Waste to Energy for Tamil Nadu Newsprint & Papers Ltd.

Waste to Energy at Tamil Nadu Newsprint and Papers Ltd.Public sector unit Tamil Nadu Newsprint and Papers Limited (TNPL) manufactures high quality newsprint at its plant in Karur, Tamil Nadu. It has full scale effluent treatment plant to treat the waste water generated from various sources within the mill premises.

Bagasse, the raw material used here for producing paper pulp, is stored in huge piles and water is sprinkled over it, to avoid dry bagasse fines being carried away by the wind. The leachate from the piles, called bagasse wash water, contains high concentration of sugar based organics. TNPL wanted to produce methane rich biogas from this waste water to supplement its energy requirement by using biogas as an alternate energy source, and the contract was awarded to Ion Exchange Waterleau after a competitive techno-commercial tender process.

In this waste-to-energy plant, raw bagasse wash water is treated in a high rate solids contract clarifier to remove suspended solids to the maximum extent (to avoid choking of the anaerobic reactor) and then passed through an upflow anaerobic sludge blanket (UASB) reactor for biogas generation and reduction in organic pollutants in the effluent. UASB treated effluent flows to the existing effluent treatment plant for further downstream treatment.

Effluent Treatment for JSW Steel

JSW Steel made use of fresh water from the Tungabhadra River for their operations at Toranagallu, Bellary in Karnataka. Keen on reducing fresh water intake, as a first step JSW decided to treat the cooling water blowdown from three units viz. the hot strip mill, basic oxygen furnace (BOF) and cold rolling mill (CRM); this water was not being treated and was used mostly for low-end applications such as pellet plant and slag quenching,

Ion Exchange India was awarded the contract for treating 125 m3/h cooling tower blowdown which will give 105 m3/h reverse osmosis (RO) permeate of excellent quality, with TDS < 250 ppm. The process comprises physico-chemical treatment with high rate solids contract clarification, sand and carbon filtration, ultra filtration and two-stage RO. The treated water will be used for high-end applications like the process requirements of the CRM. The RO reject will be used for slag quenching.

The contract is on EPC plus O&M model as, apart from constructing the plant, the scope includes 10-year complete O&M services – inclusive of manpower, maintenance and supply of all spares, chemicals and consumables.

Once this plant is operational, JSW plants to recycle about 400 m3/h more waste water from various other sources to further reduce fresh water consumption.

Auto Success at Maruti Suzuki

Ion Exchange Waterleau was awarded turnkey execution of 960 m3/day effluent treatment plant for Maruti Suzuki’s greenfield project at Manesar, Haryana. Right from inception Ion Exchange India has been the preferred vendor of Maruti Suzuki, with contracts for water, effluent and sewage treatment and effluent recycling entrusted to us as per Maruti’s expansion programme. Understandably, way back in 1997, we were the obvious choice for the first ever effluent recycling based on reverse osmosis in the automobile sector.

So, no surprise then that the turnkey concept-to-commissioning contract for effluent treatment plant was awarded to Ion Exchange Waterleau, for Maruti Suzuki’s 300,000 cars/year expansion project at Manesar, Haryana. Effluents from all the operations are treated in a 960 m3/day centralized effluent treatment plant comprising dissolved air floatation followed by aerobic bio-degradation and regenerative filtration. The treated output will be reused for auxiliary and gardening.

Their Choice of Brew

When Heinekein, the world’s leading beer manufacturer, decided to put up a greenfield project in India - Asia Pacific Pearl Pvt. Ltd. at Hyderabad, to produce their world famous brands, IEI was the obvious choice for water and waste water management, particularly as breweries produce complex effluents high on organics.

Based on its global domain expertise of many years in treating brewery effluent, Ion Exchange Waterleau was awarded the order for a 1000 m3/day effluent treatment plant. The state-of-the art, PLC operated plant comprises a LUCAS anaerobic system (UASB), which converts 2000 kg/day of COD into the valuable by-product of biogas, followed by a LUCAS secondary aerobic system based on cyclic activated sequencing batch reactor (SBR) treatment process. The LUCAS SBR treatment process offer the advantages of a compact, modular, easy to operate and expand system with less maintenance compared to conventional systems, due to the absence of a secondary clarifier mechanism and sludge recirculation pumps.

To conserve water, it was decided to recycle the treated effluent for use in utility and auxiliary applications. The recycle system added on comprises a high rate solids contact clarifier for silica removal, regenerative filtration followed by ultra filtration and reverse osmosis. Biogas, as an energy source, and water from the effluent recycling plant are the net resource gains. The water treatment and management system was supplied by Ion Exchange thus completing total water management solutions for the brewery.

Restoring Clear Waters at Hebbal Lake

The eutrophication of the large 50 hectare Hebbal lake at Bangalore was adversely affecting realty value in the vicinity and had also become a prime impediment to the development of a high end complex in the area by to East India Hotel of Delhi.

LUCAS technology offered by Ion Exchange Waterleau is the ideal solution for nutrient removal to abate eutrophication of water bodies. Together with East India Hotel, Ion Exchange Waterleau took up this lake cleaning and restoration project. Ion Exchange Waterleau installed a state-of-the-art 4 MLD capacity sewage reclamation plant based on its proprietary technology of cyclic activated sequencing batch reactor process with co-current removal of nutrients - the culprits behind the eutrophication. The cyclic sequencing batch reactor (SBR) technology of Ion Exchange Waterleau is ideal for sewage and industrial effluent reclamation as it offers very compact modular solutions (requiring just 25% area of conventional systems) that are also very user friendly with PLC operations. Ion Exchange Waterleau will also undertake the responsibility of operating and maintaining the system.

The treated sewage, free from organics and nutrients, will be used to replenish water losses from this large water body. The restored lake has not only added to the aesthetics and value of the area but will be developed as a recreational tourist attraction to generate revenue.

Sewage Treatment at Reliance Industries

Ion Exchange Waterleau is executing a 80 m3/day (2 X 40 m3/day) new generation packaged sewage treatment plant (NGPSTP) for treating sewage from the administrative block of Reliance Industries Ltd. (Petroleum Project) gas exploration unit (KGD6 block development project). The treated sewage will be used for gardening. Our NGPSTP was selected from various available options because of its compact, easy to operate, modular design that also blended in with the aesthetics of the surrounding area.

Successfully Commissioned

Ion Exchange Waterleau successfully completed and handed over the Phase-I, of the 2200 m3/day effluent treatment plant for JSW Steel’s CRM unit at Bellary. In the Phase II effluent treatment plant, under commissioning, the complex effluents from various CRM operations containing very high oil and grease, organics and heavy metals in highly acidic and alkaline streams are treated in a specifically designed system to achieve safe disposal standards in line with pollution control board requirements. This contract followed Ion Exchange India’s Success in treating CRM effluent earlier for Tata Steel.

Essar Contract for Effluent Treatment

Essar Steel Ltd. awarded Ion Exchange Waterleau the contract for effluent treatment plant for its CRM unit at Hazira. The treatment scheme involves customised, segregated treatment of various streams to treat very high oil and grease, organics, heavy metals in highly acidic and alkaline streams to achieve safe disposal standards in line with requirements of the pollution control board; the plant is PLC operated, with SCADA monitoring. With this, the steel sector has underscored its confidence in Ion Exchange Waterleau’s expertise in the field.

Order from Asia Pacific Brewery

Ion Exchange Waterleau’s first export order, from Asia Pacific Brewery, Sri Lanka, is for augmentation of the existing 250 m3/day effluent treatment plant to 500 m3/day by inclusion of LUCAS anaerobic system (UASB) followed by upgradation of the existing aerobic biological system.