AM/NS Calvert – From Waste to Resource: The Impact of Cooling Tower Water Recycling

Partners for Environmental Progress has presented a 2024 Environmental Stewardship Award to AM/NS Calvert. The steel mill is located on about 2,400 acres of land, including 160 acres of protected wetlands and has cultivated a strong commitment to wildlife habitat management and environmental sustainability.

In 2023, AM/NS Calvert embarked on a groundbreaking project to recycle S-3a blow-down water back to cooling tower S-3 in collaboration with the Hot Strip Mill’s cooling water circuit team. This project collaborated with the Hot Strip Mill’s cooling water circuit team, their water and waste engineer, and their third-party process chemicals supplier, ChemTreat.

The Project at AM/NS Calvert

Recognizing the need for sustainable water management, AM/NS Calvert collaborated with the Hot Strip Mill’s cooling water circuit team, their water and waste engineer, and representatives from ChemTreat, their process chemicals supplier, to initiate a groundbreaking project. The goal was to recycle the blow-down water from cooling tower S-3a back into cooling tower S-3, reducing water waste and chemical usage.

Key Project Details

The project involved installing a six-inch diameter, stainless-steel pipe connecting cooling tower S-3a’s blow-down line to cooling tower S-3’s water basin. This straightforward yet impactful installation has led to significant annual benefits, including:

• Recycling Approximately 43 Million Gallons of Industrial Water: By redirecting the blow-down water back into the system, we have managed to conserve an incredible amount of water, reducing our reliance on freshwater sources.
• Chemical Usage Savings of Approximately $76,000: The recycled water reduces the need for additional chemicals to treat fresh water, resulting in substantial cost savings.
• Greenhouse Gas Emissions Avoidance of Approximately 125,000 Pounds: This reduction is equivalent to the annual energy use of seven homes, highlighting the project’s positive impact on reducing our carbon footprint.

This innovative project involved the installation of a new six-inch diameter, stainless steel pipe, which now allows for the recycling of approximately 43 million gallons of industrial water annually. Not only does this project save approximately $76,000 in chemical usage each year, but it also avoids the release of approximately 125,000 pounds of greenhouse gas emissions—the equivalent of the annual energy use of seven homes.

The Broader Impact

This cooling water recycling project at AM/NS Calvert is a prime example of how industrial operations can align with environmental stewardship. By rethinking waste and finding innovative ways to recycle resources, we can make significant strides toward sustainability.

Environmental Benefits

• Water Conservation: Recycling industrial water helps preserve natural water sources, ensuring their availability for future generations.
• Reduced Chemical Use: Lower chemical use means less environmental contamination and lower operational costs.
• Decreased Greenhouse Gas Emissions: Reducing energy consumption and emissions helps mitigate climate change and its associated impacts.

Economic Benefits

• Cost Savings: Reduced chemical treatment costs and lower water procurement expenses contribute to overall savings.
• Operational Efficiency: Recycling processes can streamline operations, reducing dependency on external water sources and enhancing reliability.

A Commitment to Sustainability

AM/NS Calvert’s core values emphasize sustainable practices and environmental responsibility. This cooling tower water recycling project is a testament to their dedication to these principles. By continuously seeking innovative solutions, AM/NS Calvert aims to lead by example in the industrial sector. 

PEP extends special recognition to ChemTreat for their assistance with this project.