Modernization of the District Heating System for a Steel Plant

Technical Challenge

The plant's existing district heating system, over 25 years old, presented major thermal losses (estimated at 18-22%), inconsistent network pressure, and critical corrosion points. This led to excessive energy consumption and unplanned production interruptions during peak winter periods.

Design Approach

We adopted a three-phase strategy, based on digital network modeling and detailed thermohydraulic analysis.

• 1 Advanced diagnostics with thermography and flow/pressure measurements at 45 key points.
• 2 CFD Simulation of flow and temperature distribution to identify optimizations.
• 3 Design of a hybrid system integrating new-generation insulation, variable speed pumps, and centralized automation.

Implementation and Realization

The work was executed in stages to minimize impact on the production process. We replaced 2.8 km of pre-insulated pipes, installed 12 new pumping stations with automatic control, and implemented a dedicated SCADA system for real-time parameter monitoring. The system was integrated with the existing thermal power plants.