Nalco Program Reduces Water, Energy Usage at Gallatin Steel
04/22/2011 - Nalco helped Gallatin Steel’s mini-mill in Ghent, Ky., reduce its raw water use by 179 million gallons per year and decrease pump operations, saving 2.3 million kW·h of energy annually.
Nalco has helped Gallatin Steel’s mini-mill in Ghent, Ky., reduce its raw water use by 179 million gallons per year and decrease pump operations, saving 2.3 million kW·h of energy annually. The energy cutback reportedly avoided nearly 2400 tons of annual greenhouse gas emissions while improved filtration eliminated landfilling 410 tons of sludge each year.
The Gallatin mill, a major recycler of scrap metal, makes rolled steel that is used in the pipe and tube industry, construction, transportation, and other markets. To minimize the amount of Ohio River water used to cool the hot steel, Gallatin filters and recycles water in the cooling process; however, oil and grease buildup in the filtration system was causing increased water use, consuming more energy to run pumps and requiring more frequent filter replacements.
Nalco engineers worked with Gallatin employees to understand the mechanical and operating factors affecting water system performance. Nalco CAT-FLOC® technology was used to reduce oil and solids in water that directly contacts the steel during production, improving filtration operations. Nalco 3D TRASAR® technology optimized cooling system water, enhancing water reuse and recycling.
“We recognize that environmental protection is a key value and good business,” said Tobin Pospisil, President of Gallatin Steel. “As a major recycler of millions of tons of scrap metal, we wanted to find ways to improve our cooling system operation to save water and energy as well.”
Nalco is the world’s largest sustainability services company focused on industrial water, energy, and air applications. It is a member of the Dow Jones Sustainability World and North America Indexes. More than 12,000 Nalco employees operate in 150 countries supported by a comprehensive network of manufacturing facilities, sales offices, and research centers to serve a broad range of end markets.
Gallatin Steel, a joint venture between ArcelorMittal and Gerdau Ameristeel, is a flat-rolled carbon steel producer located in Ghent, Ky., on the banks of the Ohio River approximately one hour from Louisville, Ky., and Cincinnati, Ohio.
