Gerdau awarded Russula the contract to supply the Contact Cooling Water Treatment Plant for its 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/ft3 (5,200 kg/m3).
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 feature Russula's "Four Stage Process" for contact water circuits. Water from the rolling mill will be treated first in the scale pit, followed by the decanting process, ring filtration and cooling towers.
While the basic engineering has already commenced, the construction of the water treatment plant is scheduled to be completed and operational in September, 2016.
Rebar made at the Gerdau Sayreville mill is typically sold in the northeast and Canada. The rebar runs the gamut from no. 3 rebar, which is 3/8 of an inch in diameter, to number 18 rebar, which is about 2¼ inches in diameter.
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