{"id":21462,"date":"2022-03-10T12:29:18","date_gmt":"2022-03-10T12:29:18","guid":{"rendered":"https:\/\/ionexchangeglobal.com\/?p=21462"},"modified":"2022-11-08T05:51:47","modified_gmt":"2022-11-08T05:51:47","slug":"automotive-case-study","status":"publish","type":"post","link":"https:\/\/ionexchangeglobal.com\/int\/automotive-case-study\/","title":{"rendered":"Automotive Case Study"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"21462\" data-post-id=\"21462\" data-obj-id=\"21462\" class=\"elementor elementor-21462 dce-elementor-post-21462\">\n\t\t\t\t\t\t<div class=\"elementor-inner\">\n\t\t\t\t<div class=\"elementor-section-wrap\">\n\t\t\t\t\t\t\t\t\t<section class=\"has_ma_el_bg_slider elementor-section elementor-top-section elementor-element elementor-element-bdbb465 elementor-section-boxed elementor-section-height-default elementor-section-height-default jltma-glass-effect-no\" data-id=\"bdbb465\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t\t\t<div class=\"elementor-row\">\n\t\t\t\t\t<div class=\"has_ma_el_bg_slider elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-926c675 jltma-glass-effect-no\" data-id=\"926c675\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-column-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t<div class=\"elementor-widget-wrap\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-f15c3fb jltma-glass-effect-no elementor-widget elementor-widget-elementskit-simple-tab\" data-id=\"f15c3fb\" data-element_type=\"widget\" data-widget_type=\"elementskit-simple-tab.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<div class=\"ekit-wid-con\" >        <div class=\"elementkit-tab-wraper   elementskit-fitcontent-tab \">\n            <ul class=\"nav nav-tabs elementkit-tab-nav  elementskit_tab_border_bottm elementskit_tab_border_bottm\">\n                                    <li class=\"elementkit-nav-item elementor-repeater-item-5e654d8\">\n                        <a class=\"elementkit-nav-link  active show left-pos\" id=\"content-5e654d86a025558c2b16-tab\" data-ekit-handler-id=\"introduction\" data-ekit-toggle=\"tab\" data-target=\"#content-5e654d86a025558c2b16\" href=\"#Content-5e654d86a025558c2b16\"\n                            data-ekit-toggle-trigger=\"click\"\n                            aria-describedby=\"Content-5e654d86a025558c2b16\">\n                            <span class=\"far fa-eye elementskit-tab-icon\"><\/span>                            <span class=\"elementskit-tab-title\"> Introduction<\/span>\n                        <\/a>\n                    <\/li>\n                                        <li class=\"elementkit-nav-item elementor-repeater-item-ffd8178\">\n                        <a class=\"elementkit-nav-link  left-pos\" id=\"content-ffd81786a025558c2b16-tab\" data-ekit-handler-id=\"the-challenge\" data-ekit-toggle=\"tab\" data-target=\"#content-ffd81786a025558c2b16\" href=\"#Content-ffd81786a025558c2b16\"\n                            data-ekit-toggle-trigger=\"click\"\n                            aria-describedby=\"Content-ffd81786a025558c2b16\">\n                            <span class=\"icon icon-warning elementskit-tab-icon\"><\/span>                            <span class=\"elementskit-tab-title\"> The Challenge<\/span>\n                        <\/a>\n                    <\/li>\n                                        <li class=\"elementkit-nav-item elementor-repeater-item-94dfaef\">\n                        <a class=\"elementkit-nav-link  left-pos\" id=\"content-94dfaef6a025558c2b16-tab\" data-ekit-handler-id=\"the-solutions\" data-ekit-toggle=\"tab\" data-target=\"#content-94dfaef6a025558c2b16\" href=\"#Content-94dfaef6a025558c2b16\"\n                            data-ekit-toggle-trigger=\"click\"\n                            aria-describedby=\"Content-94dfaef6a025558c2b16\">\n                            <span class=\"fas fa-notes-medical elementskit-tab-icon\"><\/span>                            <span class=\"elementskit-tab-title\"> The Solutions<\/span>\n                        <\/a>\n                    <\/li>\n                                        <li class=\"elementkit-nav-item elementor-repeater-item-d8f6f8b\">\n                        <a class=\"elementkit-nav-link  left-pos\" id=\"content-d8f6f8b6a025558c2b16-tab\" data-ekit-handler-id=\"benefits\" data-ekit-toggle=\"tab\" data-target=\"#content-d8f6f8b6a025558c2b16\" href=\"#Content-d8f6f8b6a025558c2b16\"\n                            data-ekit-toggle-trigger=\"click\"\n                            aria-describedby=\"Content-d8f6f8b6a025558c2b16\">\n                            <span class=\"icon icon-save-money elementskit-tab-icon\"><\/span>                            <span class=\"elementskit-tab-title\"> Benefits<\/span>\n                        <\/a>\n                    <\/li>\n                                        <li class=\"elementkit-nav-item elementor-repeater-item-f2e59f3\">\n                        <a class=\"elementkit-nav-link  left-pos\" id=\"content-f2e59f36a025558c2b16-tab\" data-ekit-handler-id=\"result\" data-ekit-toggle=\"tab\" data-target=\"#content-f2e59f36a025558c2b16\" href=\"#Content-f2e59f36a025558c2b16\"\n                            data-ekit-toggle-trigger=\"click\"\n                            aria-describedby=\"Content-f2e59f36a025558c2b16\">\n                            <span class=\"fas fa-hand-holding-medical elementskit-tab-icon\"><\/span>                            <span class=\"elementskit-tab-title\"> Result<\/span>\n                        <\/a>\n                    <\/li>\n                                <\/ul>\n\n            <div class=\"tab-content elementkit-tab-content\">\n                                    <div class=\"tab-pane elementkit-tab-pane elementor-repeater-item-5e654d8  active show\" id=\"content-5e654d86a025558c2b16\" role=\"tabpanel\"\n                         aria-labelledby=\"content-5e654d86a025558c2b16-tab\">\n                        <div class=\"animated fadeIn\">\n                            <p>The customer is one of the leading manufacturers of world-class quality motor vehicles. It expanded its manufacturing set up with its \u201cGreenfield\u201d 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 &amp; industrialization.<\/p>                        <\/div>\n                    <\/div>\n                                    <div class=\"tab-pane elementkit-tab-pane elementor-repeater-item-ffd8178 \" id=\"content-ffd81786a025558c2b16\" role=\"tabpanel\"\n                         aria-labelledby=\"content-ffd81786a025558c2b16-tab\">\n                        <div class=\"animated fadeIn\">\n                            <p>The major challenges faced by the customer included:<\/p><ol><li><strong>Stringent Regulations and Disposal Norms:<\/strong> 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).<\/li><li><strong>Water Scarcity &amp; High Fresh Water Cost: <\/strong>During the setup phase of the plant Anantapur,\u00a0 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.<\/li><li><strong>Inconsistent Raw Water Quality:<\/strong> 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.<\/li><\/ol>                        <\/div>\n                    <\/div>\n                                    <div class=\"tab-pane elementkit-tab-pane elementor-repeater-item-94dfaef \" id=\"content-94dfaef6a025558c2b16\" role=\"tabpanel\"\n                         aria-labelledby=\"content-94dfaef6a025558c2b16-tab\">\n                        <div class=\"animated fadeIn\">\n                            <ol>\n    <li>Ion Exchange mitigated the above-listed challenges using its pioneering concept of Integrated <span\n        style=\"font-size: inherit;\">Water Management with the benefits of:<\/span>\n      <ul>\n        <li>Source Reduction<\/li>\n        <li>Product Recovery<\/li>\n        <li>Waste Minimization<\/li>\n        <li>Water Reuse<\/li>\n      <\/ul>\n    <\/li>\n    <li><strong><strong><u>Turnkey execution of the project included:\u00a0<\/u><\/strong><\/strong><strong>Water Treatment\n        Plant\n        (WTP):<\/strong>The WTP was important to cater to the industrial and potable water requirements of the customer.\n\n      The process &amp; technology used for the industrial water treatment plant is pre-treatment, ultra-filtration\n      (UF),\n      reverse osmosis (RO), designed with 80% water recovery. The RO membrane cleaning system is designed for use with\n      standard cleaning solutions as well as special cleaners. The capacity for water treatment plant is as listed\n      below:\n      <ul>\n        <li>WTP i.e. Industrial Water Supply Scheme:\n          <ul>\n            <li>Raw Water Feed @ 2000 CuM \/ Day i.e. 100 CuM \/ Hr<\/li>\n            <li>RO Capacity 56 CuM\/Hr @ 80% recovery<\/li>\n          <\/ul>\n      <\/ul>\n      The Potable Water supply scheme for factory and subsidiary is designed with pre-treatment including Clarifier,\n      followed by UF, Activated Carbon Filter and Ultra-Violet treatment to feed potable water to designated locations\n      within the factory &amp; its subsidiary. The potable water capacity for the main factory is 750 CuM \/ Day\n      <br \/><br \/>\n      Wastewater Treatment Plant (WWTP):<br \/>\n      The wastewater which is treated comes from seven sources through car assembly plant namely Phosphate Renewal,\n      Phosphate Rinse, Degrease Press Shop, Degrease Rinse, Misc Wastewater, Electro Deposition rinse and the water\n      treatment plant i.e. RO waste-water, CWS waste-water. This is then recycled.\n      <br \/>\n      The capacity for wastewater treatment plant is as listed below\n      <br \/>\n      <ul>\n        <li>\n          WWTP with Multi-Effect Evaporator (MEE) &#038; ZLD\n          <ul>\n            <li>\n              Raw Effluent Feed @ 2150 CuM \/ Day\n            <\/li>\n            <li>\n              RO-Stage-I Capacity \u2013 71.9 CuM\/Hr x 2 nos. skids\n            <\/li>\n            <li>\n              RO-Stage-II Capacity \u2013 14.4 CuM\/Hr x 2 nos. skids\n            <\/li>\n            <li>\n              RO-Stage-III Capacity &#8211; 14.4 CuM\/Hr x 2 nos. skids\n            <\/li>\n            <li>\n              MEE Capacity \u2013 150 KLD (CuM\/Day)\n            <\/li>\n          <\/ul>\n        <\/li>\n      <\/ul>\n      Key processes under the wastewater treatment plant are as under:<br \/>\n      <ul>\n        <li>For phosphate renewal and phosphate rinse wastewater: Coagulation &#038; flocculation, Lamella Clarifier, wherein\n          clarified water is collected in equalization tank and the sludge goes to sludge pond, centrifuge &#038; finally to\n          sludge\n          disposal area<\/li>\n        <li>For Degrease, Assembly Press Shop and Degrease rinse waste-water: Equalization tank, followed by\n          flocculation,\n          dissolve air flotation, aeration, sedimentation (sludge removal), UF with 93% recovery, RO-I with 80%\n          recovery,\n          RO-II with 75% recovery and RO-III with 60% recovery<\/li>\n        <li>Permeate from RO-I and RO-II is directly fed to the Industrial Water supply pond, while reject is treated at\n          a\n          subsequent stage of RO<\/li>\n        <li>Reject from the RO-III is collected in a high saltwater pond and subjected to MEE (4, in this case) to\n          recover\n          maximum water in the form of condensate and thereby disposing of the generated sludge<\/li>\n        <li>Chemical dosing systems are deployed for pre-treatment, as well as main treatment systems as per need &#038;\n          necessity\n          of the treatment\/scheme<\/li>\n      <\/ul>\n      Sewage Treatment Plant (STP):<br \/>\n      <p>A state-of-the-art design based on INDION MBR technology treats the sewage collected from various sources. STP\n        plant\n        with the capacity of 900 CuM\/d was designed based on INDION MBR technology, thereby providing an alternate\n        source other\n        than industrial effluent recycle for process, utility and low-end applications.<\/p>\n      Water Quality Monitoring System <br>\n      <p>The Plant is automated with 24&#215;7 monitoring of critical operations and the critical parameters, through a\n        central\n        Programmable Logic Controller system. It also has various other online quality monitoring systems including the\n        pH\n        meters, conductivity analyzers etc. installed at various key locations as per the requirement for monitoring of\n        different quality parameters.\n        The \u2018permeate\u2019 from all stages of RO i.e. RO-I, RO-II and RO-III for the WWTP as well as the WTP\/industrial\n        water &#8211; RO\n        has an online conductivity monitoring system. The flow measurements are captured through online mag-flow meters.\n        Apart\n        from the above, monitoring of some critical parameters is done in-house on a continuous &#038; daily basis to\n        maintain a\n        record for future reference. A local water-testing laboratory setup is provided to do all these routine tests\n        in-house.\n        At the project\u2019s concluding stage, when Ion Exchange was carrying out the commissioning and performance\n        guarantee tests\n        at the site, complete water analysis was done through detailed testing of jointly taken samples, from the\n        NABL-accredited laboratory. The samples were taken at designated locations (sampling points) at a pre-decided\n        schedule.\n        After commissioning of the project our O&#038;M team deployed at the site ensured water quality testing and\n        monitoring, apart\n        from the complete operation of the system.\n      <\/p>\n    <\/li>\n    <li>Project Timelines\n      <p>Ion Exchange completed the detailed engineering, procurement, supply, construction, erection, commissioning &#038;\n        O&#038;M of the\n        integrated water management project with all required approvals from the customers &#038; consultants, in a record\n        time of\n        just over a year to meet the critical project milestones. Performance Guarantee tests were also completed in\n        2019 in a\n        phased manner to hand over the complete facility to the end customer<\/p>\n    <\/li>\n  <\/ol>                        <\/div>\n                    <\/div>\n                                    <div class=\"tab-pane elementkit-tab-pane elementor-repeater-item-d8f6f8b \" id=\"content-d8f6f8b6a025558c2b16\" role=\"tabpanel\"\n                         aria-labelledby=\"content-d8f6f8b6a025558c2b16-tab\">\n                        <div class=\"animated fadeIn\">\n                            <p><strong>Economic benefits of the project<\/strong><\/p><p>The economic benefits accrued from our Integrated Water Management are as given below:<\/p><ul><li>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.<\/li><li>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.<\/li><li>Apart from meeting stringent ZLD obligation, the company also saves costs related to CESS on water discharge.<\/li><li>The customer has received excellent payback on investment through<ul><li>Assured availability of water for process needs as well as low end uses.<\/li><li>Reduced freshwater consumption. Therefore, considerable savings in freshwater costs.<\/li><li>Additional savings through the recovery of valuable by-products for reuse in the process<\/li><li>Compliance with pollution control regulations and a clean environment through reduced \/ zero effluent discharge.<\/li><\/ul><\/li><\/ul><p><strong>Social benefits of the project<\/strong><\/p><ul><li><strong>Zero Liquid Discharge: <\/strong>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 &amp; community use. It also ensured that the water sources were no longer contaminated from complex liquid effluents, leading to improved ground &amp; surface water quality in the adjoining regions.<\/li><li><strong>Achieving the lowest specific water consumption:<\/strong><ul><li><strong>Zero Wastage<\/strong>: The recovery of the water in the project, resulted in freeing up tremendous quantities of freshwater for reuse &amp; also the freshwater cost associated with purchasing raw water for the customer &amp; also pressure on local bodies is reduced.<\/li><li><strong>Low sludge:<\/strong> 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.<\/li><\/ul><\/li><li><strong>Waste Recycling &amp; its multiple usages:<\/strong><ul><li>The project supports the industries in the area to reduce groundwater and\/or surface water consumption<\/li><li>Customer has reused the water for industrial processes &amp; low-end applications like gardening, landscaping etc.<\/li><li>ZLD system has helped the customer to maintain greens around the area<\/li><\/ul><\/li><\/ul>                        <\/div>\n                    <\/div>\n                                    <div class=\"tab-pane elementkit-tab-pane elementor-repeater-item-f2e59f3 \" id=\"content-f2e59f36a025558c2b16\" role=\"tabpanel\"\n                         aria-labelledby=\"content-f2e59f36a025558c2b16-tab\">\n                        <div class=\"animated fadeIn\">\n                            <p>The \u201cGreenfield\u201d project was successfully completed on schedule. It is fully operational and meets &amp; 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 &amp; Maintenance service for 12 months as per the contract.<\/p>                        <\/div>\n                    <\/div>\n                            <\/div>\n        <\/div>\n    <\/div>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>Introduction The Challenge The Solutions Benefits Result The customer is one of the leading manufacturers of world-class quality motor vehicles. It expanded its manufacturing set up with its \u201cGreenfield\u201d 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&hellip;<\/p>\n","protected":false},"author":5,"featured_media":21425,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"elementor_header_footer","format":"standard","meta":{"inline_featured_image":false},"categories":[83,1],"tags":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v20.12 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Automotive Case Study - Ion Exchange<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ionexchangeglobal.com\/int\/automotive-case-study\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Automotive Case Study - Ion Exchange\" \/>\n<meta property=\"og:description\" content=\"Introduction The Challenge The Solutions Benefits Result The customer is one of the leading manufacturers of world-class quality motor vehicles. It expanded its manufacturing set up with its \u201cGreenfield\u201d car manufacturing facility at Anantapur, Andhra Pradesh. 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It expanded its manufacturing set up with its \u201cGreenfield\u201d car manufacturing facility at Anantapur, Andhra Pradesh. 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