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Tata Steel Trostre - Pickle Line

Reducing Energy Usage

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Project Overview

Using our specialist cost reduction and engineering skills, CR Plus successfully designed and implemented a cascade water system on a steel coil acid pickling line for the Trostre steel works in 2009.

Overall improvements delivered from 2009:

•Water: – From 4000 m³/wk down to 850 m³/wk i.e. 79% reduction
•Financial: – >£290 k/y - (Capex cost £192k)
•Natural gas: – 2,050 GWh £42k p.a. cost saving
•Steam: – 0.4 t/h = ~3200 t/y
•Production: – no change to pH values and grey scale quality “significantly improved”

Summary of Improvements

Following a successful 3 month period whereby CR Plus carried out continuous on site investigations at the Trostre works work to find and implement quick win savings around the sites various process heating systems (steam, water, natural gas) CR Plus were then engaged to deliver a larger project – implement a cascade water recycling system on the plants acid pickling line.

Initial efforts focussed on the process heating loads where two projects were implemented:
  1. Concept and Design; Having studied the plant in detail, CR Plus developed the concept through to a costed design.  
  2. Turn Key Delivery; CR Plus effectively acted as EPC for this project. Procuring and managing the installation followed by commissioning and optimising the project.
The net result was an acid pickling line which used 79% less water and reduction in heat via steam, to produce the same volume of product and an improvement in strip cleaning achieved via the addition of upgraded spray nozzles and pumping capability within the system. 

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