NATIONAL POWER TRAINING INSTITUTE (ER)

Focus on Water Treatment Plants

Presented By:(PDC 24TH BATCH)

Arpit Dey, Vipin kumar Singh, Hemant Kumar , NillaMadhaba Khandai

Guidance by
SATRUPA SATPATI
BOP comprises of

• Coal/ lignite handling plant • Compressed air System

• Ash handling plant • Mill reject handling system

• Cooling tower • HVAC

• Plant Water Systems • Fire protection system

• Chimney • Switchyard

• Fuel oil handling & storage

system
Plant Water System (PWS)
• Raw water/ fire water • Condensate Polishing Units
reservoir, Raw water pumps
• Cooling Water Treatment
• Raw water Pre-treatment systems- SSF
Plant
• Chlorination
• Softening
• Mill Scale filtration
• Demineralisation
• Effluent Treatment and
• Ultra Filtration recycling

• Reverse Osmosis • Sewage Treatment

• Desalination
Integrated - Total Water Management Capability
Shift from Individual systems to Integrated Systems

Individual System Ordering

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

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

A word about us

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

B&H Cooling Turnkey Power Plants Chemicals Enviro

• Package boilers • Steam fired chillers • Solid fuel based • Ion exchange resins •ESP & Bag filters
• Large capacity • Hot water fired • Gas - combined cycle • Cooling water chemicals • Scrubbers
Power boilers chillers • Waste heat recovery • Fireside chemicals • Air purification
• Thermal oil / • Direct fired chillers based • Polyelectrolyte • Retrofit & Revamp
Water heaters • RE based incl. Biomass,
• Energy recovery Heating Bagasse, solar, etc. Water and wastewater
systems • Packaged solid fuel • O&M of power plants
fired boilers • BOP of Large power • Wastewater & Effluent
• Packaged oil/gas plants treatment systems
fired boilers • Water recycling
• Fired thermic fluid • Waste management
heaters
• Exhaust waste heat
recovery boilers

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
 The Water Systems
Compete Range of Water and Waste Water solutions

RO & Ultra-fiH:rati:on1
CPUs for supef'crmcam
over 250 ns.tall'atrons Techno'l.o,gy
Capacity: s,oto e:o,o m3lhr

Sea Water RO,Plant cladfication

eo,o im3lhr ov,er-eo instaHaHon.s
i:ota,cl aipa,e!Jty 1500m3lhr Capacity: 3500 m3Jh1r

Wat,er softening & fUtl'at1ons, Waste Water

Orver 300 instaUaUons
Treatm,ent
Capacity.:: 100 to 3-50 m.3/hr Capacity 40,0 m31hr
 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. 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. Parameters Units Quality

No.

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

LIME+DOLOMITE

PE FeCl3

HRSCC pH CORRECTION TMBR AAF - I

RO - I

pH CORRECTION DGT
REJECT TANK

REJECT HANDLING
RO - II AAF - II
SYSTEM
SR EQUIPMENT PURPOSE
NO
1 HRSCC (WITH FLUORIDE/SILICA/TSS
LIME-DOLOMITE REDUCTION
DOSING)
2 TMBR COD/BOD/TSS REDUCTION

3 ACTIVATED FLUORIDE REDUCTION

ALUMINA FILTER

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 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
Owner’s Consultant : DESEIN
RIL’s 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 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

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 Description Flow Unit Information

1 RWTP 2 x 115 m3/hr Dual Media Filters

2 DMP 25 m3/hr net Output. SAC - DGT-LBA-MB
3 X 50%
Iron Removing Filters
3 X 220 m3/h3
3 CPU
2 X 100%
MB (CPU)
2 X 220 m3/hr
2 X 300 m3/hr SSF
4 CWTP
Chemical Dosing
ClO2 Dosing 300 gm/hr For RWTP
5
system 25 kg/hr For CWTP
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 m³/day Effluent Treatment

and Recycle Plant
(Zero Liquid Discharge Facility)
Site Photograph
 More than
350 Large
and Medium
Highly experienced Projects
team of engineers
(150 Engs)
In-house
Design Team (17)
Detail Engineering (45)
Project Management (90)
Quality Assurance (10)
Executing Fast-Track Projects

Vast On Time
experience in
WTP/WWTP Conformance Strong team of Project
to high quality dedicated and Completion
& international validated -
engineering Vendors &
practices Suppliers

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