PRESENTATION ON DESALINATIONBharat Heavy Electricals LimitedRanipet, India

March 11

Land21%Salt water 98.5%Fresh water 1.5%Earths SurfaceWater on EarthFrozen in Ice Caps in Greenland and Antarctica (70%)Moisture in SoilDeep Underground Reservoirs< 1 %Readily AccessibleReplenished by rain & snowfall (Hence sustainable) Fresh water availabilityWater79% Water resources on the earth and available fresh water

DESALINATION PROCESS

GLOSSARYMGD : Million Gallons per Day (1 MGD = 3785 m3/day)MIGD : Million Imperial Gallons per Day (1 MIGD = 4546 m3/day )MLD : Million Liters per Day (1 MLD = 1000 m3/day)PPM : Parts Per Million = mg/lTDS : Total Dissolved Solids

Global Scenario on Desalination A snapshotROTHERMALRO Vs Thermal Exponential growth in Desalination over last 30 years RO technology getting preference over thermal during last 15 yearsInstalled membrane Vs Thermal capacity 1980-2009Source: GWI Desal Data /IDA

Annual new contracted capacity by feedwater type, 1990-2009Source: GWI DesalData / IDA

Installed Capacity as of June 2009

Indian Scenario on Desalination A snapshot

FILTRATION SPECTRUM

PRINCIPLE OF REVERSE OSMOSIS(RO)

REVERSE OSMOSISOsmosis:It is the diffusion of water through semi permeable membrane separating two different solutions of different solute concentration. The water flows in a direction to equalize the concentration.

Reverse Osmosis:Transport of the solvent from a concentrated to a dilute solution through a membrane under the influence of a pressure head,which exceeds the osmotic pressure of the solution.Product water flux is proportional to excess pressure.

HOLLOW FINE FIBRE MEMBRANE MODULE

SPIRAL WOUND CONFIGURATION OF RO MEMBRANE

SPIRAL WOUND CONFIGURATION OF RO MEMBRANE

FACTORS CONSIDERED FOR THE DESIGN OF RO PLANTRaw water source Open sea, beach well, deep bore well etc.,Feed water quality- Physical, Chemical & biologicalEnd use of water- Potable, Industrial, wastewater treatment etc.,Recovery of the plant desiredCapacity of the plant Operation of the plantType of brine disposal

Our Experience

In Building

SWRO & BWRO Desalination plants

RO PLANT REFERENCE LIST BAP, BHEL RANIPET

1. 1MGD (SWRO) Narippaiyur: 1NO. 2. 300 M3/Day (SWRO) Rameswaram : 1 No. 3. 300 M3/Day (HBWRO)Kusavankudi: 2 Nos.Pottagavayal 4. 300 M3/Day (BWRO)Panaikulam : 1 No. 5. 50 M3/Day (BWRO) Uthirakosamangai: 1 No. 6. 30 M3/Day (BWRO)Urathur : 1 No. 7. 20 M3/Day (BWRO)Perungulam : 4 Nos. Keelambal, Keelaparithiyur, Kidathirukkai

8. 560 M3/Day (BWRO) Airport Chennai: 1 No. 9. 2280 M3/Day (Stage-1, BWRO) Bellary TPS: 1 No. 1824 M3/Day (Stage-2, BWRO) Bellary TPS: 1 No.

TWAD SWRO & BWRO Desalination plants

20 Cu.M/Day - BWRO DESALINATION PLANT

300 Cu.M/Day - HBWRO DESALINATION PLANT

Process Flow Diagram-1 MGD SWRO Plant

1 MGD - SWRO DESALINATION PLANT FOR DRINKING WATER AT RURAL TAMIL NADU

1 MGD - SEAWATER INTAKE SYSTEM

1 MGD - FILTER FEED PUMPS

1 MGD - DUAL MEDIA FILTERS

1 MGD - MEMBRANE RACK ASSEMBLY

Largest Capacity In India For Drinking WaterMaximum Recovery of 50% For Seawater Power < 6 KWHr /Cu.M with ERD Inbuilt Chlorine GenerationPLC based Auto Operation Corrosion Resistant Materials Like Duplex SS, SS316L, uPVC, GRP, HDPE etc.,Low Consumption of ChemicalsPLANT HIGHLIGHTS

RO-DM Plantat BTPS Bellary 500 MW

GENERAL DETAILS Customer : Karnataka Power Corporation Limited, Bellary. 1x500 MW Thermal Power Plant

Plant Description : RO-DM Plant

Raw water Source : From Maralihalla River water

Design Raw water TDS: 1500 PPM

Plant Capacity : 75 M3/Hr (Net)- DM water : 10 M3/Hr - Potable water

Design Temperature : 30 deg CContd..

DESIGN - PLANT PERFORMANCE 1. Pretreatment SystemInlet TSS : 100 ppmOutlet SDI15 : < 5

2. Membrane Life : 3 years RO Stage - I Permeate TDS : 80 ppm RO Stage - II PermeateTDS : 10 ppm

3. Mixed Bed Exchanger Inlet TDS : 10 PPM (21 mic.S/cm) Outlet Cond. : 0.1 mic.S/cm

DM PLANT - GUARANTEED OUTPUT QUALITY1. pH: 6.8 - 7.22. Conductivity Max: 0.1 mic.S/cm 3. Silica reactive as SiO2: 0.015 PPM 4. Organic matter : < 0.2 mg of KMnO4/l

KPCL UNIT - 1 *

RAW WATER POND

KPCL - BELLARY RO-DM PLANT- CLARIFIER

FILTER, RO-DM PLANT EQUIPMENT LAYOUT

FILTER SHED

RO MEMBRANE RACK

MB SYSTEM & PIPINGMBMBDGT

CONTRACTS ON HAND 1. KPCL-Bellary Unit-2 RO-DM Plant (UF+BWRO1+BWRO2+MB) Plant Capacity : 96 M3/Hr BWRO1 x 1W : 76 M3/Hr BWRO2 x 1W: 75 M3/Hr DM plant x 1W

2. GSPC, Gujarat, Pipavav 2x350 MW (PT+SWRO+BWRO+DM) Combined Cycle Plant Plant Capacity : 100 M3/Hr SWRO x 2W+1SB : 26 M3/Hr BWRO x 1W+1SB: 25 M3/Hr DM plant x 1W+1SB

3. TNEB, North Chennai 2x600 MW (PT+UF+BWRO+DM) Plant Capacity : 100 M3/Hr BWRO x 2W+1SB: 90 M3/Hr DM plant x 2W+1SB

4. PPCL, PRAGATHI-III, NEW DELHI 1500 MW (MBR+BWRO1+BWRO2+MB) Plant Capacity : 28.5 M3/Hr BWRO1 x 2W : 25.5 M3/Hr BWRO2 x 2W : 25 M3/Hr MB plant x 2W+1S5. YERMARUS- 2 X 800 MW (PT+UF+BWRO1+BWRO2+MB) Plant Capacity : 105 M3/Hr BWRO1 x 2W : 87 M3/Hr BWRO2 x 2W : 87 M3/Hr MB plant x 2W+1S6. RPCL-EDLAPUR 1 X 800 MW RO-DM Plant (UF+BWRO1+BWRO2+MB) Plant Capacity : 2x107 M3/Hr BWRO1 1W + 1S : 2x87 M3/Hr BWRO2 1W + 1S: 2x85 M3/Hr MB plant 1W +1S7. KPCL-Bellary Unit-3 RO-DM Plant (UF+BWRO1+BWRO2+MB) Plant Capacity : 96 M3/Hr BWRO1 x 1W : 76 M3/Hr BWRO2 x 1W: 75 M3/Hr DM plant x 1W

MAJOR EQUIPMENT SCOPE COMPARISON KPCL, BELLARYUNIT -2

PRETREATMENT : (127m3/hr) -UF System (2x50%) (Submerged)

2. RO Stg-1 (1x100%) (95 m3/hr)3. RO Stg-2 (1x100%) (76 m3/hr)4. MB Sys (1x100%) (75 m3/hr)

*UNIT -1

PRETREATMENT : (127m3/hr)-Clarifier (1x100%)-PSF (4x50%)-ACF (4x50%)

2. RO Stage-1 (2x100%) (95 m3/hr)3. RO Stage-2 (2x100%) (76 m3/hr)4. MB System (2X100%) (75m3/hr)

KPCL UNIT-1 & UNIT-2 MAJOR SCOPE COMPARISION

S.NODESCRIPTIONUNIT-1UNIT 21PRE TREATMENTClarifierCWSTCW pumps PSF ACF UF systemFW tank127 m3/hr1x100%500 m32 x 100%4 x 50%4 x 50% N/ A200 m3127 m3/hrN/ AN/ AN/ AN/ AN/ A2 x 50%300 m32RO Stage -1RO block (2x100%)RO block (1x100%)3RO Stage -2RO block (2x100%)RO block (1x100%)4MB SYSTEM2 x 100%1 x 100%5Total weight (MT)

KPCL UNIT - 2 *UF systemMB systemRO 2RO 1

KPCL , BELLARY- 500 MWRO-DM PLANT UNIT-1RO SYSTEMDM SYSTEMPT SYSTEM*

IMPROVEMENTS IN KPCL UNIT-2ULTRA FILTRATION SYSTEM*UF system Unit 2PSF & ACF Unit-1Clarifier Unit-1UF system In place of Clarifier, PSF & ACF

*Improved Dosing System Skid

NORTH CHENNAI UNIT-1 & 2GENERAL DETAILS *

S.NODESCRIPTIONCAPACITY1PRE TREATMENTDMFUF (pressurized)268 m3/hr6 Nos3 x 50%2BWRO system 200 m3/hr (3 x 50 %)3DM SYSTEM-Degasser-SAC-SBA-MB180m3/hr3 x 50%3 x 50%3 x 50%3 x 50%

NORTH CHENNAI UNIT 1 & 2 *UF systemDM systemBWRO

FILTER SHED

SACSBAMBRO-CCTNORTH CHENNAI RO-DM PLANT EQPT. LAYOUT

Hollow Fiber Configurations - PressurizedInside-OutOutside-In

TYPICAL UF SYSTEM SKID (PRESSURIZED)

TYPICAL RO SYSTEM SKID

Tenders Participated

Sl. No.Customer / ProjectRemarks1HEL Haldia 2x270MW Offer submitted2PPCL Pragati II CCPP 750MW, Bamnauli Offer submitted3TNEB Ennore 1x600MW Offer submitted4India Bulls Tertiary treatment plant, STP, Nashik , 130 MLD Offer submitted thro ROD5 TNEB- Udangudi 2x 800MW RODM confirmed6 DB PowerOffer submitted to L&T thro ROD7 Visa powerOffer submitted to L&T thro ROD

RO-DM ECONOMICS

Boiler Feed Makeup Water Quality Requirement

Drum Pressure Kg/cm261 100 >100 Conductivity @ 25C S/cm0.3 - 0.50.1 0.2Silica as SiO2 Max. ppm0.020.01pH6.8 - 7.26.8 7.2

Available Strategies for Boiler Pretreatment Softeners Dealkalizers Demineralizers Reverse Osmosis (RO) Electro De-Ionization (EDI)

Process Vs Impurity Removal

SYSTEMImpurity Softener Softener with Dealkalizer Reverse Osmosis(RO) DM (SAC, SBA & MB) RO + MBTotal Dissolved Solids No NoYesYesYesHardness YesYesYesYesYesAlkalinity NoYesYesYes YesSilica NoNoYesYesYesCO2 & Oxygen NoNoNoYesYes

Feed Water Quality Considered

ParametersUnit Case-1200 ppmCase-2400 ppmCase- 3800 ppmFeed sourceRWRWRWpH8.48.48.4Ionic load as CaCO3ppm2605601190Approx. TDSppm200400800Calcium as CaCO3ppm4080125Magnesium as CaCO3ppm4079115Sodium as CaCO3ppm44121347Potassium as CaCO3ppm000Chloride as CaCO3ppm35104251Sulfate as CaCO3ppm1836151carbonate as CaCO3ppm81617Bicarbonate as CaCO3ppm71123167Silica as SiO2 (Total)ppm2525.025

Basis for O & M cost - GeneralContd

Description DetailsPlant Life (Years)20Interest Rate Per Year (%.)8.0Net output - DM water (M3/h)170Plant Availability (days/yr.)330Operating hours per day24No. of streams (W)2Temperature (0C)30Electrical Power Cost (Rs / Kwh.)3.24IX Regen. Waste discharge pHNeutral

1. FOR 400 ppm TDS -Detailed calculation made w.r.t above said basis for 2 stage RO and conventional treatment2. FOR 200 ppm TDS -RO-2 is not in operation & RO-1 is alone operational-MB regen. once in 36 hrs & MB regen chemicals twice the consumption as compared to that of 400 ppm feed TDS due to higher ionic load for MB feed. Conv. DM plant regn. chemicals Half that of 400 ppm feed TDS due to lower ionic load for MB feed of 400 ppm3. FOR 800 ppm TDS -RO1 additional power 10 KW due to higher feed TDS-Conv. DM plant regen. chemicals - twice the consumption as compared to that of 400 ppm feed TDS due to higher ionic load for DM feed TDSBASIS OF CALCULATION FOR DIFFERENT FEED TDS

ComparisonBetween Single Stage RO and Two Stage RO

1. For 400 ppm feed TDS Savings in Rs/ m3 x flow/hr x no of Hrs/day x no of days /yr8.61 x 170 x 24 x 330 = Rs.116 lakhs/ year

2. For 800 ppm feed TDS 25.91 x 170 x 24 x 330 = Rs. 349 lakhs/ year

3. If the plant operation for 8 months per annum (2/3) with 400 ppm feed TDS & 4 months per annum (1/3) with 800 ppm feed TDS Deducing from 1 & 2 above , 116 x 2/3 + 349 x 1/3 The saving per year is Rs. 193 lakhs O & M COST SAVING WITH RO-DM PROCESS

EFFLUENT GENERATION AND DISPOSAL Lower IX effluent & Minimize disposal cost (~1/16th ) Lower capacity of neutralising pit. BWRO reject can be used for cooling tower make up or wash water or gardening.CHEMICAL CONSUMPTION / HANDLING Lower regeneration chemicals / cost (~1/10th). To minimise the TDS loading in the effluent discharge. Lower storage, handling (~1/10th) & minimise hazards. Increasing cost of regeneration chemicals leads RO option more cheaper.Advantages of RO-DM over a Conventional DMContd.

RAW WATER QUALITY Economical at Moderate & high TDS Break even at feed TDS of 100 to 200 ppm. Effective removal of Silica & Organics

RESIN PERFORMANCE Lower organic load increases resin performance Less resin volume leads to smaller vessel size and lower replacement cost.

OUTPUT QUALITY & QUANTITY OBR of DM will be increased due to lower ionic loads of RO permeate. Consistent output water quality. Advantages of RO-DM over a Conventional DM

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