Focus on Water Treatment Plants

Presented By: Thermax LimitedSulakshana SuleWater & Waste Solutions (WWS)

• Coal/lignite handling plant

• Ash handling plant

• Cooling tower

• Plant Water Systems

• Chimney

• Fuel oil handling & storage system

BOP comprises of

• Compressed air System

• Mill reject handling system

• HVAC

• Fire protection system

• Switchyard

• Raw water/fire water reservoir, Raw water pumps

• Raw water Pre-treatment Plant

• Softening

• Demineralisation

• Ultra Filtration

• Reverse Osmosis

• Desalination

• Condensate Polishing Units

• Cooling Water Treatment systems- SSF

• Chlorination

• Mill Scale filtration

• Effluent Treatment and recycling

• Sewage Treatment

Plant Water System (PWS)

Integrated - Total Water Management Capability

Shift from Individual systems to Integrated Systems

Integration of packagesLess no. of vendors to deal withParticipation by reputed and qualified vendors onlySingle point responsibilityMinimal resource requirement for customer

Risk assessment & Risk Mitigation is a key to success

Individual System Ordering

Low cost of purchaseChoice of vendor selectionControl over individual System Specs

Experienced manpower requiredProject monitoring difficultHigh level of Customer-Consultant-Vendor interface

Key issues / challenges for EPC contractors

• Changes in water analysis/schemes/water source/specifications

• Delays in approvals due to number of agencies involved

• Unavailability of Civil fronts

• Dependency on completion of BTG package

• Unavailability of skilled manpower

Solutions to Key issues / challenges

• Standardisation of schemes, quality plans, documentation for quick approvals

• Industry wise standard specs

• Standardisation of vendor list to avoid delays in sub-vendors approvals

• Approvals to be taken in soft form to save time

• Civil to be included in EPC contractor’s scope to avoid civil fronts delays

• Better payment terms for better cash flow management

• Bonus clause for early completion

Future Developments

Developments in process:• Process optimisation for reducing water consumption

• Change in process equipments e.g. from water cooled condensers to air cooled condensers

Developments in water treatment systems:• Use of sea water as an alternative

• Reusing wastewater to reduce fresh water consumption

• Zero liquid discharge solutions

Thermax Limited: An Overview

A word about us

Cooling

• Steam fired chillers• Hot water firedchillers

• Direct fired chillers

Heating• Packaged solid fuelfired boilers

• Packaged oil/gasfired boilers

• Fired thermic fluid heaters

• Exhaust waste heatrecovery boilers

B&H

• Package boilers• Large capacity Power boilers

• Thermal oil / Water heaters

• Energy recovery systems

Turnkey Power Plants

• Solid fuel based• Gas - combined cycle • Waste heat recovery based• RE based incl. Biomass, Bagasse, solar, etc.• O&M of power plants• BOP of Large power plants

Chemicals

• Ion exchange resins• Cooling water chemicals• Fireside chemicals• Polyelectrolyte

Water and wastewater

• Wastewater & Effluent treatment systems

• Water recycling• Waste management

Enviro

•ESP & Bag filters• Scrubbers• Air purification• Retrofit & Revamp

Boilers & Heaters Cooling & Heating Power Generation Chemicals & Water Air Pollution Control

Services Group - Operations and Maintenance, Steam on Hire, Renovation & Modernization, Power plant improvement services, etc…

• Contracted over 72 Power Projects in India and Abroad on turnkey basis including total BOP

• Over 1000 MW Projects already commissioned. Another 1050 MW under commissioning.

• Series of Bullet bonus for early completion of turnkey projects.

• O&M contracts for Power Projects representing over 1000MW

• Over 850,000 Hours of operational & maintenance experience.

• Boilers supplied produce steam equivalent to over 10,000 MW worldwide.

• Over 6000 Environment abatement systems working

• Can undertake complete mechanical , electrical BOP for utility Power plants on EPC basis

A word about us

Thermax Presence in Water Systems

Hindalco Industries Ltd - WTP

Client : Hindalco Industries LtdGroup: Aditya BirlaPlant : Smelter Project With 6 X 150 MW Captive Power PlantProject Site : Mahan MPConsultant : DCPL Kolkata

Design, Engineering, Supplies, Erection & Commissioning, including Civil Work for

-Raw Water Pre Treatment Plant and DM Water Plant for power plant applications. 3 x 1750 M3/Hr HRSCC and 3 x 80 M3/Hr DM Plant

-Cooling Water Treatment Plant

Hindalco Industries Ltd-Mahan- Smelter ETP & Recycling

Client: Hindalco Industries LtdGroup: Aditya Birla

Consultant: Engineers India LtdPlant: Smelter Project with 6 X 150 MW Captive Power PlantProject Site: Mahan, Madhya Pradesh

Project : Design Engineering Supplies including Civil Work and Erection and Commissioning of Effluent Treatment & Recycling Plant for Smelter

Feed Water Analysis

Sr. No. Parameters Units Quality

1 pH -- 6.5-7.0

2 TSS PPM 100

3 Oil & Grease PPM Traces

4 BOD PPM 90

5 COD PPM 150

6 Fluorides PPM 35

7 TDS PPM 600

8 Sodium as Na PPM 142

9 Total Hardness as CaCO3 PPM 120

10 Calcium hardness as CaCO3 PPM 100

11 Magnesium hardness as CaCO3 PPM 20

12 Total Alkalinity (MO) as CaCO3 PPM 120

13 Chlorides as Cl PPM 105

14 Sulpahtes as SO4 PPM 150

12 Iron as Fe PPM 1.1

14 Reactive Silica as SiO2 PPM 40

15 Temperature Deg c 25

Treated Water Quality

Sr.No.

Parameters Units Quality

1 pH (After pH correction) -- 7.0-7.5

2 TSS PPM <5

3 Oil & Grease PPM <2

4 BOD PPM <5

5 COD PPM <30

6 Fluorides PPM <1

7 TDS PPM <50

Treatment Scheme

HRSCC pH CORRECTION TMBR AAF - I

REJECT TANK

RO - I

RO - II

DGTpH CORRECTION

AAF - II

LIME+DOLOMITE

PE FeCl3

REJECT HANDLING SYSTEM

SRNO

EQUIPMENT PURPOSE

1 HRSCC (WITH LIME-DOLOMITE DOSING)

FLUORIDE/SILICA/TSS REDUCTION

2 TMBR COD/BOD/TSS REDUCTION

3 ACTIVATED ALUMINA FILTER

FLUORIDE REDUCTION

4 RO BLOCK TDS REDUCTION

Hindalco Industries Ltd-Mahan Power Plant –ETP & Recycling

Client : Hindalco Industries Ltd

Group: Aditya Birla

Project : Smelter Project with 6 X 150 MW Captive Power Plant

Project Site : Mahan, Madhya Pradesh

Consultants : DCPL Kolkata

System : Effluent Treatment & Recycling Plant for Treatment of Power Plant Effluents

Scope : Design Engineering Supplies including Civil Work and Erection and Commissioning of Effluent Treatment plant comprising of

3 x 170 m3/hr ETP and1 x 300 m3/hr Nano-filtration

Avantha Group – Chattisgarh Project

Client : Korba West Power Corporation LtdConsultant : Fichtner, BangalorePlant : 2 X 600 MW Thermal Power Plant Project Site : Raigarh, Chattisgarh.

Project : Design Engineering Supply including Civil Work and Erection and Commissioning of Pre Treatment Plant, Demineralization Plant, Effluent Treatment Plant, Chlorination System and Cooling Water Treatment Plant

1 X 2500 M3/Hr Raw Water Pretreatment Plant2 X 40 M3/Hr UF-RO-MB Plant5 X 210 M3/Hr SSF1 X 90 Kg/Hr & 1 X 25 Kg/Hr Chlorination Plant

HPGCL Hissar, through R-INFRA

Client : Haryana Power Generation Corporation LtdEPC Contractor : Reliance Infrastructures LtdOwner’s Consultant : DESEINRIL’s Consultant : DCPLPlant : 2 X 600 MW Thermal Power PlantProject Site : Hissar, Haryana

Project : Pre Treatment Plant, Demineralization Plant, Effluent Treatment Plant & Cooling Water Treatment Plant

3 X 1600 M3/Hr Pre Treatment Plant3 X 90 M3/Hr Demineralization PlantCooling Water Treatment Having 14 X 2700 M3/Hr SSFEffluent Treatment Plant

Talwandi Sabo Power Ltd – Mansa - ZLD

Client: Talwandi Sabo Power LtdGroup: Vedanta

Consultant: DCPLPlant: Zero Discharge Recycle Plant for 3 x 660 MW Supercritical Power PlantProject Site: Talwandi, Punjab

Project : Design Engineering Supplies including Civil Work and Erection and Commissioning of Zero Discharge Recycling Plant

Inlet Water Quality

Sr No PARAMETER VALUE

1 SOURCE COOLING TOWER BLOW DOWN

2 CTBDFLOW 440 m3/hr

3 TSS 25 ppm

4 TDS 1000 ppm

5 TOTAL CATION 590.5 ppm

6 TOTAL ANION 590.5 ppm

7 REACTIVE SILICA 12.9 ppm as SiO2

8 COLLODIAL SILICA 70 ppm as SiO2

Outlet Water Quality

Sr No PARAMETER VALUE

1 pH 7 +/- 0.2

2 TURBIDITY < 2 NTU

3 SILICA < 5 ppm as SiO2

4 TDS < 135 ppm

5 TOTAL HARDNESS < 150 ppm as CaCO3

6 TOTAL ALKALINITY < 125 ppm as CaCO3

Process Flow Diagram

1 x 125 MW Concentrated Solar Thermal Power Plant

Client : Rajasthan Sun Technique Energy Private LimitedEPC Contractor : Reliance Infrastructures LtdEPCM Consultant : AREVA Renewable Energies India PMC Consultant : EILPlant : 1 x 125 MW Concentrated Solar Thermal Power Plant based on the Compact Linear Fresnel Reflector (CLFR) technologyProject Site : Dhursar, Rajasthan

Project : Pre Treatment Plant, Demineralization Plant, Condensate Polishing Units & Cooling Water Treatment Plant

Plant Capacities

Sr No Description Flow Unit Information

3 X 50% 3 X 220 m3/h3 Iron Removing Filters

2 X 100%2 X 220 m3/hr MB (CPU)

2 X 300 m3/hr SSFChemical Dosing

300 gm/hr For RWTP

25 kg/hr For CWTP

25 m3/hr net Output.

4 CWTP

2 DMP SAC - DGT-LBA-MB

5 ClO2 Dosing system

3 CPU

Dual Media Filters 1 RWTP 2 x 115 m3/hr

FEW INSTALLATIONS

• LP Condensate Polishing Unit– 5 x 125 cum per hr

Low Pressure Condensate Polishing Unit

• High rate filters – 44 x 250 cum per hr & 21 x 246 cum per hr• Side stream Filters – 2 x 300 cum per hr

High Rate Filters

Sea Water Desalination

Sea Water Reverse Osmosis Plant in Gujarat, India Producing 600 m3/hr high quality permeate today.

Scheme :

PT ---> PSF --> DMF --->

CF -->HPP-->Primary RO-->Secondary RO

Pre-treatment :Tube Settler (1275 m3/hr) Pressure Sand Filters (375 m3/hr - 4 Nos) , Dual Media Filters (375 m3/hr - 4 Nos) Pre-treatment for RO:Cartridge Filters, High Pressure Pumps.Primary RO:( 4 x 150 m3/hr)Secondary RO: ( 4 x 150 m3/hr)TOTAL CAPACITY: 1500 cum per hr.

Industrial Effluent Recycle Plant

10350 m³/day Effluent Treatment and Recycle Plant(Zero Liquid Discharge Facility)

Site Photograph

Improving Your Business is our Business

More than 350 Large

and MediumProjects

In-houseDesign Team (17)

Detail Engineering (45)Project Management (90)Quality Assurance (10)

Highly experienced team of engineers

(150 Engs)

On Time Project

Completion

Vastexperience in WTP/WWTP Conformance

to high quality & international

engineering practices

Strong team of dedicated and

validated -Vendors & Suppliers

Executing Fast-Track Projects

Thank You