A process integration approach to industrial water conservation: A case study for a Chinese steel plant

A systematic approach to optimizing water network has traditionally been utilized to exam and plan water conservation in industrial processes. In the present case study, water-pinch technology was used to analyze and optimize the water network of a steel plant near Chinaʹs Zhangjiakou city. A system design was developed and a limiting constraint (Cl− concentration) was identified based on investigations of water quality then the minimum freshwater and wastewater targets were determined without considering water losses. The analysis was then extended by calculating the additional input of freshwater required to balance the actual water losses. A nearest-neighbor algorithm (NNA) was used to distribute the freshwater and recycled water among each of the plantʹs operations. The results showed that with some reconstruction of the water network, the flow rates of freshwater and wastewater could be decreased by 57.5% and 81.9%, respectively.