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Focus on Water Treatment Plants

Presented By: Thermax Limited


Sulakshana Sule Water & Waste Solutions (WWS)

BOP comprises of
Coal/lignite handling plant Ash handling plant Cooling tower Compressed air System Mill reject handling system HVAC Fire protection system Switchyard

Plant Water Systems


Chimney Fuel oil handling & storage system

Plant Water System (PWS)


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

Integrated - Total Water Management Capability

Shift from Individual systems to Integrated Systems

Individual System Ordering


Low cost of purchase Choice of vendor selection Control over individual System Specs Experienced manpower required Project monitoring difficult High level of Customer-Consultant-Vendor interface

Integration of packages
Less no. of vendors to deal with Participation by reputed and qualified vendors only Single point responsibility Minimal resource requirement for customer Risk assessment & Risk Mitigation is a key to success

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 contractors 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

Boilers & Heaters

Cooling & Heating

Power Generation

Chemicals & Water

Air Pollution Control

B&H Package boilers Large capacity Power boilers Thermal oil / Water heaters Energy recovery systems

Cooling Steam fired chillers Hot water fired chillers Direct fired chillers Heating Packaged solid fuel fired boilers Packaged oil/gas fired boilers Fired thermic fluid heaters Exhaust waste heat recovery boilers

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

Enviro
ESP & Bag filters Scrubbers Air purification Retrofit & Revamp

Water and wastewater


Wastewater & Effluent treatment systems Water recycling Waste management

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

A word about us

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

Thermax Presence in Water Systems

Hindalco Industries Ltd - WTP


Client : Hindalco Industries Ltd Group: Aditya Birla Plant : Smelter Project With 6 X 150 MW Captive Power Plant Project Site : Mahan MP Consultant : 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 Ltd Group: Aditya Birla Consultant: Engineers India Ltd Plant: Smelter Project with 6 X 150 MW Captive Power Plant Project 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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12 14 15

Parameters pH TSS Oil & Grease BOD COD Fluorides TDS Sodium as Na Total Hardness as CaCO3 Calcium hardness as CaCO3 Magnesium hardness as CaCO3 Total Alkalinity (MO) as CaCO3 Chlorides as Cl Sulpahtes as SO4 Iron as Fe Reactive Silica as SiO2 Temperature

Units -PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM PPM Deg c

Quality 6.5-7.0 100 Traces 90 150 35 600 142 120 100 20 120 105 150 1.1 40 25

Treated Water Quality

Sr. Parameters No. 1 2 3 4 5 6 7 pH (After pH correction) TSS Oil & Grease BOD COD Fluorides TDS

Units Quality -PPM PPM PPM PPM PPM PPM 7.0-7.5 <5 <2 <5 <30 <1 <50

Treatment Scheme

LIME+DOLOMITE PE HRSCC FeCl3 pH CORRECTION TMBR AAF - I

RO - I pH CORRECTION REJECT HANDLING SYSTEM DGT REJECT TANK RO - II AAF - II

SR EQUIPMENT NO 1 HRSCC (WITH LIME-DOLOMITE DOSING) TMBR ACTIVATED ALUMINA FILTER RO BLOCK

PURPOSE FLUORIDE/SILICA/TSS REDUCTION COD/BOD/TSS REDUCTION FLUORIDE REDUCTION TDS REDUCTION

2 3 4

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 and 1 x 300 m3/hr Nano-filtration

Avantha Group Chattisgarh Project

Client : Korba West Power Corporation Ltd Consultant : Fichtner, Bangalore Plant : 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 Plant 2 X 40 M3/Hr UF-RO-MB Plant 5 X 210 M3/Hr SSF 1 X 90 Kg/Hr & 1 X 25 Kg/Hr Chlorination Plant

HPGCL Hissar, through R-INFRA

Client : Haryana Power Generation Corporation Ltd EPC Contractor : Reliance Infrastructures Ltd Owners Consultant : DESEIN RILs Consultant : DCPL Plant : 2 X 600 MW Thermal Power Plant Project Site : Hissar, Haryana
Project : Pre Treatment Plant, Demineralization Plant, Effluent Treatment Plant & Cooling Water Treatment Plant
3 X 1600 M3/Hr Pre Treatment Plant 3 X 90 M3/Hr Demineralization Plant Cooling Water Treatment Having 14 X 2700 M3/Hr SSF Effluent Treatment Plant

Talwandi Sabo Power Ltd Mansa - ZLD


Client: Talwandi Sabo Power Ltd Group: Vedanta Consultant: DCPL Plant: Zero Discharge Recycle Plant for 3 x 660 MW Supercritical Power Plant Project Site: Talwandi, Punjab
Project : Design Engineering Supplies including Civil Work and Erection and Commissioning of Zero Discharge Recycling Plant

Inlet Water Quality


Sr No
1 2 3 4 5 6 7 8

PARAMETER
SOURCE CTBDFLOW TSS TDS TOTAL CATION TOTAL ANION REACTIVE SILICA COLLODIAL SILICA

VALUE
COOLING TOWER BLOW DOWN 440 m3/hr 25 ppm 1000 ppm 590.5 ppm 590.5 ppm 12.9 ppm as SiO2 70 ppm as SiO2

Outlet Water Quality


Sr No 1 2 3 4 5 6 PARAMETER pH TURBIDITY SILICA TDS TOTAL HARDNESS TOTAL ALKALINITY VALUE 7 +/- 0.2 < 2 NTU < 5 ppm as SiO2 < 135 ppm < 150 ppm as CaCO3 < 125 ppm as CaCO3

Process Flow Diagram

1 x 125 MW Concentrated Solar Thermal Power Plant

Client : Rajasthan Sun Technique Energy Private Limited EPC Contractor : Reliance Infrastructures Ltd EPCM Consultant : AREVA Renewable Energies India PMC Consultant : EIL Plant : 1 x 125 MW Concentrated Solar Thermal Power Plant based on the Compact Linear Fresnel Reflector (CLFR) technology Project Site : Dhursar, Rajasthan
Project : Pre Treatment Plant, Demineralization Plant, Condensate Polishing Units & Cooling Water Treatment Plant

Plant Capacities

Sr No 1 2

Description RWTP DMP

Flow 2 x 115 m3/hr 25 m3/hr net Output. 3 X 50% 3 X 220 m3/h3 2 X 100% 2 X 220 m3/hr 2 X 300 m3/hr 300 gm/hr 25 kg/hr

Unit Information Dual Media Filters SAC - DGT-LBA-MB Iron Removing Filters MB (CPU) SSF Chemical Dosing For RWTP For CWTP

CPU

4 5

CWTP ClO2 Dosing system

FEW INSTALLATIONS

Low Pressure Condensate Polishing Unit

LP Condensate Polishing Unit 5 x 125 cum per hr

High Rate Filters

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

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

Site Photograph

In-house Design Team (17) Detail Engineering (45) Project Management (90) Quality Assurance (10)

Highly experienced team of engineers (150 Engs)

More than 350 Large and Medium Projects

Executing Fast-Track Projects

Vast experience in WTP/WWTP

Conformance to high quality & international engineering practices

Strong team of dedicated and validated Vendors & Suppliers

On Time Project Completion

Improving Your Business is our Business

Thank You