate slurry from the blast furnace and sinter plant
clarifier underflows and vacuum filter over-flow.
The concentrated sludge was then to be pumped to the
vacuum filters, with sludge concentrator overflow
returned as cleaned water to the recycle system. As
operated in this manner, the overflow from the sludge
concentrator was not adequately clarified. It was not
unusual to experience suspended solids contents of
over 400 ppm. Eventually the hot well filled with
sludge to the point that it had to be pumped out and
shoveled clean. Water sprays at the cooling tower
also plugged.
56
-------
LOCATION OF SAMPLING POINTS
LTBOUGrt TO #L*M PuttNA&C CLARfflt*
fcovcftriow r^OM insr ru**Acc ciAmm*
XeLAM ruK»*tt iT3?tW HOT WltL
t«LA2T ruftMACt S*STfii COL© WtU.
4UMCW RIVCK W*T(R
I. OLOWDOivN. PU.AJT tuPNt'.l 9VS11U
t UMOCnriOW,BLAST fURHAtl CLAMUtft
I t*ouCM to 3mu» «H.*« i eu»Hini*
» ovcnrujw, Mtua mni dAMnm
O SlNttB CLANT irittM MOI WCLt.
II SiNTt* I'.*».» HJtCM CJ.O WCIA
a. UXDtHLOW, 3IKUR PLANT CLAKIiLA
IJ BLOWOOWM, SKI CB (M.ANI
U. OVERFLOW, SLUOCl COHCtHTHAtOh
SCRUBBERS
*18
SYSTEM
SCRUBBERS
70 3V«TARY SCWCR*
pouelectholitc
VELECTOOliTC
CONVEYOR TO
SWtER PLANT
VACuCO
FU.EB
rVRATt
SLUDGE . -
CONC£NT«ATO« \ *3
BLAST rURNACC
CLAWFitR
JNtCP i LAN I
CLAHlf i£R
COOL'NG
TOWEH
SLOWDOWN T
SAWTAfiT * LWlh
-MAKC-UP WAT CM
I
SLOWDOWN 10
SANITARY SEWE
COOtJMG
TOW Ld
COLD
© **<-L
OT
wtlL Q
MAKE/UJ* WATER—^
WATCN
blast f y-HACC - RFC rCLC svstlm
snter plant nccvct.r svsfrM
COLD * \ HOT
WELL @ \WaL ®
OVERFLOW WEIR
Fig. 12 - Blast Furnace & Sinter Plant Scrubber Mater Recycle Systems -
Modified to Permit llake-up & Slowdown Cither Before or After Cooling Tower
-------
Ut
>-4
LOCATION Of SAMPLING POINTS
fOUCLCCTHOLITt
WTHOUOM to «!.*&? fUHNAtt tLAHlftt*
feOKww* r»ou Bi*%r ru««Act tiAum*
LBIAM ruMMACC &TSKW NOT WILL
4i|.A5T rUKNACC »V£ftN COkOftCU.
StMAKC-U** MVCf» **Tl*
fcBlOwDO*f«,*t*)t fU&WAft* 3«3fiw
t iMocnrii,3**C» #L*Nf
*O*£»'L0W#*i.uOCl CONCfcKTflATOM
MB
SVStEW
«
7DSAHTAHY SCWCR^
LYEUCT»OliTE
COMVlVOw to
SINTER PLANT
OUBtit
*.*. £*•»
SLUDGE . _
CONCENTRATOR \ M
BLAST rURNACC
CCARiriCR
StfTCP
LLAKlf llX^J Q
COOLING
TOWER
slowdown t
SANiTAftr *E*£R
- MAKE' UP WATCH
I
SLOWDOWN TO
SANITARY 5EWE
COOLING
TOWiR
COLO
© VVCLL
mot
WUL ©
MAHE-UP
WATCN
MA HE.* UP WATER
BLAST f^NACC - RECYCLE STStiM
StfMTER Plant PEC^ltC SVSTCM
COLO _
WELL @
*£LL ®
overflow WEift
Fig. 12 - Blast Furnace £ Sinter Plant Scrubber Water Recycle Systems -
Modified to Permit Make-up & Blotjdown Cither Before or After Cooling Tower
-------
To improve this situation, it was necessary to
lighten the load on the concentrator by reducing
the flow of sludge to this unit, as shown in Figure
13. This was done by feeding only the blast furnace
clarifier underflow to this unit, and sending the
sinter plant clarifier underflow directly to the
vacuum filter. Filter overflow was directed to the
sinter plant clarifier to further reduce the hydraulic
load on the sludge concentrator. This accomplished
only partial relief from the problem, and it was
decided that the concentrator would be abandoned.
Piping was rearranged to direct blast furnace clarifier
underflow to the sinter plant clarifier, as it had
been before installation of the recirculating system.
Figure 14 shows this mode of operation. The sludge
concentrator has been retained as a spare unit for
temporary use during maintenance of the sinter plant
clarifier.
3. Coarse Particulates
Although certain changes, as described in earlier
paragraphs had to be made to improve operations, the
system operated in a satisfactory manner from March
to July, 1970. On July 17th, a serious emergency
occurred. Both underflow lines from the blast furnace
clarifier plugged and the clarifier rake stalled. All
efforts to unplug the underflow lines failed, and the
decision was made to shut both furnaces down, pump the
clarifier water and sludge into the ore yard, and free
the rake and underflow lines. Drainage of the ore
yard is by seepage and evaporation only. The entire
clean-out was accomplished in approximately 24 hours.
No mechanical failures were discovered, but the
slurry removed from the underflow lines contained a
large amount of very coarse particulate matter (minus
%-inch, plus 100 mesh). The evident reason for the
failure was the high settling rate of these coarse,
high density sludge particles which eventually
completely plugged the lines. This, in turn, caused
a building up of solids in the bottom of the clarifier
58
-------
Ln
TPOLYCLECtROLtTE
'povftLZCimutc
& n
CONVEYOR TO
sinter plant-
tSgiCHMlC H iAtVt
——I POSITION t6 oi*
BLCT JSlHTtfiF #»L1
CLARlfiCR UNC3LR
fLOW TO VACUUM
- flUC*
5LU0GE
CONCENTRATOR
BLAST rURNACt
r.i.AKiriEH
INTCP I (.ANI
' LAKlr
¦€~M—««=r
SLOWDOWN 70^-
r.mUNr,
TOWEH
SLOWDOWN .w—
iANiTARt SEWER
-r\J
MAKE-UP WAT C«
(t -
SLOWDOWN TO
SANITARY 5EWEI
MAKE-UP WATER—^
liLA-.T ru^NACC - RECYCLE 5YSTLM
SNTfR PLANT WCCVCIT SYSTrM
OVCWfLO^ WEl«
Fig, 13 - Blase Furnace & Sinter Plant Scrubber Water Recycle Systems -
Modified to Reduce Load on Sludge Concentrator
-------
TDSAMTAW 5CWC
CONVCVOR TO
SINTER PLANT-
7 -=.
EVAPOBATION-TOCPM
Evaporation-»opm
- (AAKr-'gP WATCH
.".5
300 CPM SLOWDOWN TO
SANITAW JCVkEI
230 GPM MAKE-UP WATER
31C.M
t:i_A',T ( „'-t,ACC - RFCrCt-r. STSUM
asirrc plant °r<~
?v» WE'R
Fig, 14 - Elast Furnace & Sinter Plant Scrubber Mater Recycle Systems -
Modified to Eliminate Flow to Sludge Concentrator
-------
to the point that the rake drive load limits were
exceeded. Since the experience in July, 1970, there
have been several occasions when the slurry has become
very coarse and dense, but changes in operating
procedures prevented any major shutdowns until June,
1971. There are two underflow lines and pumps from
the blast furnace system clarifier, one on stream and
one on stand-by. Since July, 1970, the pump on stand-
by has been given prompt corrective and preventive
maintenance so that it is ready for immediate use when
needed. If there is evidence of plugging, both under-
flow pumps are immediately put on stream. Prior to
July, 1970, there were periods when both underflow
pumps were shut down for a short time. Now one pump
is kept running at all times.
When the recycle systems were built, a back-up pump and
transmission line were provided for every vulnerable
part of the system, to insure uninterrupted operation.
Our experience of July 17, 1970 demonstrated the
vulnerability of the clarifier and the need for a
spare. Interlake is presently in the process of
installing a second clarifier for the blast furnace
system. This second unit will be large enough to
handle all the gas cleaning water during repairs or
failure of the first clarifier. Figure 15 shows a
diagram of the system with a stand-by clarifier. Un-
fortunately, another emergency shut down of the
clarifier, and consequently the blast furnaces,
occurred on June 28th, 1971. The cause was indeter-
minate, but probably was the same as that of the
earlier failure.
4. Pump and Valve Maintenance
This problem was evident within a few weeks after
start-up, and has been a continual one. There are a
total of 23 rumps and over 100 valves associated with
the two syst ..as. Maintenance of these units has been
out of proportion to their size and number. The
recycle and cooling tower pumps have been a constant
61
-------
a*
N3
SCRUBBERS
location or sampling points
iTROttCH TQ BL*it fu»NAQ
LARlflC
r!Ll fi h
Km CAR
SLUDGE
CONCENTRATOR
PL/5T
* i.Ai-iif fDt
S»4IF.R I LAN I
*LAHIMl*
-i-vn*
TOW> W
6?i OWf OWN TO
D\ER
Atl.TA^t
ma*o up v.atcm
SLOWDOWN TO
5ANITAHT seweb^
jOUN
TOWt«
COUj
V41U
MAK£-ye»
m ll
watch
MAKE-UP WATER
sr'>n M
yi?i ^ plant
"Cri-
COLD _
WELL ©
WELL
rt£
-------
source of bearing and drive shaft problems. One
change made to alleviate this condition was a sub-
stitution of high pressure mill water for recycle
system water in the bearing seals. This should
eliminate scale or solids build-up in that area and
reduce bearing failure.
Slurry pumps and valves have been a continual problem.
We are continually investigating and trying new valves
that will not plug with slurry when shut off. Our
present thinking is that rubber pinch valves are the
best for this service, however, it is axiomatic, in
designing any sludge handling system, that dead sec-
tions of pipe in which solids can settle and consoli-
date must be eliminated or held to the minimum possible
length. Three-way or four-way plug cocks which allow
water flushing in various directions should be used
wherever possible.
5. Control of Chemical Stability - Blast Furnace System
A build-up of scale or chemical formations in the
blast furnace recycle system was not anticipated, and
the only provisions originally made for pH control were
those provided for the sinter plant system. It was,
however, recognized that the rate of blow-down of both
systems would have a significant effect on the chemical
stability of the systems and that some measure of this
chemical stability was a necessity.
Although the Ryznar Stability Index (a function of
dissolved solids content, temperature, total
alkalinity, calcium content, and pH) has been used
primarily for boiler feed water evaluation, it was
believed that this index would provide a dependable
factor with which to monitor and evaluate the recycle
system stability. In practice, a stability index of
under 6 is indicative of a scaling tendency in a system,
while an index over 6 shows the existence of corrosive
conditions. See Appendix C for a more detailed
discussion of stability indexes and their significance.
63
-------
After the recycling systems had been placed in
operation and had achieved a fair degree of hydraulic
stability, the blow-down rate from the blast furnace
system was established at 10%, while the blow-down
rate from the sinter plant system was stabilized at
50%. These rates were set by determining the quantity
of blow-down needed to obtain an acceptable Ryzr.ar
Stability Index in the recycle systems.
In order to prevent either corrosive or scaling
conditions within the recycle system, it was our
intention to maintain the stability index of the
recycle system at 6. Without reliable continuous
monitoring instrumentation (none is available), it is
almost impossible to keep the recycle water system at
a constant stability. The system was controlled
manually, which procedure, in the early days of
startup, resulted in a time lag of several hours
before corrective action was taken to bring the
stability index back to the desired value.
Figure 16 shows the stability index during the month
of November, 1969, when the blast furnace system was
first started. During the first month, the system
was hydraulically overloaded, with an excessive amount
of water being blown down. Approximately 50% of the
total flow was diverted. This accounts for the
stability index being greater than 6 during most of
this period.
Fig. 16 Blast Furnace Water System Stability
During Initial Operation with 50
Percent Blow-down Rate
64
-------
Figures 17 through 19 show the blast furnace system
stability iry3ex by month through December, 1970.
During the first seven months, attempts were being
made to tighten up the recycle system by reducing
blow-down to a minimal quantity. This was necessary
to effectively reduce the hydraulic load imposed upon
the sanitary sewer. Reduction of the blow-down rate
improved the hydraulic balance but had an undesirable
side effect, namely: reduction of the stability index.
Figure 17 indicates that the stability index moved
downward into the scaling range, during this period,
as the hydraulic balance was improved.
Fig. 17 Effect of Reduction of Blast Furnace
Water System Blow-down Rate from 50
Percent to 10 Percent
65
-------
As demonstrated in Figure 17, it became apparent that
some method of control was needed to correct the
depression of the stability index. As a corrective
measure, the blow-down was periodically increased
to about 25% for short periods of time (15 minutes),
allowing more make-up water to be introduced
(dilution). Figure 18 (June) shows that this concept
worked, with resultant elevation of the stability
index into a more desirable range.
Fig. 18 Effects of Periodic Purging on Blast
Furnace Water System Stability
Although the chemical stability was effectively
improved, our sanitary sewer could not accommodate a
blow-down of more than 25%. The practice had to be
abandoned, and the stability index again moved into
a lower range, as shown on Figure 19 (July, 1970
through December, 1970).
6C
-------
l£
a
« • i i » * * J 'I it* ' . *
* 4 >1 <1 It #4 II JO
"»MH> ¦»»*
¦¦"ft*
Fig. 19 Blast Furnace Water System Stability Under
Scaling Conditions Prior to Acid Addition
By March, 1971, 3/4 of an inch of scale had formed in the
recycle system piping. Flow meters were constantly being
serviced, and eventually they became inoperable. At the
rate the system was scaling, the blast furnace water
system would have been plugged solid within a short period
of time had not some corrective measure been taken. Acid
addition for control of scaling was the obvious solution
but its use would have to be carefully regulated. Using
the Ryznar Index as a reference, the amount of acid
needed to slowly dissolve the scale was calculated to be
200 gallons per day. Sulfuric acid was chosen because the
by-product of its reaction, calcium sulfate, could be
collected in the clarifier.
67
-------
A metering pump and pH recorder were installed to feed acid
into the cooling tower basin. On April 5, 1971, acid
treatment began and has continued to date. 66° Baume
sulphuric acid (35N) was fed into the system at a rate of
about 10 tons per week. Figure 20 shows the Ryznar Index
during the April, 1971 through July, 1971 period. As acid
dissolved the scale, characteristics of the water changed,
and regulation of acid additions was necessary. In the
light of experience at the sinter plant, as described in
sub-section 6, page 70, it was feared that the system
might be overdosed; the acid feed rate, therefore, was
limited to prevent a repetition of that experience.
Periodic inspection indicated that the scale was being
removed, even though the Index was below 6. Acid additions
have been maintained since April, 1971.
II
§
3*
jU.
~N.
* 3 * i* it
Fig. 20 Effect of Continuous Acid Addition on
Blast Furnace Water System Stability
68
-------
6. Control of Chemical Stability - Sinter Plant System
When the sinter plant produces a high basicity sinter,
the lime and magnesia content of dusts collected in
the sinter plant scrubbers is fairly high, and the
water discharged from the scrubbers has a pH which
always exceeds 12. It was known, from the beginning,
that control of the stability index would be
difficult, even with addition of hydrochloric acid.
Figure 21 shows the range and variation of stability
indexes in the sinter plant recycle system during
the first six months of operation.
Ml
**r
t mum hm
JU>
Fig. 21 Sinter Plant Water System Stability During
Initial Operation with 25 Percent Blowdown
Rate and Intermittent Acid Additions
69
-------
As is evident in some of the above plots, the acid
additions were effective in lowering the pH and, in
turn, raising the stability index, but a stable
condition was not obtainable with the manual control
initially provided. Manual control was carried out
in the following manner: The operator monitored the
pH in the recycle system. When the pH exceeded 9,
the operator increased acid flow rate to the
clarifier overflow basin, adding about 50 additional
gallons of acid to the system on each such occasion.
The system stability index jumped to as high as 9
before making a gradual drop back to the level of 3
or less. This cycle normally took a 3 to 4 day
period for completion, as shown in the plot of
stability factor for January, 1970, Figure 21.
The above practice was continued through August, 1970;
stability factors through this period are shown on
the first 4 monthly charts of Figure 22, on the
following page. Eventually the corrosion of recycle
system concrete sumps reached a critical state and
continuous or frequent acid additions were halted.
Starting in September, 1970, a different tack was
taken; a chemical balance of the system was attempted
by increasing the blow-down rate, which, up until now,
had been held at a maximum of about 25%.
On Figure 22, the plot of stability indexes in
September, 1970 shows the gradual climb of the index
back to the 6.0 level, as the blow-down was increased
to 50%.
70
-------
:
'p-jVfj n; ; ;
* /. M It
f f* 1* IC
Fig. 22 Effect of Increase of Sinter Plant Water
System Blow-down Rate from 25 Percent to
50 Percent
71
-------
Figure 23 shows that the index remained at the higher
level through the remainder of the plotted period.
«'««« •"» »¦» »IW ¦»*>
Fig. 23 Sinter Plant Water System Stability with
50 Percent Blow-down Rate
Starting in June, 1971, a new control concept was
tried. The high blow-down rate was maintained, with
no acid additions during the days of sinter plant
operation (6 days a week). On shut-down day, acid
was added, and pH was controlled in the 2 to 4
range, with a portable pH monitor. This practice,
continued to this date, has been very effective in
inhibiting scale formation in the sinter plant
recycle system.
72
-------
SECTION VII
ANALYSIS OF PERFORMANCE
The purpose of installing the recirculating water system
at the blast furnaces and sinter plant was to eliminate
the discharge of contaminated water to the Calumet River.
Prior to the installation of the recirculating system, the
blast furnace and sinter plant wet scrubber water systems
were shown in Figure 6 and described in Section IV. Table
7, shown on page 34 , shows typical analyses of the
waters at different locations in the scrubber water system
as they existed before recirculation. Also shown in Table
7 are the quality limitations of the Illinois Water Pollu-
tion Control Code (SWB-15), which had to be met. It
should be noted that the Calumet River water does not meet
this code in relation to content of suspended solids,
hexane solubles, ammonia nitrogen, and cyanide. As stated
on page 33 , the data in Table 7 generally represent the
average values of a number of grab sample analyses. Not
all analyses were performed on each sample, but it is
believed that the tabulated figures are representative of
the system water quality and quantity. See appendix E for
complete tabulation of collected data.
Table 8 shows a material balance of the system. The figures
in Table 8 were obtained by multiplying the concentrations
shown in Table 7 by the corresponding flow figures, and
applying the appropriate conversion factors for the units
involved.
Control of Cyanides and Suspended Solids
It was intended that the recycle system would minimize the
discharge of contaminants to the river, principally by
reducing the levels of cyanide and suspended solids. Re-
search had proven that the cyanide content could be
effectively reduced by settling and aeration. Settling is
also effective in reduction of suspended solids, particular-
ly if it is preceded by proper flocculation.
73
-------
TABLE 8
MATERIAL BALANCE PRIOR TP RECYCLE
Suspended
Hcxane
Ammonia
Flow
Solids
Solubles
Nitrogen
Cyanide
Phenol
Iron
Location
(GPM)
(#/Min.)
<0/Mln.)
O'/Min.)
(f'/Mln.)
(ii/mn.)
(ff/Min.)
.67
Intake
24,400
10.5
3.7
1.0
.010
.0018
North Sewer (CO-2)
11,300
7.6
1.7
.50
.038
.0044
.56
South Sewer (CO-3)
7,220
4.6
1.5
.084
.025
.0008
.15
Blast Furnace Clarifier
Influent
3,690
28.6
.25
.49
.052
.0053
11.4
Blast Furnace Clarifier
Effluent (CO-1)
3,490
1.3
.17
.29
.008
.0023
.33
Blast Furnace Clarifier
Underflow
130
27.3
.08
.011
.044
.0030
11.1
*Sinter Plant Clarifier
Influent
560
43.2
.06
.16
.037
.0019
12,9
Sinter Plant Clarifier)
Effluent )
Sinter Plant Outfall )
630
1.6
.05
.14
.011
.0016
.18
(CO-4) )
Sinter Plant Clarifier
Underflow
50
68.9
.09
.011
o
r-.
O
.0033
23.8
Steam and Evaporation
Loss
1,760
-
-
-
-
-
-
Total Discharge
(Gross)
15.1
3.42
1.02
.082
.0091
1.22
Total Discharge
(Net)
+ 4.6
- 0.28
+0.02
+ .072
+.0073
+ .55
Total Allowed
(SWB-15)
4.72
2.8
.47
.006
.038
1.89
* Does not include underflow from Blast Furnace Clarifier
-------
At both the blast furnace and sinter plant clarifiers,
operators are presently feeding a cationic polymer, Nalco
610, in an amount of .05 parts per million, allowing it to
mix, and are then introducing the anionic polyelectrolyte,
Nalco 676, in an amount of one part per million. At each
clarifier, a 600 gallon mixing tank with dispersant funnel
and lightning mixer has been provided. This arrangement
has been effective in flocculating fine particulates and
thus increasing the thickener efficiency.
A reduction of cyanide level has been realized across both
the blast furnace and sinter plant cooling towers. In
section IV, page 43 , reference was made to tests con-
ducted at ccke plant cooling towers, and the results of
these tests are tabulated in Appendix B. The coke plant
cooling tower tests indicated an average cyanide removal of
almost 507c by the aeration treatment, whereas data collected
at the recycle system show that removal efficiency in such
a system is only about 20 %. Checks have been made to
determine if any free hydrogen cyanide gas is being
liberated at the cooling tower, but no evidence of such
gas has been found within the detectable limit of one part
per million.
As described in other sections of this report, initial
operation of the recycle system was accompanied by many
difficulties, These difficulties were mainly associated with
establishing a hydraulic balance. Once these problems were
corrected and a good hydraulic balance was obtained, the
system also achieved a reasonably good chemical balance.
Table 9 shows a typical chemical balance achieved once the
system as diagrammatically shown on Figure 14 reached an
acceptably stable operation. The data in Table 9 generally
represent the average values of a number of grab sample
analyses.
A tabulation of all collected data appears in Appendix E.
75
-------
TABLE 9
RECYCLE SYSTEM - CHEMICAL BALANCE
Suspended
Hexane
Ammonia
Flow
Solids
Solubles
Nitrogen
Cyanide
Phenol
Iron
Location
(CPM)
(ppm)
(ppm)
(ppm)
(ppm)
tppb)
(ppm)
E»
Intake
20,850
65
8.0
3,0
.014
13.6
1.9
8.1
North Sewer (CO-2)
11,300
46
8.0
2.3
.014
10.6
2.9
8.1
South Sewer (CO-3)
7,220
45
11.0
3.0
.019
6.4
2.0
8.2
Blast Furnace Clarifier
Influent
4,500
1,038
7.5
64.
7.53
104
475
8.2
Blast Furnace Clarifier
Effluent
4,300
* 41
4.0
64.
4,64
26
10
8.3
Blast Furnace Clarifier
Underflow
130
34,600
125
60
107
2,800
16
,150
8.5
~Sinter Plant Clarifier
Influent
560
10,500
35.0
37
16.3
672
3
,200
11.0
Sinter Plant Clarifier
Effluent
630
400
14.0
31
9.40
18
37
11.0
Sinter Plant Clarifier
Underflow
50
202,000
550
30
340
14,300
77
,500
11.2
Steam and Evaporation
Loss
1,740
Blast Furnace System
Blowdown
450
41
4.0
64
4.64
26
10
8.3
Sinter Plant System
Slowdown
300
400
14.0
31
9.40
18
37
11.0
Sanitary Sewer
Discharge
750
184
8.0
51
6.5
24
21
9.1
Sanitary Sewer Code
-
N/A
100
N/A
10.0
N/A
50
4.5 - 1
Code, SWB-15
-
25
15
2.5
.030
200
100
6 - 1
* Does not include underflow from Blase Furnace Clarifier.
-------
Table 9 shows that the quality of non-contact effluents
flowing to the river from the north and south sewers now
essentially equals the intake river water quality.
Note that the river water analysis (with the exception of
suspended solids content) now essentially meets the code,
SWB-15, showing a general improvement in quality as
compared with analyses taken prior to recycle, as recorded
in Table 7. This fact has several possible explanations
including the following:
1. Normal variation of water quality.
2. General river quality improvement in the 2 or 3
year interval.
3. Elimination of back-flow or cross-flow from
Interlake outfalls to the intake. The Calumet
River, at this point, usually exhibits no
definite directional flow.
As previously stated, the process water blow-down from both
the blast furnace system and the sinter plant system goes
to the sanitary sewer. Although the sinter plant blow-
down does not quite meet the sanitary sewer code, the
composite discharge is well within code limitations.
Table 10 shows the mass balance of the recycle system.
Figures in Table 10 were obtained by multiplying the con-
centrations shown in Table 9 by the corresponding flow
figures, and applying the appropriate conversion factors.
It should be noted that the combined cyanide mass rate from
the north and south sewers is the same as the intake water.
This indicates the successful separation of contact and
non-contact waters in the blast furnace plant system.
Table 11, comprising selected data from Tables 7 and 9, is
presented to provide a comparison of operation of the
blast furnace system under once-through conditions as
compared with recirculating conditions. The data clearly
shows the effectiveness of the blast furnace clarifier in
reducing suspended solids, cyanide and phenol. It is
observed that the influent water quality on recycle is
77
-------
Location
Intake
North Sewer (CO-2)
South Sewer (CO-3)
Blast Furnace Clarifier
Influent
Blast Furnace Clarifier
Effluent (CO-1)
Blast Furnace Clarifier
Underflow
*Sinter Plant Clarifier
Influent
Sinter Plant Clarifier)
Effluent )
Sinter Plant Clarifier
Underflow
Steam and Evaporation
Loss
Blast Furnace System
Blowdown
Sinter Plant System
Blowdown
Sanitary Sewer
Discharge
TABLE 10
RECYCLE SYSTEM - MASS BALANCE
Flow
(GPM)
Suspended
Solids
WMim)
Hexane
Solubles
(f?/.Min.)
Ammonia
Nitrogen
(0/Min.)
Cyanide
WMin.)
Phenol
(0/Min.)
20,850
11,300
7,220
11.3
4.3
2.7
1.4
.75
.66
.52
.22
.18
.002
.001
.001
.0024
.0010
.0004
4,500
39.0
.28
2.4
.283
.0039
4,300
1.47
.14
2.3
.167
.0009
130
37.5
.14
.07
.116
.003
560
49.1
.16
.17
.076
.0031
630
2.10
.07
.16
.050
.0001
Iran
.33
.27
.12
.36
17.5
15.0
.19
50 84.5 .23 .01 ,142 .0060 32.3
1,890
450 .15 .01 .24 .017 .00010 .04
300 1.00 .04 .08 .024 .00005 .09
750 1.15 .05 .32 .041 .00015 .13
* Does not include Underflow from Blast Furnace Clarifier.
-------
TABLE 11
MATER QUALITY CHANGES IN BLAST FURNACE SCRUBBER MATER SYSTEM
Suspended
Hexane
Ammonia
Flow
Solids
Solubles
Nitrogen
Cyanide
Phenol
Blast Furnace Scrubber
(GPM)
(ppm)
(ppm)
(ppm)
(ppm)
(ppb)
£li
Once Through - Clarifier Influent
3,690
928
8.0
16.0
1.70
171
8.4
Clarifier Effluent
3,490
44.6
6.0
10.0
0.26
80
8.4
Percent Removal
95%
85%
53%
Recycle - Clarifier Influent
4,500
1,038
7.5
64.
7.53
104
8.2
Clarifier Effluent
4,300
41
4.0
64.
4.64
26
8.3
Percent Removal
96%
38%
75%
-------
higher in content of ammonia nitrogen and cyanide.
The efficiency of the clarifier in removing cyanide is not
as high on recycle as it is during once-through operation.
The reason for this has not been determined, but it is
possible that the cyanide is present in different forms
depending on the nature of the operating mode. The
mechanism of phenol removal is not clear; perhaps phenol
is absorbed in the solids and removed when those solids
are settled out.
Table 12 combines data available in Tables 8 and 10, in
order to show the reduction (under recycle conditions) in
the mass discharge of pollutants from the plant entity to
the outside. This is one measure of the effect of the
recycle system on the environment. The difference between
line 1 and line 2a is the change in load to the Calumet
River. The difference between line 1 and line 2A plus 2B
is the change in load to the environment. Note that none
of the tabulated figures is corrected for the quality of the
river water intake.
Control of System Water Temperature
As discussed in some detail in Section IV, the decision
to utilize cooling towers in both the blast furnace and
sinter plant recycle systems was based on measured operating
data, as well as certain assumed conditions and operating
modes.
Actual temperature conditions in the systems have varied
considerably from those assumed preliminary to design of the
systems. Measured temperatures are shown in Table 13
(year-round averages):
80
-------
TABLE 12
MASS DISCHARGE OF POLLUTANTS FROM CHICAGO PLANT
00
1. Once-Through System -
Discharges to Calumet River
(CO-1, 2, 3, 4)
2. Recycle System
A. Discharges to Calumet River
(CO-2, 3)
B. Blowdowns to Sanitary Sewer
C. Total All Discharges
Suspended
Solids
(lb./min.)
15.1
7.0
1.15
8.15
Hexane
Solubles
(lb./min.)
3.42
1.41
.05
1.46
Ammonia
Nitrogen
(lb./min.)
1.02
.40
.32
.72
Cyanide
(lb./min.)
.082
.002
.041
.043
Phenol
(lb./min.)
.0091
.0014
.00015
.00155
Percent Reduction (1 to 2)
46%
577.
29%
48 Z
832
-------
TABLE 13
RECYCLE SYSTEM WATER TEMPERATURES
Blase Furnace System
Clarifier Influent Temperature
Clarifier Effluent Temperature
Recycle Water Temperature
River Water Temperature
- 140 degree F.
- 110 degree F.
100 degree F.
50 degree F.
Sinter Plant System
Clarifier Influent Temperature
Clarifier Effluent Temperature
Recycle Water Temperature
(cooling tower not used)
87 degree F
87 degree F.
92 degree F.
The implications of these data are as follows:
The target temperature of 100 degree F. has been
achieved in the blast furnace system cold well. The
cooling tower is required in order to reach this
temperature.
The sinter plant system, as presently operated, does
not require the cooling tower. When the system was
designed, a blow-down rate much lower than the
present 50% rate was assumed. With the present rate
of blow-down, the water cooling requirements are
drastically reduced. The high blow-down is required
for chemical balance of the sinter plant system, and
it is doubted that it will be possible to substantially
change the water distribution without automatic
control of chemical stability in the system.
82
-------
Cost Analysis
The cost of engineering and building the combined blast
furnace and sinter plant recirculating system was $1,109,400.
A breakdown of the cost is presented in Table 14.
Operating costs of the system are tabulated in Table 15.
The estimated additional cost of operating the recirculating
system is shown to be about $23,700 per month, or $285,000
per year. Against this additional operating cost, there
are potential savings which should accrue from a reduction
of payments to the Corps of Engineers and from increased
recovery of iron units formerly discharged to the river.
In accordance with a 1963 agreement with the Corps of
Engineers, Republic Steel and Wisconsin Steel, Interlake
has been paying (through 1971) $8,333 per year to the
Corps, to remunerate them for solids discharged to the
Calumet River and dredged from the river by the Corps of
Engineers. Now that we have a negative net discharge to
the river, we should be allowed to stop these payments. In
addition to this saving, the value of the iron units in
the solids formerly discharged amounts to about $1,700 per
year.
Assuming the above two credits, the net additional cost of
operating the recirculating system is about $275,000 per
year.
83
-------
Table 14
COST OF RECIRCULATING SYSTEM
Land
Buildings and Equipment:
New 30' Diameter Sludge Concentrator
at Sinter Plant $ 68,900
Sludge Pumphouse Extension at
Sinter Plant 15,900
Recycle Pumphouse at Sinter Plant 61,800
Cooling Tower at Sinter Plant 51,500
Piping at Sinter Plant 68,800
Recycle Pumphouse at Furnace Plant 118,100
Cooling Tower at Furnace Plant 138,500
Coagulant Aid System at Furnace Plant 10,800
Piping at Furnace Plant 261,000
Interconnecting Sludge Piping 21,000
Vacuum Pumps for Sludge Filters 23,100
New Electric Power Supply, Including
#4 Substation 86,200
pH Control at Sinter Plant 16,600
Spares 11,100
Revisions to Existing Equipment;
Relocation of Existing Gas Cleaning $ 16,300
Water Piping at Furnace Plant
Stove Water Diversion 22,800
Engineering;
Engineering and Construction
Supervision
Total Cost of Project
953,300
39,100
117,000
$1,109,400
84
-------
TABLE 15
OPERATING COST OF RECIRCULATION SYSTEM
Direct and Indirect Labor $ 13,100
Overtime and Other Premiums 900
Purchased Repair and Maintenance 3,500
Acids 900
Miscellaneous Operating Supplies
(including Chemicals} 2,000
Repair and Maintenance Expense Distributed 6,300
Utilities Distributed 10,700
Labor Pool - Furnace Plant 200
Supervisory and Administrative Expense 11,700
Fixed Costs 4,400
* Monthly Operating Cost $ 53,700
* The above cost is not the cost over and above the
cost of supplying water to the original scrubber
systems, and operating the clarifiers, filters,
and other portions of the sludge handling system
which existed prior to installation of the
recirculating system.
The cost of operating the original scrubber water
and sludge handling systems is estimated to have
been about $30,000 per month.
85
-------
SECTION VIII
ACKNOWLEDGMENTS
The valuable assistance of Dr. W. R. Samples and Dr. F.
C. McMichael, senior fellows of the Mellon Institute
Water Resources Fellowship, is gratefully acknowledged.
The assistance rendered by Mellon Institute was supported
by a research grant from the American Iron and Steel
Institute.
The original studies of the Chicago Blast Furnace Plant
water system and the design of the recirculating system
were performed by Stanley Consultants of Muscatine, Iowa.
This work was done under the leadership of Lowell D. Titus,
L. G. Koehrsen and R. W. Richards.
The initiation of this project was accomplished by the
Interlake, Inc. Environmental Control Project Team, con-
sisting of F. K. Armour, Vice President-Engineering;
W. P. Forcelli, Assistant Secretary and Corporate Attorney;
H. H. Henderson, Director - Public Relations; and F. G.
Krikau, Manager-Environmental Control. Refinement of design,
field construction and initial system operation were carried
out under the guidance of Interlake, Inc. Corporate
Engineering Department personnel including R. S. Patton,
R. P. Winters, T. R. Kinney, E. W, Lollock, R. F. Draus,
and R. B. Bayr, This report was assembled and prepared by
R. E. Touzalin.
The support of the project by the Environmental Protection
Agency, and the assistance provided by Mr. Stephen Poloncsik,
Research and Monitoring Program Representative and Mr.
Clifford Risley, Jr., Project Officer, is acknowledged with
gratitude.
Preceding page blank "
-------
SECTION IX
REFERENCES
1. McMiehael, F. C., Maruhnich, E. D. and Samples, W. R.,
"Recycle Water Quality from a Blast Furnace,'*"
Journal Water Pollution Control Federation, 43 (4):
(1971)
2. McMiehael, F. C., and Samples, W. R., "Notes on
Recycle Objectives and Procedures for a Combined
Blast Furnace and Sinter Plant Gas Cleaning System
for Interlake Steel Corporation," June 1969, report
in files of Mellon Institute. Appendix D.
3. Camp, J. M., and Francis, C. B., "The Making Shaping
and Treating of Steel," 6th Edition, United States
Steel, Pittsburgh, Pennsylvania, (1951).
4. Forsythe, R., "The Blast Furnace and the Manufacture
of Pig Iron," Third Edition, David Williams Company,
New York City, (1913).
5. "Betz Handbook of Industrial Water Conditioning,"
Sixth Edition, Betz Laboratories, Inc., Trevose,
Pennsylvania, (1962).
6. "Standard Methods for the Examina ion of Water and
Waste Water," 12th Edition, published AWWA/APHA/FWPCA,
(1965).
Preceding page blank 89
-------
SECTION X
PUBLICATIONS
Koehrsen, L. 6. and Krikau, F. G. "Rx For Steel
Mill Wastes, Recognition, Removal, Reuse and
Research," paper presented at 24th annual Purdue
Industrial Waste Conference, May 7, 1969.
DeCaigny, R. R. and Krikau, F. G., "Prescription
for Blast Furnace - Sinter Plant Closed Water
Pollution Control," paper presented at San
Francisco Regional Technical Meeting of American
Iron and Steel Institute, November 18, 1970.
Preceding page blank
-------
SECTION XI
APPENDICES
APPENDIX A
PROCESSES FOR EFFLUENT TREATMENT
The processes considered for treatment of the various out-
fall contaminants included the following;
Cyanide
For the removal of cyanide three basic procedures
were investigated.
1. Oxidation of Cyanide to Cyanate
Essentially this procedure involves raising the
alkalinity of the effluent and treating it with
an oxidizing agent. Typical of such processes
is the method of "Alkaline Chlorination" which
brings about the reaction:
Na CN + Cl2 + H20 Na CNO + 2H CI
Other oxidizing agents may be used, such as
hypochlorite, chlorine dioxide, ozone, lime
sulphur, silver nitrate, potassium permanganate
or ferrous sulfate, but the basic mechanism of
reaction remains the same.
2. Acidification
If water containing a cyanide is acidified to a
pH below 6, the cyanide is converted to hydrogen
cyanide gas which evolves from the water. The
reaction is as follows:
Na CN r HC1 — Na Cl + HCN +
This process is impractical due to the toxicity
of the hydrogen cyanide gas.
Preceding page blank 93
-------
3. Biological Degradation by Activated Sludge
After careful preconditioning, activated
sludge is capable of effecting a significant
reduction in the cyanide content of an
effluent.
Phenol
For the removal of phenol, three methods were
considered.
4. Absorption
Phenols and analogous compounds can be removed
by the use of a liquid-liquid extraction tower
using either light oil or benzol. The phenol
is recovered from the light oil by absorption
in a caustic soda solution, to form sodium
phenolate.
5. Extraction
Multi-stage centrifugal extractors of the
Podbielniak type will remove phenol from a
liquid effluent.
6. Biological Degradation by Activated Sludge
As is the case with cyanide, phenols may be
degradated by biological activity.
Suspended Solids
Practical experience with this category of pollutants
provided a basis for evaluation of the two most
effective treatment methods:
7. Secondary Clarification
This involves the settling out of fine
particulates in a secondary clarifier which
would handle the effluent from existing
clarifier units. The secondary unit would
provide a longer dwell time and lower rise
94
-------
rate Chan that of the existing units.
8. Flocculation
Chemical flocculation could be performed in
the existing clarifiers, or could be used
in conjunction with secondary clarification.
Aggregation of fine particulates into large
floes would increase the settling rate of
suspended solids and substantially reduce
the concentration of suspended solids in
effluent waters.
Others
Other commonly accepted methods which were reviewed
relative to treatment of plant effluents were acid
addition for pH control and evaporative cooling for
temperature control.
95
-------
APPENDIX B
CYANIDE TREATMENT IN A COOLING TOWER
As part of an investigation of odor control in Mar ley-
cooling towers, Interlake's Corporate Research Department
conducted extensive water testing at the Chicago and
Toledo Coke Plants during March, April, May, and July,
1971. The data resulting from this study is tabulated on
Table 16. Although the waters being analyzed varied in
quality from that in a blast furnace recycle system, the
effectiveness of aeration in reduction of cyanide
concentration is further demonstrated by this data.
Preceding page blank
97
-------
TABLE 16 Analyses of the Waters from the Marley Cooling Towers at the Toledo
and Chicago Coke Plants
Concfcntrations, mg/1 (except pH)
Date
of
Before Marley Tower
UT
After Marley Tower
Plant
Sample
nm3
CN
S"
soi
pH
nh
CN
S=
soi
pH
Toledo
c. March 25
3750
354
74 3
•135
8.9
3525
255
606
130
8. 9
May 18
3125
425
534
-
9.2
2710
145
42
-
9.2
May 19
2890
310
463
-
9.2
2430
113
101
-
9. 1
Chicago
April 4
1000
275
7
902
8.3
963
170
7
887
8.4
April 30
850
258
-
110
8.3
750
175
-
10
8.3
May 3
650
308
17
120
8. 1
550
193
-
170
8. 2
May 4^2)
2100
370
810
50
9.2
1150
178
63
75
9.2
May 5
675
245
1.4
150
8.5
600
133
11
135
8.5
May 6
675
260
-
190
8.5
625
170
-
165
8.4
May 18
850
349
63
-
7.9'
750
180
14
-
7. 9
May 19
1450
450
44
-
8.0
1100
210
15
-
8, 1
July 22
1060
-
-
-
-
860
-
-
-
-
(1]
(2)
Before Marley Tower refers to water flowing from the final coolers to the top of the
Marley tower. After Marley Tower refers to water flowing from the bottom of the
Marley tower to the final coolers.
On May 4, the ammonia absorber at the Chicago Plant was by-passed because of
operating problems. Make-up water was added to the system at a high rate.
-------
APPENDIX C
SCALE FORMATION AND CONTROL (STABILITY INDEX)
In its travel through a gas-contact system, water may
become associated with and dissolve a variety of chemicals.
Some of these chemicals will induce a corrosive condition,
while others will propagate the formation of scale. People
concerned with boiler feed systems are very much aware of
this problem and have been studying and attempting to
control it for many years.
Generally, the terra "scale" applies to deposits which
result from crystallization or precipitation of salts from
solution. However, the corrosion or eating away of a metal
may also result in a deposit (iron oxide). In each case,
the mechanism of formation is different and must be treated
in a different way.
In blast furnace gas scrubber water systems, the formation
of carbonate scale is normally prevalent. Calcium
carbonate is usually the chief ingredient of scale formation
due to its low solubility in water, which solubility decreases
as the temperature increases. The factors that affect scale
formation are temperature, calcium, magnesium, silica,
alkalinity, dissolved solids, and the pH of the water.
Two useful tools that are generally used to predict the
scaling tendency, in a water system, are the Langlier's
Saturation Index and the Ryznar Stability Index. These
indexes, which take into consideration the quantitive values
of pH, calcium, total alkalinity, dissolved solids, and
temperature, are applicable for waters with a pH between
6.5 and 9.5.
The equations for both of these indexes take into account
the pH at which water is in equilibrium with calcium
carbonate (pHs). In a laboratory test, equilibrium is
assumed to be reached after standing overnight in contact
with pure CaC03. The pH value measured is the pHs. pHs
can also be determined from the parameters noted above by
99
-------
Che relationship:
pHs - 6.301 + pl<2 - pKs + pCa + pA + S + Ft (1)
Where:
p the negative logarithm (base 10)
Ks the second dissociation constant for carbonic
acid in water; this equals 4.83 x 10 ^
K2 the activity product of calcium carbonate in
water; it equals 4.69 x 10
Ca the calcium ion concentration in milliequivalents/
liter (me/1)
A total alkalinity as calcium carbonate (me/1)
S a function of the ionic strength u; this is
known as the Larson and Buswell Salinity
Correction Factor, having the relationship shown
in Formula 3 of the sample calculation (page 102).
Ft the temperature correction factor; see Formula 4
in sample calculation.
The effects of temperature on pHs are shown on Figure 48.
Note that the saturation pH (pHs) increases with increases
in temperature.
Langliers' Saturation Index is defined as the algebraic
difference between the actual measured pH of the water and
the calculated pHs at saturation with calcium carbonate.
IL = pH - pHs
Thii1 index shows qualitatively the tendency for deposition
or solution of calcium carbonate. A positive index
indicates scaling tendencies, and a negative index indicates
corrosive trends. A zero index denotes that the system is
in equilibrium with calcium carbonate. While a high
100
-------
8.0
^ 7.9
^jl
7.8
a
7.7
7.6
7.5
7.4
7.3
50 60 70 8.0 90 100 110 120 130 140 150
TEMPERATURE (°f)
I?ig, 48 - Tnnpcrature Effects on Saturation pit (pHs)
-------
hardness water, with a positive Saturation Index will
definitely lead to calcium carbonate scale formation,
a low hardness water with the same positive Saturation
Index may not form any appreciable amount of scale.
In an attempt to secure a quantitative index, Ryznar
proposed the Stability Index:
When the Index is higher than 7.5 to 8, a corrosive
condition exists. At levels above 6 to 7, scale will tend
not to form. If the water has an Index lower than 6, the
tendency is to form scale and lessen the possibility of
corrosion.
Although neither index is completely reliable, they give an
operator a useful tool by means of which he may monitor his
system. For this reason we use the Ryznar Stability Index
as a control mechanism.
Sample calculations of indexes follow:
With a given water, having the following analysis, calculate
the Ryznar and Langlier indexes.
IR = 2 pHs - pH
Sample Calculation
PH
Temperature
CaC03
MgC03
Alkalinity
Conductivity
8.1
102 F (38.9 C)
28 mg/1
175 mg/1
375 mg/1
1900 umho/cm^
102
-------
Ionic Strength (u)
u, the ionic strength, is a function of the summation
of the product of all dissolved chemical concentrations
(cj) and their charge (z^). It is formulated as follows:
All of the chemicals dissolved in water contribute to
the total ionic strength of a solution. For simplicity
of calculation, only the major contributors, Magnesium
and Calcium Carbonates, will be considered.
The milliequivalent weight of the calcium (Ca) ion in
Calcium Carbonate is 20.08; for Magnesium (Mg), it is
12.2. The charges associated with Ca and Mg are plus
2. The calculation proceeds as follows:
u = 5 x 10"4
x c^z^ (2)
U = 5 X 10~4 X (C]Z;l + C2z2^
u = .0005 x x 2 + -jji| X 2) = .0157
Salinity Correction Factor (S)
S
2.5 vi
(3)
1 + 5.3 u + 5.5 u
S
2.5 (.0157)
.179
1 + 5.3 (.0157) + 5.5 (.0157)
Temperature Correction Factor (Ft)
Ft « (T-25) .015
FC - (38.9-25) .015 = .21
(4)
103
-------
Saturation pH (pHs)
pHs = 8.313 + pCa + pA + S + Ft (1)
pHs — 8*313 + - log 10 (20^04) 10 (^^q)
+ .179 + .21
= 8.702 - log 10 (1.387) - log 10 (7.5)
= 8.702 - .143 - .875 =7.684 or 7.7
Ryznar Stability Index
IR » 2 pHs - pH = 2 (7.7) - 8.1 =7.3
Langlier Saturation Index
IL = pH - pHs - 8.1 - 7.7 = .4
During operation of the recycle system the Nalco Aquagraph
was used to determine the stability of the systems. This
device, which applies the slide rule principle to a
nomograph-type determination, used the relationship between
conductivity and dissolved solids, in addition to the
factors used in the sample calculations.
Conductivity = 1900 umho/cm^
Dissolved Solids = 1900/1.9 = 1000 tng/1
The above value, 1,9, was determined during the operation of
the recycle system; data was obtained and the correlation
between conductivity and dissolved solids was found to be
1.9"t .2 for our system.
Conductivity = 1.9 + .2
Dissolved Solids —
104
-------
For a demonstration of the use of the Nalco Aquagraph,
refer to Figure 49.
Procedure:
1. Select the water temperature, 102°F, on scale "A",
and move scale "B" so that the P.P.M. (parts per
million) of dissolved solids, 1000, is opposite
102° F.
2. Scale "C" is integral with, and moves with, scale
"B".
3. Move scale "D" so that the P.P.M. total alkalinity,
3/5, is opposite the P.P.M. of Calcium (CaCO^) 28,
on scale "C".
4. On scale "E", locate the system pH, 8.1. Read the
Stability Index on scale "F" opposite 8.1 on scale
"EM. The indicated Stability Index is 7.1.
105
-------
APPENDIX D
NOTES ON RECYCLE OBJECTIVES AND PROCEDURES
FOR A COMBINED BLAST FURNACE AND SINTER PLANT
GAS CLEANING SYSTEM FOR INTERLAKE STEEL CORPORATION
By
W. R. SAMPLES
F. C. McMICHAEL
WATER RESOURCES FELLOWSHIP
MELLON INSTITUTE
CARNEGIE-MELLON UNIVERSITY
PITTSBURGH, PENNSYLVANIA
2 JUNE 1969
This work was supported by a research grant
from the American Iron and Steel Institute.
The purpose of this report is to summarize some of the
ideas and questions resulting from a visit by W. R. Samples
and F. C. McMiehael of the Water Resources Fellowship with
R. E. Touzalin, F. G. Krikau, E. Lollock, R. Bayr, and
R. Patton of Interlake Steel Corporation on 24 April 1969
in Chicago. Interlake is undertaking a research and
development grant from the Federal Water Pollution Control
Administration for pollution control of a blast furnace
gas washer through recirculation. The Fellowship has been
carrying on research on water quality changes resulting
from the recycle of gas cleaning waters for the past three
years and welcomed this opportunity to participate in a
controlled full-scale study.
The numbered statements in this report are made directly
to the participants at the Chicago meeting. By themselves
they may appear sparse, but hopefully they contain the
kernel of that meeting.
Preceding pap blank
-------
1. To observe and control the operation of a recycle water
system, it is necessary to make a total water and
material balance which encompasses the whole system.
This means that all make-up water inputs and all
discharge points must be monitored for volume of flow
as well as the chemical and physical description of
the water. Economically and operationally this
suggests that the make-up locations and the discharge
(or blowdown) locations be kept to an absolute
minimum. The ideal system for monitoring should have
only one make-up water location and one blowdown loca-
tion. Simply, operation requires a description of the
quantity and quality of water throughout the system.
2. The chemical and physical parameters of the water system
can be classed advantageously as conservative and non-
conservative. Conservative substances, such as sodium
and chloride, are added to the water by the gas clean-
ing process and generally tend to build up in con-
centration with time. By the means of blowing down,
or discharging from the system, a portion of the gas
cleaning water, the concentration of the conservative
substances can be held nearly constant. Non-conserva-
tive substances, on the other hand, are also added to
the water by the gas cleaning process. These substances
may undergo chemical reaction and be precipitated, be
volatilized, or otherwise be lost from the system.
Their behavior is not readily predicted. The system of
calcium, alkalinity, pH, ionic strength, and temperature
is a group of interacting or non-conservative
substances. These non-conservative materials are also
effected by blow-down. It is necessary for operational
control to determine the response of the water recycle
system with regard to the non-conservative substances.
Broadly, some non-conservative substances may change
concentration by large amounts, reach saturation
levels, precipitate, and entirely change the chemical
composition of the recycle water stream. The prediction
and control of this chemical system is the principal
problem of the recycle operation. Ideally, this
system should be controlled with a minimum of outside
activity. Hopefully, control of the non-conservative
108
-------
substances may be managed by the same technique as for
the conservative substances, that is, blow-down from
the system.
3. To predict recycle system performance and measure
system response, the following parameters must be
measured at all input (make-up) and discharge (blow-
down) locations of the recycle water system with the
frequency noted. Regular intervals at this time
cannot be well defined.
Physical
1. Flow-continuous monitoring.
2. Temperature-regular intervals or continuously.
3. Suspended Solids-regular intervals.
Chemical - for operation control.
1. Calcium.
2. Magnesium.
3. Alkalinity.
4. pH.
5. Conductivity (dissolved solids) - continuous
monitoring.
Chemical - for pollution control (blowdown).
1. Ammonia.
2. Cyanide.
3. Phenolics.
4. Iron.
Chemical - for further system analysis and control.
1. Sodium - less frequent intervals.
2. Chloride - less frequent intervals.
3. Total inorganic analysis - cation and anion
balance - composite samples over a complete
operational interval.
109
-------
4. Interlake Sampling Locations
All additions and subtractions from the water system
must be accounted for by measurement. Locations
refer to flow schematic CA-3253, Interlake Steel
Corporation.
Blast Furnace System
1. Influent to 90 ft. diameter clarifier, say
at gas washer pump house.
2. Pump discharge from manifold leading to
blast furnace cooling tower.
3. Effluent line from blast furnace cooling tower.
4. Slowdown (6 in. diameter) line from manifold
leading to blast furnace cooling tower (flow
rate only).
5. Make-up water (6 in. diameter) line leading
to pump sump for blast furnace cooling tower
pumps.
6. Discharge manifold from sludge pumps leading
to 4 in. diameter sludge line to sinter plant
system.
7. Llowdown from new 4 in. diameter sludge line
and old 4 in. diameter sludge line.
8. Presently there are three additional discharge
points, two from the stoves, and one overflow
before the gas washer pump house, that must be
eliminated from system or monitored when used.
Sinter Plant System
1. Mill water line which provides make-up water.
2. Inlet trough to 40 ft. diameter clarifier.
110
-------
3. Outlet from 40 ft. diameter clarifier leading
to pump sump for sinter plant cooling tower.
4. Effluent line from sinter plant cooling tower.
5. Blowdown (4 in. diameter) line from manifold
from sinter plant recycle pumps (flow rate
only).
6. Blowdown line (trench) from 40 ft. diameter
clarifier leading to outfall CO-4.
5. Frequency of Sampling
Flow rate at input and discharge points should be
monitored continuously. Other physical and chemical
parameters may be measured at selected intervals.
The frequency of sampling is based on the response
time of the gas washer water system. One measure of
this response time is the detention time obtained by
dividing the volumetric capacity of the water system
by the flow rate through the system.
Blast Furnace Volume
1. Clarifier - 90 ft. diam., 12 ft.
deep. 76,000 ft.3
2. Cooling tower reservoir - 2 ft. x
22-1/2 ft. x 62-1/2 ft. 2,800
3. Cooling tower pump sump - 20 ft. x
15 ft. x 9 ft, 2,700
4. Recycle pump sump - 20 ft. x 15 ft.
x 9 ft. 2,700
Total 84,200 ft.3
Estimated detention time =
4,200 gpm
7.48 gal.
—j-Z 3 = 150 minutes
ft- = 2-1/2 hours
111
-------
Sinter Plant
Volume
1. Clarifier - 40 ft, diam., 17 ft.
deep.
2. Cooling tower pump sump - 12-1/2
ft. x 10 ft. x 10 ft.
3. Recycle pump sump - 12 1/2 ft. x
10 ft. x 10 ft.
Total
Estimated detention time =
600 gpm
7.48 ^al. = 300 minutes
ft.J = 5 hours
The chemical parameters sampled most frequently should
not be monitored at intervals more often than say one-
half the detention time. Sampling at intervals
shorter than one detention time should be done only
when the system is undergoing change. Less frequent
sampling is required when the system is naarly at
steady state. Changes in operation should not be made
more frequently than several detention times. If the
system were completely mixed, it would take about three
detention times to flush out 95 percent of a conservative
contaminant.
6. Presently the plan of operation for the combination of
the blast furnace and sinter plant gas washer systems
is to use the blowdown from the blast furnace system
to provide the make-up water for the sinter plant
system. The blowdown from the blast furnace system
carries the solids from the blast furnace clarifier to
the sinter plant system, that is, to the sinter plant
thickener. This technique of maintaining a relatively
dilute underflow for solids removal and blowdown seems
to be a good idea. Steel industry experience to date
shows that a blast furnace gas washer system can be
operated on recycle using blowdown as the operational
control at 20 percent blowdown. Tighter recycle with
less blowdown than 20 percent requires more operational
21,400 ft.3
1,250
1,250
23,900 ft.3
112
-------
care than presently has to be provided with once-
through operation. Using the 20 percent blowdown
value as a starting point, and a voliane flow rate of
4200 gpm for the blast furnace system, results in a
blowdown of 840 gpm being delivered to the sinter
plant system. Hie present flow rate of the sinter
plant gas washer system is about 600 gpra which means
that at 20 percent blowdown from the blast furnace
system water is being supplied .:o the sinter plant
cleaning operation at a rate that requires 100 per-
cent blowdown or once-through cleaning. If the blast
furnace system is tightened to 5 percent blowdown,
or say 210 gpm makeup to the sinter plant system, the
sinter operation can be put on recycle of about 67
percent. These flow rates are based on water dis-
charge only excluding evaporation losses and moisture
losses with filter cake removal. The question that
presents itself is the magnitude of the ultimate
blowdown from the combined operations - its location,
quantity and quality. To recycle water in the sinter
plant operation will require some type of alkalinity
control which in steady operation means the removal
per cycle of the incremental addition of alkalinity
added to the gas cleaning water. There are alternative
ways of controlling alkalinity. More than likely
precipitated calcium carbonate can be removed in the
clarifier and acid can be added for pH control.
Disposal and treatment of the ultimate blowdown will
depend wholly on the tightness of the recycle.
Two direct statements of Fellowship experience with
blast furnace recycle systems should be made regarding
pollution abatement. Our analyses show that the
quality of clarifier effluents from once-through and
recycle operations in terms of suspended solids remains
about the same. This means that for the blast furnace
system, by itself, the percent reduction in volumetric
discharge by the recycle operation represents the
percent reduction in solids disposed of to the receiving
water course. Cyanide concentrations in recycle waters
similarly do not seem to show large increases in con-
centration and consequently the recycle operation can
appreciably affect the total mass discharge of these
two particular pollution parameters.
113
-------
APPENDIX E
DATA TABULATION
DATA KEY
TIME: BASED ON A 2*100 HOUR CLOCK
Location:
1.TROUGH TO PRIMARY CLARIFIER
2,OVERFLOW FROM PRIMARY CLARIFIER
3. SUMP TO COOLING TOWER-PR I MARY
if. SUMP RECYCLE WATER-PR J MARY
5. RIVER WATER-MAKE UP
6. HLOWDOWM FROM BLAST FURNACE SYSTEM
7. SLUDGE FROM PRIMARY TO SINTER PLANT CLARIFIER
8. SCRUBBER WATER TO SECONDARY THICKENER
9. OVERFLOW FROM SECONDARY THICKENER
10. SUMP TO COOLING TOWER-SECONDARY
11. SUMP FROM COOLING TOWER-RECYCLE WATER
12. SLUDGE FROM SFCOMDARY THICKENER
13. BLOWDOW1I-SECONDARY
1*1. OVERFLOW SLUDGE TANK
CONDUCTIVITY: UMHOS/CM 0 25°C
CAC03: CALCIUM CARBONATE-MG/L
MGC03: MAGNESIUM CARBOMATE-MG/L
ALKALINITY: MG/L
SUSP. SOLIDS: FILTERABLE SOLIDS-MG/L
ph: ph of ststem
phs: SATURATION PH-CALCULATED
1: STABILITY INDEX
<6 PLATING SITUATION
>6 CORROSIVE SITUATION
IS: SATURATION INDEX
<0 CORROSIVE SITUATION
>0 PLATING SITUATION
°F: TEMPERATURE
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TIMR LOCATION CONDUCTIVITY
17m iu i"33
ll/iC/c* 7303 1 mao
ll/l'./f? 23CO 6 1950
2313 5 3'10
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DATE TIME LOCATION CONDUCTIVITY
f! uni i:""" u nr,n
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6/ 5/7a 11 e«00
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f/rr/7o »""» ^ ?]fo
2/;C/73 n
6/27/70 I. 2ri;0
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LOCATION CONDI.'-TIVI TV
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7/17/70 «««»
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3'>Q3
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DATE TIME
LOCATION
CONDUCTIVITY
U!
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DATE
-1/ 3/71-
1/ '1/71
1/ 6/71
TIME
- 800-
Soo
600
LOCATION
1,
1
-1/7/71-
1/ 7/71
1/ 7/71
1/ 7/71-
1/ 7/71
1/ 8/71-
1/ 9/71
1/10/71
1/11/71-
'1/12/71
-900-
9'i0
1000
-1130-
I'lOO
-800-
800
800
800 -
800
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1/13/71
-1/11/71-
1/15/71
800
-800-
8oo
1/16/71
-1/19/71-
1/20/71
1/21/71
-4/22/71-
800
-800-
800
1/23/71
1/21/71
•1/27/71
1/29/71
800
—800-
800
800
- 8oo •
801
1/29/71
1/29/71
-A/29/71-
1/30/71
—1585
800
915
-1100-
SOO
CONDUCTIVITY
200':
31C0
3100
-3000-
3900
1120
-m?o-
1 >><8n
-<|R00"
':R00
3900
-3900
5200
5*500
-5150-
5000
1500
-MUUKIiUUM-
1800
1700
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6700
IfiOO
— 3'ico
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1320
cacoi Mf.coi alkalinity susp.solids ph phs i/is
" 2?'l.00 205.00 600 j tf 6. 3 "" 1.7/ «1.6
_'rf.00_ ??/ tlil
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loh.nn—?<»3.on fin 5 »»!»««» B77 *7? r;i/~tJ.i
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570.00 1S1.00 575 aaaaaaaa 8.3 6.0 3.7/ »2.3
510.00 119.00 550 jntnitMHit:: 7>f,— ».2/~il.T
3*0.00 1_1 5.00 175 7.7 *,1 5, 8/. tl, 0
ua;:a:ta>: 275 aaaaaaaw 8.0 Kitau K»au»/Mnun:i
300.00 9"».00 170 im:i«K!!!i!t *«»*— Hiiuft—Sanaa/ ~o7o
1J0.OO 1?.^0 H70 aaaaaaaa 6.? 6.2 1| .3/ «?.0
350.30 91.00 675 miitisnaii* 8.7 6.1 3.6/ »2.6
212.00 -109.00 11*0 «::«««!:irir "8,R 6. J 1.1/"*?. 7
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210.00 127.00 550 aaaaaaaa 0.J g.ft (, .f / 4l>fl
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3'0. CO 105. 0 l';00 «'««««*«» 8.0 5.H 1. *7 ~ 2,2
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'ISO. 00 1^0. ^0 550 am:aamsK fl.n 6.1 1»3/_tl>JL
-------
OATf TIME
5/ 1/71 800
5/ ?/71
—5/ 3/71
5/ ».m
"" 5/ 5/71
8oo
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8*0
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loo
5/ 6/71— 800-
5/ 7/71 809
5/13/71 8W~
5/11/73 830-
5/13/71 800
5/13/71
--5/H./71
800
no-
ii-
*
LOCATION
4
CONDUCTIVITY
CACO}
hKfn
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344.00
4?00-
1*8.nt
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31'.GO
4S00
356.00
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fin. or,
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5/15/71
800
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5/l€/71
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5/21/71
800
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5/22/71
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5/26/71
300
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-------
OATC TIME
"5/2R/TI "*•''.00
80ft.
5/31/71
"6/ i/7l"
800
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6/ 1/71 BOO
~~ i/*i/n~8oo"
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6/ 6/71 800
~6/ 7/71 "800
... 6/ 8/71.._80.0.
6/ 9/71 800
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" £/13/7i~ 800"
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f.fl'ni80"}"
_6/17/71 8oq..
6/18/71 800
6/15/71 8C1~
. 6/20/71 eoo_
6/21/71 800
" 6/22/71 800"
6/23/7,
LOCATION
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10200
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CACOI W.C03 ALKALINITY
311,,no' l'ft.no" 390'"
jsiissssjs;:«ss
SUSP.SOLIDS
sjbmks iit» kmukiikkk
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'• 90.00—195.00 2ts_
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5S6.00 ' 217.00 270"
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120.00 23".,03 fi«i5
104.00 ft7fi.no 600
378.00 2'10.00 505-
290.00 379.00 570
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-------
DATE TIME .LOCATION CONDUCTIVITY
Jlf 21/71 800 !l 2';CQ_
tntni 800 i 'coo
6/27/71 8no it 3fon
6/23/71 Sag I) HC8Q.
6/20/71 800 'I
6/JC/71 800 1 5?30
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-------
APPENDIX F
MODIFICATIONS OF THE RECIRCULATION SYSTEM
Since preparation of the preceding final report in 1972,
minor changes have been made to provide a system which is
easier to control and maintain. These changes are described
and explained below.
Vacuum for Sludge Filters
During the early operation of the recirculation
system, reciprocating vacuum pumps were used to
develop the required suction at the secondary
clarifier sludge filters. Due to the high
incidence of failure and excessive maintenance
requirements, the pumps have been replaced by
steam ejectors. These units have provided
satisfactory service.
Control of Solids Build-up in The Recycle System
About a year ago, the blast furnace gas systems
began to experience high pressure drops through
the counter-current spray towers or gas coolers.
High back-pressure was found to be the result
of suspended solids plugging the openings in
banks of ceramic drip tile within the gas
coolers. In order to reduce the high-pressure
drops, the gas coolers were acid cleaned every
week or two. Use of a corrosion inhibitor was
considered, but the benefits were doubtful and
the cost would have been excessive.
Several water treatment companies were asked
to analyze the problem and recommend a
procedure or chemical treatment which would
prevent clogging of the tile banks. The
procedure which has been in use during the
past six months was developed by Calgon Company.
It involves the addition of a chemical named
Calgon CL-134. During the six months that this
chemical has been used, there has been no
evidence of plugging in the coolers; in fact,
there has been a gradual decrease in the
pressure drop through these units.
Preceding page blank
-------
We are presently in the final stages of installation
of a chemical addition system designed to control pH
and suspended solids in the recycle system. We will
add acid and Calgon CL-134 in controlled quantities.
The initial cost of this additional chemical control
system will be about $56,000.
Secondary Clarifier Cooling Tower
As is stated on page 82 of this report, the
installation of a cooling tower at the sinter plant
recycle system was not required. The circulation
of high pH water through the cooling tower has
resulted in attack on the tower structure which
finally caused it to deteriorate to the extent that
it was unusable. The cooling tower has therefore
been by-passed with no noticeable undesirable effects.
150
------- |