Rolling Wastewater Reuse Project of a Large Steel Mill in Shandong
Project Background
Industrial Policies & Standard Requirements
Against the backdrop of stricter industrial environmental supervision and the implementation of water recycling policies, production water, reuse water and wastewater treatment of all industries must strictly comply with national water quality standards. Water treatment systems in mining, power, metallurgy, chemical and other industries are required to be equipped with front-end pre-filtration units to remove suspended solids, colloids, sediment, oil contamination and other impurities from raw water, so as to ensure stable operation of downstream equipment and qualified production water.
In addition, intelligent water treatment equipment has become a mainstream industry trend. Traditional crude filtration equipment is gradually replaced by intelligent automatic multimedia filtration systems to meet the requirements of green production, energy conservation & consumption reduction and intelligent factory construction.
Pain Points of Traditional Water Treatment Facilities
- Low filtration accuracy and unstable water quality: Traditional single-medium filters only adopt one type of filter medium, which can only intercept large-particle contaminants but cannot remove colloids and fine suspended solids. The effluent turbidity fluctuates drastically, easily causing blockage and scaling of downstream pipelines, filter elements and membrane equipment.
- Severe equipment wear and high operation & maintenance costs: Substandard water quality accelerates wear and aging of reverse osmosis membranes, hydraulic equipment and water supply pipelines, greatly shortening equipment service life. Frequent component replacement and shutdown maintenance lead to high maintenance costs and production losses.
- Heavy dependence on manual labor: Traditional equipment requires regular manual patrol inspection, manual start/stop of backwashing and manual filter medium replacement. Cumbersome operations raise labor costs, and human errors may disrupt continuous water treatment.
- High energy consumption and serious resource waste: Outdated equipment delivers low filtration efficiency with unreasonable backwashing frequency, resulting in massive waste of water and electricity. It fails to satisfy production demands of energy saving and water recycling, accompanied by low water resource utilization efficiency.
- Lack of intelligent control and data support: The equipment is not equipped with online water quality monitoring, operating data recording or fault early warning functions. Operators cannot grasp real-time equipment status and effluent quality, leading to delayed detection of water quality problems and difficult traceability & rectification.
Project Construction Value
The intelligent multimedia filtration system can efficiently purify raw water and stabilize effluent indicators to fully protect downstream water treatment and production equipment. It realizes automatic operation, intelligent backwashing and unattended maintenance, greatly cutting labor and equipment maintenance costs. The system improves the recycling rate of industrial wastewater and production water, saves water and energy, helps enterprises pass environmental acceptance, implement green low-carbon production, and meet the construction standards of intelligent and standardized factories.
Project Solution
Construction Objectives
Construct a fully automatic intelligent multimedia filtration water treatment system. Multi-layer composite filter media are adopted for graded filtration to efficiently remove sediment, suspended solids, colloids, trace oil stains, particulate matter and other impurities in raw water, keeping effluent turbidity, SDI value, suspended solids and other indicators stably up to standard. The system realizes full-automatic equipment operation, intelligent backwashing, online monitoring, remote control and unattended running. It effectively extends the service life of downstream equipment, improves water resource utilization efficiency, and enables energy-saving, stable and efficient operation of the entire water treatment system.
Core System Configuration & Working Principle
The system adopts a modular integrated design, taking multi-layer composite medium filtration as the core, and is matched with intelligent electric control, water quality monitoring, automatic backwashing and pressure-stabilized water supply units to adapt to various complex industrial water quality conditions.
The core filter medium adopts a multi-layer graded structure composed of anthracite, quartz sand, garnet and modified filter materials. Contaminants are intercepted step by step according to particle sizes: the upper layer traps large-particle sediment and suspended solids, the middle layer adsorbs colloids and organic matter, and the bottom layer performs fine filtration of trace impurities to realize high-efficiency gradient filtration.
- Main Tank Unit
Tanks are made of high-strength FRP fiberglass or anti-corrosion carbon steel, featuring acid & alkali resistance, corrosion resistance, strong sealing performance and long service life. They are applicable to water with a wide pH range, easy to install and occupy a small floor area, suitable for underground and harsh industrial environments.
- Multi-stage Filtration Unit (Core)
Filled with layered composite filter media, this unit features gradient filtration, high dirt holding capacity and high filtration accuracy. It can effectively reduce raw water turbidity and intercept fine particulate matter, solve the problems of turbid water and excessive impurities, and purify water quality from the source.
- Intelligent Automatic Backwashing Unit
Three washing modes are available: differential pressure trigger, timing trigger and manual operation. When the filter medium is saturated with contaminants, the system automatically starts backwashing and forward washing procedures without manual intervention. It thoroughly cleans impurities in the filter layer to restore filtration performance, prevent filter layer hardening and filtration failure, and guarantee long-term stable operation.
- Online Monitoring Unit
Equipped with sensors for turbidity, differential pressure, flow rate and pressure, it monitors inlet & outlet water quality and equipment operating parameters online in real time. All data is uploaded synchronously to dynamically track water quality variations.
- Intelligent Control Unit
Supports dual modes: local touch screen operation and remote monitoring. Functions include one-click start & stop, customizable parameter adjustment, automatic fault alarm, as well as archiving and traceability of operating data. The system can be connected to the factory intelligent management platform to realize integrated intelligent operation and maintenance.
- Pressure-Stabilized Water Supply Unit
Equipped with pressure stabilizing pipelines and filter protection structures, it maintains stable water pressure and balanced effluent flow during filtration, ensuring continuous and stable operation of downstream water supply and water treatment systems.
Core Technical Advantages
- High filtration accuracy and stable water quality
The multi-layer gradient composite filtration structure boasts large dirt holding capacity and stable effluent quality. It can reduce raw water turbidity to below 5 NTU and stabilize the SDI value within 3, satisfying pre-treatment standards for all types of industrial water.
- Fully automatic intelligent operation
The whole process of filtration, backwashing and operation monitoring is fully automated without dedicated on-site staff, greatly reducing labor input and avoiding human operation errors.
- Energy saving, low consumption and high utilization efficiency
Intelligent on-demand backwashing reduces unnecessary waste of water and electricity, significantly lifting the recycling rate of water resources and helping enterprises cut costs and boost efficiency.
- Strong adaptability and high durability
The anti-corrosion tank design adapts to complex working conditions in mining, metallurgy, power, chemical and other industries. The equipment is pollution-resistant, wear-resistant, low in failure rate and easy to maintain.
- Traceable data and convenient maintenance
All operating data is recorded and archived in real time with automatic fault early warning, facilitating daily operation management and traceability for environmental acceptance.