Uncategorized Archives - Ion Exchange

원수 처리

anurag khare — Sat, 09 Dec 2023 06:30:34 +0000

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지속 가능성

anurag khare — Sat, 09 Dec 2023 06:24:40 +0000

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Electronics Case Study

Ion Exchange — Fri, 01 Apr 2022 06:45:09 +0000

A leading electronics company whose facility is located in a water stressed area and the little available fresh water is very costly. Availability of raw water as well as disposal regulations in the area were concerns and the client was looking for a cost effective effluent recycle system to reuse their waste water. The challenge was also to produce high purity water having 10 meg-ohm resistivity.

Based on past performance and total experience, the company awarded Ion Exchange the contract to manage waste water to produce high purity water, a solution that would address and solve both their major problems. We designed a high end SSE recycle system consisting of:

Chlorination
Filtration
Ultra Filtration
Reverse Osmosis
Two stage Mixed Bed system

Our high end use recycle system which produced high purity water of 10 meg-ohm resistivity from effluent, exceeded the customer’s expectations
This company produces more than 82,000 gallons per day high purity water and 513,000 gallons per day water for low end purposes such as gardening and flushing by recycling effluent
The customer reported a payback period of less than two years on capital investment

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Power Case Study

Ion Exchange — Mon, 28 Mar 2022 11:50:20 +0000

Jindal Steel & Power’s 6 MTPA integrated steel plant envisaged a coal gasification based reduction gas facility. During the coal gasification process, liquid effluents are generated; these effluents contain fluorides, cyanides, sulphides, thiocyanates, nitrogen, phenols and various heavy metals. Other parameters are biological oxygen demand (BOD) up to 4,000 mg/l, chemical oxygen demand (COD) up to 6,500 mg/l, total suspended solids (TSS) 125 mg/l as well as oil and grease up to 50 mg/l. These toxic contaminants are harmful to the environment and aquatic life and need to be treated before discharge; they are also extremely challenging to treat. Environmental sustainability concerns led JSPL to seek a state-of-art effluent treatment plant so that the treated effluent would meet stringent discharge parameters.

Ion Exchange Waterleau, our joint venture with Waterleau, Belgium, was awarded the turnkey contract for treating the complex liquid waste generated in the greenfield expansion project of Jindal Steel and Power Limited (JSPL) at Angul, Odisha.

The contract also includes turnkey civil design, complete electricals, instrumentation and a remote monitoring system.

Effluent Treatment: The plant is designed to treat a combined flow of 400 m3 /h consisting of 350 m3 /h stripped gas ammonia liquor (SGAL – effluent post ammonia stripper) and 50 m3 /h oily waste and rainwater. Apart from oil removal, the process employs cyanide and sulphide removal technologies and advanced biological treatment (ABT) where several stages of anoxic and aeration significantly reduce BOD, COD, TKN, trace phenols and cyanides. The effluent is further subjected to a tertiary treatment process. The final treated effluent is pH neutral, containing BOD <30 ppm, COD <150ppm, TKN <10 ppm, NH3N <5ppm, oil & grease <10 ppm, cyanide<0.2 ppm, fluoride <2ppm, sulphide and phenol <1 ppm.

Solid Waste Treatment: The plant includes two belt filter presses (BFPs) for treating solid waste (chemical and biological sludge) generated during treatment. Solids will be concentrated to 18-20 per cent slurry for safe disposal. The excess water drained from the BFPs is recovered and treated in the main effluent treatment plant.

Auxiliary Process Equipment with Air Treatment: Since the process uses a large quantity of lime, a sophisticated, automated lime handling, solution preparation and dosing system are provided with a lime dust handling system to meet the stringent air/particulate emission limits.

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Food & Beverage Case Study

Ion Exchange — Wed, 23 Mar 2022 07:51:59 +0000

Patanjali Ayurved Limited is an Indian consumer goods company. The company manufactures mineral and herbal products. Patanjali planned to set up a green field food park project in Haridwar where fresh water cost is very high. Water scarcity and stringent discharge norms were major challenges for Patanjali.

Ion Exchange made an unsolicited bid to Patanjali for a proposal to treat the complex effluent for the treated water to be reused at their facility. Patanjali considered this proposal and the contract was awarded. IEI installed State of the art – 5 MLD complex effluent recycling plant with complete “Zero Liquid Discharge” set up.

This helped Patanjali to not only adhere to the local discharge norms but also helped them to become more water efficient by reducing their intake of fresh water in a water scarce area where their facility was located.

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Textile Case Study

Ion Exchange — Mon, 21 Mar 2022 12:32:34 +0000

Welspun India Ltd, part of the $2.3-billion Welspun Group, is one of the world’s largest home textile manufacturers, with a distribution network in more than 50 countries. Welspun’s facility is located at Anjar, Gujarat which is a highly arid region where fresh water is scarce. Acute water scarcity in the region (Kutch) with no rainfall coupled with ambitious expansion plans needing a secure source of fresh water.

Ion Exchange (India) Limited (IEI) & Welspun made an unsolicited bid to the Government of Gujarat for a proposal to treat the sewage from the nearby villages of Anjar and Gandhidham for the treated water to be reused at their facility to meet their substantial water needs. The Gujarat government considered this proposal & based on a Swiss challenge, the contract was awarded to IEI. The project was executed on a Public Private Partnership (PPP) basis such that Welspun funded the project & IEI was appointed as the EPC contractor for the design, fabrication & supply for the systems required in the project. Ion Exchange partnered with Welspun to design, erect and commission a sewage treatment and recycle plant along with operation & maintenance. The 30 MLD sewage treatment plant is treating sewage generated from two cities – Anjar and Adipur, supplied by their respective local municipalities.

This project has reduced the burden on local municipal authorities to treat sewage generated by communities in the water scarce Kutch region. The sewage generated from two cities Anjar & Adipur is treated and reused as an alternate source of water at the Welspun facility which would otherwise be discharged and pollute the Nakti Creek, Gulf of Kutch. It is also a unique public-private partnership model for treating and reusing municipal sewage by the industry.

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Steel & Metallurgy Case Study

Ion Exchange — Mon, 21 Mar 2022 08:46:03 +0000

Effluent Recycle using Hydramem Membrane for a Leading Steel Manufacturer. The Customer is one of the leading integrated steel and power manufacturer in India.

The major challenges faced by the customer were:

Adherence to stringent effluent discharge norms set by the Pollution Control Board
Scarcity of water
High cost of fresh water

The Ion Exchange Effluent Recycle plant was set up at the customer’s largest integrated Steel and Power Plant manufacturing facility in Central India which has a production capacity of 2.5 million tons per annum.

Ion Exchange mitigated the challenge with the following solution:

The Effluent Recycle Stream with capacity 360 m³/h was recycled through our state-of-the-art HYDRAMEM membrane systems:

HYDRAMEM UF Membrane System and
HYDRAMEM RO Membrane System

The RO permeate was used as cooling tower makeup and for various other process applications.

Effluent Recycle has been successfully executed with the system running to the customer’s satisfaction & achieving desired results
Treated water TDS is significantly lower than inlet effluent
The treated water is currently being used as Cooling Tower make up and for various process applications.

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Cement Case Study

Ion Exchange — Tue, 15 Mar 2022 11:11:29 +0000

Ambuja Cements Ltd, a part of the global conglomerate Lafarge Holcim, is among the leading cement companies in India. Since its inception it has incorporated various sustainable development projects and environment-friendly practices. Ambuja Cement has five integrated cement manufacturing plants and eight cement grinding units across the country. One of its plant is located at Dist. Ropar, Punjab where Ion Exchange has supplied a state-of-art zero discharge plant.

This plant was successfully commissioned and is operational since the past one decade. It has a 30 MW power plant which includes two turbines, each of 15 MW capacity, high and medium pressure boilers 80/45 T/h capacity with operating boiler pressure of 67 kg/sq. cm. each.

The total effluent generated from the utility section of the power plant, is about 500 m³/day. This includes blow down from cooling towers, reject/effluent from softeners, DM plant and pressure sand filters.

A sharp decline in the water levels of the region, stringent discharge norms and an overall environmental consciousness led the company to look for an efficient waste water management system the first of its type within the group, to enable their vision for water conservation and zero discharge.

To treat the effluents, Ion Exchange recommended & implemented a scheme that includes extensive pretreatment of water, INDION® Ultra filtration(UF) followed by two-stage INDION® Reverse Osmosis (RO) and finally evaporation to handle the reject from the membrane systems.

The plant, recovers 85% of the waste water for reuse and achieves zero discharge.
At the same time it helps conserve water by reducing fresh water intake through this recycling program and thus helps in preserving fresh water in an area where the water levels are depleting.

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Automotive Case Study

Ion Exchange — Thu, 10 Mar 2022 12:29:18 +0000

Benefits

The customer is one of the leading manufacturers of world-class quality motor vehicles. It expanded its manufacturing set up with its “Greenfield” car manufacturing facility at Anantapur, Andhra Pradesh. A state which is moving slowly from irrigation to an industrial economy and has various challenges related to water use for irrigation & industrialization.

The major challenges faced by the customer included:

Stringent Regulations and Disposal Norms: The state government enforced stringent regulations and strict norms for reuse and disposal of waste. Hence, there was a strong need to maximize the recycling of wastewater and also to introduce environmentally sound, energy-saving techniques for treatment and disposal. The project was mandated to adopt Zero Liquid Discharge (ZLD).
Water Scarcity & High Fresh Water Cost: During the setup phase of the plant Anantapur, had no history of any other industry in the vicinity of the said plant. Availability of water was a major challenge and water would have to be availed from distant sources. This not only made raw water expensive but would also render it the most expensive resource for the unit.
Inconsistent Raw Water Quality: Water in the plant area had been sourced from various distant sources making water quality inconsistent and difficult to keep up to the production standards.

Ion Exchange mitigated the above-listed challenges using its pioneering concept of Integrated Water Management with the benefits of:
- Source Reduction
- Product Recovery
- Waste Minimization
- Water Reuse
Turnkey execution of the project included: Water Treatment Plant (WTP):The WTP was important to cater to the industrial and potable water requirements of the customer. The process & technology used for the industrial water treatment plant is pre-treatment, ultra-filtration (UF), reverse osmosis (RO), designed with 80% water recovery. The RO membrane cleaning system is designed for use with standard cleaning solutions as well as special cleaners. The capacity for water treatment plant is as listed below:
- WTP i.e. Industrial Water Supply Scheme:
  - Raw Water Feed @ 2000 CuM / Day i.e. 100 CuM / Hr
  - RO Capacity 56 CuM/Hr @ 80% recovery
The Potable Water supply scheme for factory and subsidiary is designed with pre-treatment including Clarifier, followed by UF, Activated Carbon Filter and Ultra-Violet treatment to feed potable water to designated locations within the factory & its subsidiary. The potable water capacity for the main factory is 750 CuM / Day

Wastewater Treatment Plant (WWTP):
The wastewater which is treated comes from seven sources through car assembly plant namely Phosphate Renewal, Phosphate Rinse, Degrease Press Shop, Degrease Rinse, Misc Wastewater, Electro Deposition rinse and the water treatment plant i.e. RO waste-water, CWS waste-water. This is then recycled.
The capacity for wastewater treatment plant is as listed below
- WWTP with Multi-Effect Evaporator (MEE) & ZLD
  - Raw Effluent Feed @ 2150 CuM / Day
  - RO-Stage-I Capacity – 71.9 CuM/Hr x 2 nos. skids
  - RO-Stage-II Capacity – 14.4 CuM/Hr x 2 nos. skids
  - RO-Stage-III Capacity – 14.4 CuM/Hr x 2 nos. skids
  - MEE Capacity – 150 KLD (CuM/Day)
Key processes under the wastewater treatment plant are as under:
- For phosphate renewal and phosphate rinse wastewater: Coagulation & flocculation, Lamella Clarifier, wherein clarified water is collected in equalization tank and the sludge goes to sludge pond, centrifuge & finally to sludge disposal area
- For Degrease, Assembly Press Shop and Degrease rinse waste-water: Equalization tank, followed by flocculation, dissolve air flotation, aeration, sedimentation (sludge removal), UF with 93% recovery, RO-I with 80% recovery, RO-II with 75% recovery and RO-III with 60% recovery
- Permeate from RO-I and RO-II is directly fed to the Industrial Water supply pond, while reject is treated at a subsequent stage of RO
- Reject from the RO-III is collected in a high saltwater pond and subjected to MEE (4, in this case) to recover maximum water in the form of condensate and thereby disposing of the generated sludge
- Chemical dosing systems are deployed for pre-treatment, as well as main treatment systems as per need & necessity of the treatment/scheme
Sewage Treatment Plant (STP):

A state-of-the-art design based on INDION MBR technology treats the sewage collected from various sources. STP plant with the capacity of 900 CuM/d was designed based on INDION MBR technology, thereby providing an alternate source other than industrial effluent recycle for process, utility and low-end applications.
Water Quality Monitoring System

The Plant is automated with 24×7 monitoring of critical operations and the critical parameters, through a central Programmable Logic Controller system. It also has various other online quality monitoring systems including the pH meters, conductivity analyzers etc. installed at various key locations as per the requirement for monitoring of different quality parameters. The ‘permeate’ from all stages of RO i.e. RO-I, RO-II and RO-III for the WWTP as well as the WTP/industrial water – RO has an online conductivity monitoring system. The flow measurements are captured through online mag-flow meters. Apart from the above, monitoring of some critical parameters is done in-house on a continuous & daily basis to maintain a record for future reference. A local water-testing laboratory setup is provided to do all these routine tests in-house. At the project’s concluding stage, when Ion Exchange was carrying out the commissioning and performance guarantee tests at the site, complete water analysis was done through detailed testing of jointly taken samples, from the NABL-accredited laboratory. The samples were taken at designated locations (sampling points) at a pre-decided schedule. After commissioning of the project our O&M team deployed at the site ensured water quality testing and monitoring, apart from the complete operation of the system.
Project Timelines
Ion Exchange completed the detailed engineering, procurement, supply, construction, erection, commissioning & O&M of the integrated water management project with all required approvals from the customers & consultants, in a record time of just over a year to meet the critical project milestones. Performance Guarantee tests were also completed in 2019 in a phased manner to hand over the complete facility to the end customer

Economic benefits of the project

The economic benefits accrued from our Integrated Water Management are as given below:

The Customer has been able to reduce scarce freshwater consumption by saving 2900 Cu Meters/day- by adapting our Integrated water management philosophy that resulted in Source Reduction, Product recovery, Waste minimization and Water Reuse.
Further they could reduce their water cost as against the cost of Rs 50/KL for buying raw water which is required to be further treated for potable purpose, production, utility etc.
Apart from meeting stringent ZLD obligation, the company also saves costs related to CESS on water discharge.
The customer has received excellent payback on investment through
- Assured availability of water for process needs as well as low end uses.
- Reduced freshwater consumption. Therefore, considerable savings in freshwater costs.
- Additional savings through the recovery of valuable by-products for reuse in the process
- Compliance with pollution control regulations and a clean environment through reduced / zero effluent discharge.

Social benefits of the project

Zero Liquid Discharge: The project was mandated to adopt Zero Liquid Discharge. The innovative technologies used by Ion Exchange in the project for achieving ZLD goals has reduced the fresh water cost, conserved precious water in the locality for agriculture & community use. It also ensured that the water sources were no longer contaminated from complex liquid effluents, leading to improved ground & surface water quality in the adjoining regions.
Achieving the lowest specific water consumption:
- Zero Wastage: The recovery of the water in the project, resulted in freeing up tremendous quantities of freshwater for reuse & also the freshwater cost associated with purchasing raw water for the customer & also pressure on local bodies is reduced.
- Low sludge: The generation of high solid content sludge means that the disposal of the removed suspended solids is much easier and will also reduce the cost, size as well as carbon footprint of the customer.
Waste Recycling & its multiple usages:
- The project supports the industries in the area to reduce groundwater and/or surface water consumption
- Customer has reused the water for industrial processes & low-end applications like gardening, landscaping etc.
- ZLD system has helped the customer to maintain greens around the area

The “Greenfield” project was successfully completed on schedule. It is fully operational and meets & supports the ever increasing production demand with the plant now approaching full capacity utilization. Post commissioning of the integrated water management plant, Ion Exchange also extended its Operation & Maintenance service for 12 months as per the contract.

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Petrochemical & Refinery Case Study 2

Ion Exchange — Fri, 18 Feb 2022 05:26:22 +0000

Umm Lulu an offshore oil field developed by Abu Dhabi Marine Operating Company (ADMA – OPCO)

A joint venture of Abu Dhabi National Oil Company (ADNOC), BP Total and Japan Oil Development Company, it is located in the Arabian Gulf 30 km north-west of Abu Dhabi, UAE.

The Umm Lulu field is being developed as part of ADNOC’S strategic initiative to reach 1.75 million barrels of offshore crude oil production a day. A consortium of NPCC and Technip was awarded a package of $1.69 bn EPC contract for Umm Lulu Phase II.

Subsequently, Ion Exchange was awarded the contract by NPCC and Technip for the critical seawater ltration package required to provide injection water for the Umm Lulu production reservoir to augment crude oil production.

The produced water from the injection well is conveyed using a lift pump, ltered, de-aerated and transferred by booster and injection pumps to the remote injection well at the Well Head Tower (WHT) via Umm Lulu Riser Platform (ULRP).

The anticipated requirement for the water injection system is to provide 3 11,90,700 m /h of water per day with stringent water quality specications (98% particles less than 2 microns).

To achieve the desired water quality, Ion Exchange designed, engineered and constructed two trains of skid 3 mounted units each with a capacity of 5,95,350 m /h that could be transported on a barge consisting of continuous coarse lter, specially designed media lters and polishing ne ltration to meet the stringent quality requirements of injection water. The offshore sea water ltration package was successfully commissioned in December 2019.

Zero Liquid Discharge for Indian Synthetic Rubber Limited

The Indian Synthetic Rubber Limited (ISRL) is a synthetic rubber manufacturing plant in Panipat, Haryana (Joint venture of Indian Oil Corporation & Marubeni, Japan & TSRC Corporation). ISRL is one of the few producers of styrene-butadiene rubber in India.

The supreme challenge faced by ISRL was stark water scarcity as well as no consent to discharge the complex effluent produced.

Ion Exchange has 3 set up and executed a 125 m /hr Zero Liquid Discharge (ZLD) unit for ISRL. The treatment integrates a radical oil removal system followed by biological treatment and a state-of-the-art membrane system which incorporates UF-RO and multi-effect evaporator to meet ZLD norms.

The operation and maintenance are also carried out by Ion Exchange. With these solutions, ISRL was able to recover 91% of water with TDS <150 ppm. This water is used in cooling-tower makeup and various process applications thereby empowering ISRL to reuse water while meeting the stringent Zero Liquid Discharge norms.

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