RUSSULA NEWSLETTER No. 11

RECENT PROJECTS
Gerdau Sayreville NJ awarded Russula contract for
Last December, Gerdau awarded
Russula the contract to supply the
Contact Cooling Water Treatment
Plant for their 800,000 tpy capacity
rebar mill, in Sayreville, NJ, USA.
The rolling mill currently produces
rebar at average/maximum rates of
78/150 short tons/h (71/136 metric
tons/h) rolling 115mm square billets.
The mill scale generated by the
rolling process at these production
rates are 1,376/2,645 Lb/h
(624/1,200 kg/h), with a mill scale
density of 325 Lb/ft 3 (5,200 kg/m 3 ).
The project will be implemented in
two phases. In the first phase, the
new water plant will treat a total
flow of 4000 GPM from the rolling
mill and reheat furnace, and the second
phase will include the quenching
system, which requires an
additional water flow of 3500 GPM.
For the 4000 GPM treatment, the
plant design will follow the Russula
"Four Stage Process" for contact
water circuits. Water from the
rolling mill will be treated first in
the scale pit to remove coarse particles
that have a size greater than or
equal to 200 microns. The density
difference between the water and
the scale, causes the larger, heavier
scale particles to be deposited on
the bottom of the pit, and subsequently
extracted by a clamshell
bucket.
After passing through the scale pit,
the water will continue to the decanting
process, where by longitudinal
drag small scale particles, oils
and grease are removed. Coarse
particles that gather at the bottom of
The 4000 GPM contact
cooling water will go
through a four stage treatment
process consisting of
a scale pit, decanting
process, ring filtration and
cooling towers. The water
treatment plant flow diagram
is illustrated on the
left.
5 Russula Newsletter No. 11 April 2015 - Copyright © by RUSSULA S.A.