The North Star BlueScope Steel facility located in Ohio uses water from Lake Erie in its manufacturing processes. Wastewater is then treated and returned to the Maumee River, which feeds back into Lake Erie. Noticing changes to both the incoming water quality and effluent quality, the client chose to explore more robust industrial water reuse options. The target of this capital project included an increase of 30+% in steel production for the facility with minimal increase in fresh water use.

Kleinfelder Water Technologies worked with BlueScope to upgrade its onsite equipment while minimizing the environmental impacts through water recycling options. Additionally, the client wanted to extend the operational lifespan of its cooling towers by avoiding frequent blowdowns. Kleinfelder provided 3D model and structural steel support design for the pipe racks around the equipment. We completed a 3D scan of the existing area, provided piping details for the steel piping, structural drawings, & a final 3D model with GA cuts.

To address these challenges, Kleinfelder proposed a comprehensive solution involving ultrafiltration and a two-stage reverse osmosis (RO) system. The client had an existing onsite water treatment system in place, which handled initial wastewater treatment of biologics and heavy metals. Kleinfelder designed and installed a two-stage RO system to further treat the wastewater, polishing it to a level suitable for reuse within the facility. The design also included hollow fiber membranes and a custom control panel design, with SCADA capabilities.

In addition to the design and installation of new equipment, Kleinfelder Water Technologies also provided preventative maintenance services to help ensure optimal performance of the system.