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 Building in Water Assurance
Ltd.
A Case in Point
10 MLD Zero Discharge at
Angeripalayam CETP
Complete water systems package for
JSW Steel Ltd.
Central Utility Complex for General
Motors India.
Urban Infrastructure Project at
Rampur .
Water at the Heart of
Hospitality
Making Waves with
Nicco
Service on Track for Rail Neer
Together with TISCO
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A major problem facing numerous housing complexes is availability of regular water supplies, and many today are dependent on tanker water.
Recycle of sullage and sewage provides an effective and dependable solution in helping end the perennial water shortages in cities – where the domestic sector consumes 80% of water supplies. It is in fact ideal for housing/commercial complexes which do not have guaranteed water supply, providing them with assurance against water shortages.
Sullage (grey water from bathrooms & kitchens) and sewage can be treated and recycled for toilet flushing, gardening, vehicle washing and other such low end uses, reducing the requirement of fresh water by ___% . This makes more fresh water available for drinking, cooking, bathing and laundry while reducing dependence on unreliable/insufficient water supplies and drastically cutting down on expenses on tanker water. Besides, with water getting increasingly scarce, it will soon be difficult even for tankers to get their supplies.
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This project, of premium builder R.
Raheja, at Thane, Maharashtra has 3 wings housing
a total of 480 flats. The total water requirement
for flushing & gardening is 150 m3/day. The
cost of tanker water @ Rs.50/cu.m amounted to
Rs.7500 daily and Rs.27 lakhs annually.
A 200 m3/day INDION fluidized media reactor
(FMR) was installed to recycle water. The total
cost including accessories such as equalization,
treated water and holding tanks, was Rs.40 lakhs.
A daily saving of fresh water which would have
otherwise been used for secondary purposes was
Rs.150 cum, amounting to an annual saving of
55000 cu. m of fresh water.
With an annual operating cost of the FMR unit
at Rs. 6 lakhs and an annual cost saving of Rs.21
lakhs, this recycle plant gave a payback in just
23 months. The additional cost incurred per sq.
foot (each flat of 1000 sq. ft) was just Rs.8. |
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Tirupur is a hosiery and export
centre located about 450 kms from Chennai in Tamil
Nadu. Around 80 bleaching and dyeing units form
part of the Angeripalayam common effluent
treatment plant (ACETP) project; these dyeing
units consume large volumes of water which they
were purchasing at around Rs.50 to 60 per cu.m
through tankers. During the dyeing process, 10 MLD
of waste water with high TDS, organics and colour
is generated by the individual units of the ACETP.
This ACETP had been set up to treat the
effluent discharged from these units. The
partially treated effluent, without reduction of
total dissolved solids (TDS), was being discharged
from the ACETP into the Noyyal River , polluting
the water and making it unfit for agriculture and
domestic use. Discharge of the high TDS effluent
into the river and its subsequent percolation into
the ground water system had also affected the
ground water quality. In view of this, all textile
units were directed by the Chennai High Court to
implement zero liquid discharge.
Ion Exchange
carried out extensive piloting to identify the
right solution to overcome the problem faced by
the units in Tirupur. Various combinations of
technologies including biological, chemical, resin
and membrane based systems were tried out. Based
on this, a 0.5 MLD plant was built to gather
further operating data after which the scheme for
the 10 MLD zero discharge system was developed and
constructed.
The main treatment scheme comprises the
membrane bio-reactor and two stage reverse osmosis
for effluent recycle, followed by silica removal,
sand filtration and nano filtration for zero
discharge. The RO permeate has TDS of <6200
ppm, COD of <5, with nil BOD, suspended solids
and colour.
Benefits of the Zero Discharge System
Apart from satisfying the High Court
mandate of zero liquid discharge, a whole host of
benefits accrue to the CETP/individual units.
- More than 82% of the feed water (10 MLD
capacity) is obtained as RO permeate of much
better quality than available raw water. This
improves the quality of the dyeing.
- 11% of the feed water, obtained as pure
brine solution from nano filtration, will be
used effectively for dyeing. This means around
93% of effluent is recycled and reused by the
dyeing industries.
- The operating cost of the project is around
Rs.40 – 45/m3,, much less than the fresh water
cost of about Rs.50 – 60/m3, - a huge saving of
costs on purchasing water.
- A much smaller footprint, as it uses the
membrane bio-reactor instead of a conventional
biological system.
- Sludge production is vastly minimised as the
physico-chemical process is avoided.
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Complete water systems package for JSW Steel Ltd.’s long product mill to manufacture bar rods and wire rods at Toranagallu, near Bellary, Karnataka.
JSW Steel is a part of the O.P. Jindal Group with revenues of US$ 3.7 billion from diversified interests in steel, energy, minerals and mining, infrastructure & logistics, cement & IT.
Ion Exchange India has been managing the water systems at JSW’s integrated steel plant at Toranagallu since 2005. Based on the excellent performance of our team in effectively and efficiently managing the complete water systems for the steel complex, JSW Steel has awarded a series of contracts for various water and waste water treatment plants for their various projects - blast furnace, CRM, coke oven etc.
As part of plans to expand capacity to 7 MTPA and thereafter to 10 MTPA, JSW is installing a 1.6 MTPA Long Product Mill to manufacture bar and wire rods. This mill like all other steel mills needed a complete water cooling and conveyance system comprising cooling towers, pumps, blowers, filters etc. - requirements that our subsidiary Ion Exchange Infrastructure is eminently suitable to handle, given their experience and capability in construction of large projects. Ion Exchange Infrastructure with the help of their steel specialist designed a water system package which JSW Steel, based on their comfort level with the system designed and our proven past performance, awarded to Ion Exchange Infrastructure, against competition from the existing supplier NICCO. Awarded in July 2007, the project status is in line with the schedule based on the infrastructure and readiness of the site.
- Indirect cooling water systems of the reheating furnaces
- Indirect cooling water systems of Bar Rod Mill and Wire Rod Mill
- Direct cooling water systems of Bar Rod Mill and Wire Rod Mill.
Each of these water systems incorporates complete pumping systems, piping, cooling towers and side stream filters for cooling towers, and also incorporates all related instrumentation, automation, electricals etc. Additionally, the direct cooling water system incorporates a series of vertical high rate pressure filters for mill scale filtration. The contract includes the complete design of the civil structures for the complex along with sizing of critical process civil structures like the scale pit etc.
Subsequently, we have been awarded the turnkey contract along with ten year O&M of the waste water recycling system at JSW Steel.
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Design,
engineering, supply, installation, commissioning,
operation and maintenance of the complete central
utility complex (CUC) for the vehicle
manufacturing plant - 1,40,000 vehicle capacity,
of General Motors India Pvt. Ltd. at Talegaon,
Pune, Maharashtra.
General Motors India Pvt. Ltd. is a wholly
owned subsidiary of General Motors Corp. (GM), the
world's largest auto maker headquartered in
Detroit, USA with over 130 car and truck
manufacturing facilities spread over 33 countries.
The annual global industry sales leader for 76
years, GMC today employs about 284,000 people
around the world, with global sales of US $180
billion. In 2006, 9.1 million GM cars and trucks
were sold globally under the following brands:
Buick, Cadillac, Chevrolet, GMC, GM Daewoo,
Holden, HUMMER, Opel, Pontiac, Saab, Saturn and
Vauxhall.
GM has one plant in India, in Halol, Gujarat,
and the second project at Talegaon was planned
considering the huge growing market for
automobiles in India.
GM, through their worldwide facilities group,
were scouting for an organization to undertake the
complete utility complex for the Talegaon car
plant, on a design and build-own-operate (BOO)
basis. Ion Exchange Infrastructure, with its
project management expertise and extensive domain
knowledge in water and waste water treatment as
well as in piping, electricals, instrumentation
etc., instilled in GM confidence in their
capability to construct the entire central utility
complex. Working closely with the customer and
various package suppliers, the complete utility
package was designed and offered to General
Motors.
After review and discussions with the worldwide
facilities group and the General Motors India
project team, the contract was awarded to Ion
Exchange Infrastructure for the turnkey design,
engineering, procurement and construction of the
central utility complex. Following its
commissioning, the Ion Exchange team has moved in
to operate and maintain the complex for General
Motors India.
The central utility complex produces and
delivers all the required utilities like
compressed air, potable water, process water, hot
water, etc. to the paint shop. The waste water
from the car plant is collected at the central
utility complex, treated in the waste water
treatment plant and delivered to the site sanitary
sewer.
The various systems constructed by us include:
- Raw water treatment to treat MIDC supplied
fresh water.
- Process water treatment to produce
demineralised water for the paint shop.
- Potable water treatment for drinking water
for the plant.
- Waste water treatment plant to treat waste
water from various shops within the car plant
including oily waste water from phosphate
stages, the ELPO waste water and general waste
water.
- Compressor to generate compressed air at
required flow and pressure for the complete car
plant.
- Hot water generator along with chimney and
other accessories to deliver hot water at
required temperature for the paint shop.
- Welder water treatment and cooling package
for the body shop.
- DG set for power backup.
- LPG storage yard with bullets and necessary
safety infrastructure.
- Fire fighting systems
The water treatment plant and all accessories
are designed and supplied by Ion Exchange India
and the 600 m3/day effluent treatment plant and
all accessories by our joint venture Ion Exchange
Waterleau Ltd. On-site and classroom training
covering process, technological, operation and
maintenance aspects of the plant were imparted to
the client’s personnel. All the systems were
integrated into the central utility complex
building which also houses the laboratory, office
complexes etc. The systems provided are fully
automatic with state-of-art instrumentation and
automation. The complete electrical work, piping,
pipe racks, storage tanks, building construction
were undertaken by Ion Exchange Infrastructure. |
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Project for laying 54 kms of
deep sewer network for Zone II of Rampur City,
Uttar Pradesh, for the Regional Centre of Science
and Environment. 
Ion Exchange Infrastructure was awarded the
contract for laying 54 kms of deep sewer network
for Zone II of Rampur, by The Regional Centre of
Science and Environment. Tetratech India,
subsidiary of US MNC Tetratech were the project
monitoring consultants for this contract. The work
involved laying a sewer network of RCC piping
ranging from 150 mm to 1000 mm dia. in very narrow
streches of the city at depths extending from 1.5
to 8 m.
Since some of the streches were so very narrow
that normal excavation was not possible, Ion
Exchange also carried out approx. 1 km of sewer
network using trenchless technology. Laying around
700 m of sewer piping in a day at peak work
progress, the complete network of 54 km was
finished within 9 months including the monsoon
period. |
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The
average per capita water consumption in a typical
five star hotel is 1500 litres/guest room/day;
assuming a 50 room hotel, the requirement would be
75,000 litres/day. Continuous availability of good
quality water in large quantity is therefore
essential,  and, with Increasing scarcity of water, its
deteriorating quality and high costs posing
problems for the hospitality industry, good water
management becomes critical.
IEI is a
preferred vendor for the Taj Group for more than
two decades, supplying central drinking water
systems, sewage treatment plants, cooling water
treatment, softeners for boiler water.....IEI News
met Mr. K. D. Deodhar, Director - Engineering
Services, The Indian Hotels Company Ltd., to learn
more about the Taj Group's philosophy, views,
preferences and on water
management.
How does the Taj Group
typically meet such large requirements of water ?
How do the hotels ensure quality standards are
met?
When a new hotel is planned, a
feasibility study determines sources, quality and
quantity of water supplies. Influent water - which
could be municipal, tanker or borewell water, is
analysed to determine treatment - whether
filtration, softening, reverse osmosis, organic
scavenger or a combination of these. Each region
has its own contaminants - down south there is
generally more dissolved iron and excess oxygen;
in Andhra Pradesh one finds mica content whereas
up north, particularly in the hilly areas , water
contains a lot of organic
matter.
When it comes to water
treatment, what does the Group look for in a
vendor? 
Reliability of product and process,
and continuous consistent performance is the
topmost priority - in other words, full-proof and
fail-safe is what we expect. Robust, user friendly
technology and equipment are very important. And
we look for very good technical guidance as well
as prompt after sales service.
What
has been the Taj experience with the performance
of systems supplied by IEI?
I think
Ion Exchange India fulfills all the conditions I
have mentioned. You are considered the experts in
your field - a solution provider with a solid
technological base and experienced technocrats. .
When one has a serious medical problem, one seeks
out a reputed specialist; well, when you have a
need for water management, you go to the proven
expert. So when companies are confronted with a
challenging problem, they approach IEI. This has
also been the Taj experience. One is assured that
IEI will undertake a proper study and extend its
full professional support - examples I can cite
are reverse osmosis treatment at Taj Bengal in
Kolkata and the organic scavenger resin which
solved our problem at Annapurna in
Nepal.
That's certainly music to
our ears! Do you have any suggestions on how we
could enhance the support we give to our
customers?
Any product, however good,
can be proven bad, if it is not used , operated or
maintained properly. You can give someone a
Mercedes, but if he cannot drive it properly, he
will say the car is bad! So one way to further
help clients gain optimum performance from their
treatment plants is to undertake site visits to
conduct a technical survey or technical audit to
ensure equipment is being used the way it should
be. During site audits, one will come across many
ways, small and big, where a technical suggestion
on correct usage or dosage may result in a much
more effective plant performance or save the
client an enormous amount of money....such soft
service which ultimately helps the customer
optimise his process, will definitely help the
vendor gain a cutting edge over competition. It
may be a simple procedure, nothing complicated or
requiring innovation, nevertheless periodical
visits to observe the operational technicalities
will help the client gain optimum performance from
his investment and would be very much
appreciated.
We at IEI do believe
in backing solutions with total service support.
Outsourcing service, particularly O&M, is
helping many of our customers to eliminate hassles
of supervision and time on water treatment and to
concentrate on their core business....perhaps the
Taj Group would find O&M very useful
too.
Well, as you know, in case of
hotels, hydraulics is only one part - perhaps
15-18%,of the utilities; since in any case we need
to maintain an in-house engineering department to
handle the many other utilities, it makes more
economic sense to do the O&M
ourselves.
What prompted the Taj
Group to go in for sewage treatment? How much
water is typically recycled by a Taj
hotel?
Most of our hotels have sewage
treatment plants; wherever we have large lawns we
use the treated water for gardening; or it is used
for the cooling towers, after further treatment.
We also use the treated water for the low end use
of toilet flushing in staff areas. First and
foremost, it was shortage of water that made us go
in for sewage treatment plants. This also helps to
reduce the requirement of tanker supplies and
thus, the cost of water. While discharge
regulations have been introduced for the hotel
industry, as far as the Taj Group is concerned, we
have been observing these much before their
introduction.  It's the Tata philosophy -
don't wait for regulations to give a disciplinary
dose; discipline yourself proactively before
regulations come. So we went in for sewage
treatment way back in 1986-87 ....at our locations
at Agra, Jaipur, Delhi and Lucknow, much before
regulations.
Typically if a hotel consumes
'X' quantity of water, about 20% goes to the
cooling towers, and the rest of the water
ultimately goes to the drain. Out of that,
recoverable water is about 50 - 55% which can be
used for cooling towers and toilet
flushing.
What are some of the
other green initiatives that the Taj Group has
adopted?
We strongly believe that
natural resources must be preserved. Therefore,
when it comes to green practices - whether
relating to water, fuel or paper, or any other, we
believe we should lead by example.
Take
air conditioning - we go for higher efficiency
machines whereby power is saved. We use machines
having superheaters - so we are able to generate
hot water free of cost directly from the
compressor. Even a saving of just 10% water
translates into a huge quantity; a hotel using 200
to 250 kilo litres/day will save 25 kilo litres
/day or 9,125 kilo litres in one year!. There is a
huge saving of quantity of water used for cooling
towers; additionally we will not be using fossil
fuel to generate hot water and thus will be
conserving a lot of energy. Finally, we will not
be polluting the air . Just one example of all
round environmental protection and preservation.
Several of our apartment hotels -
Wellington Mews in Mumbai and in Goa and Ernakulam
do not have boilers installed and generate hot
water from superheaters.
At several of our
hotels, kitchen, housekeeping and other degradable
waste such as grass is converted into methane
based bio-gas - examples are Rambagh Palace and
the Jai Mahal Palace in Jaipur . At several
hotels, kitchen waste is also used for
vermiculture and manure for the
lawns.
Any environmental awards and
certifications?
80 - 90% of our
hotels are covered by the HACCP criteria on
kitchen hygiene and food measures. Almost 50% of
our hotels are ISO 14000 certified and several of
our hotels are ISO 18000 certified. All new hotels
will be covered by ISO 14000 & 18000
simultaneously.
How will the
impending scarcity of natural resources, whether
water scarcity or the energy crunch - affect the
hospitality industry? What in your view is the way
ahead?
Every corporate has a social
and environmental responsibility and will have to
learn to manage resources much better for a
sustainable future. Companies will need to
transform their processes to reduce the burden on
the environment. When it comes to water, on the
one hand low flow fittings, rain water harvesting
and water recycle will help conserve this
resource; but innovative devices and new
technologies will also be needed to help reduce
the use of water. Preferred vendors of the future
will definitely be those who are forward looking
and willing to work in proactive partnership with
customers on improvements in technology and
processes that will benefit both the customer's
business and the environment. |
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 Effective water management is critical
to a water park, much more so to India’s largest
artificial sea beach launched by Nicco Parks and
Resorts Ltd. at Kolkata.
Says Mr. Rajeev Kaul, Chairman, Nicco Group,
"Nicco Parks is determined to maintain water
purity levels of the highest international norms
at our theme park. To achieve this, we have an
exclusive arrangement with the best provider of
total water treatment services - Ion Exchange
Services Limited. Not only is the water in our
park purified continuously, it is tested twice a
day by their trained water specialists, and the
results certified and displayed for everyone to
see."
These are the high expectations that Ion
Exchange Services Ltd. (IESL) is fulfilling daily,
to Nicco’s complete satisfaction at the extremely
popular "Wet-O-Wild Beach Tropicana".
IESL's association with Nicco Group spans
supply, installation, erection & commissioning
to total water management services for the entire
systems required for complete filling of water in
the pools, for make-up water due to evaporation
loss, backwash water supply, and for the
recirculation filter. This includes an ø850 mm
oxidation chamber, ø 1800 mm sand filter and
softener and dealkaliser. The plant recirculates a
huge 3600 cu.m water in different pools in two
hours, to maintain turbidity at the desirable
level of 5 NTU. It took a month and a team of four
from IESL, skilled in fabrication, installation,
erection and commissioning, with good operational
knowledge of water treatment equipment, to ensure
that all water treatment was in well place for the
opening of the park.
 
IESL’s service team of six, experienced in
operation and maintenance of water treatment
systems, pipelines, chemical dosage etc., is
stationed full time at the park to ensure desired
water quality is maintained at all times. At the
full fledged lab set up at site by IESL, water quality is analysed twice a
day, before the park opens and again, around
mid-day, and the results prominently
displayed.
This total water management
approach by IESL assures the customer not only of
highest water quality but also of savings on
manpower, chemical consumption and maintenance
costs. A win-win situation indeed - service
delivered with a splash! |
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 Indian Railways Catering and Tourism Corporation Ltd.
(IRCTC) has set up two drinking water treatment and
bottling plants in India for captive consumption, on
selected trains and stations. One is located at Nangloi,
a suburb of New Delhi on New Rohtak Road and the other
at Danapur, a suburb of Patna, Bihar.
 The turnkey plants, supplied and
installed by IEI, each have a capacity of 6000 cartons
(72000 one litre bottles ) per day on a 24 hour basis.
They consist of state-of-art water treatment, bottle
blowing, bottling and packaging sections. The water
treatment section, capacity 3000 litres/hour, consists
of elaborate raw water pretreatment, ultra filtration,
reverse osmosis, pH correction, two-stage disinfection
and final polishing by cctivated carbon filter for
pesticide removal. Both plants are equipped with BIS
approved modern laboratories, set up by IEI, to ensure
adherence to stringent quality standards.
IRCTC outsourced the comprehensive
operation and maintenance of both the plants to IEI
under five-year contracts starting 7th May 2003 at
Nangloi and 28th February 2004 at Danapur. The plants
are managed by our experienced manpower with specific
expertise in handling packaged water bottling plants.
The team of around 25 at each location consists of a
plant-in-charge, shift supervisors, O&M personnel,
lab chemists and labourers. Usually the plants is
operated in two shifts/day, though for a few month it
runs on a third shift.
Both the plants are
running smoothly with planned periodical maintenance in
place. Required stocks of spares and chemicals are
maintained to ensure trouble free operation and
maintenance schedules. Visits by OEMs are also planned
to ensure smooth running of the various
equipment.
Seeing the results, IRCTC is happy
with its decision to award the contracts to IEI which
also enables IRCTC to concentrate on its core
compentencies.
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 In 2000, steel giant Tata Iron
and Steel Ltd. (TISCO) commissioned a 1.5 million tonnes
per annum cold rolling mill (CRM) at its complex at
Jamshedpur. The total water management for the entire
CRM was awarded to IEI - we supplied, installed and
commissioned the water and waste water treatment plants.
The water treatment section consists of main filtration
3 X 160 m 3/h, demineralisation - 2 X 40
m 3/h, softening 2 X 20 m 3/h and
side stream filtration 4 X 147 m 3/h. The
waste water treatment plant treats chrome, alkaline,
oily and acidic wastes, as well as 25 m 3/h
backwash waste from the filtration plant and 25
m 3/h DM plant waste.
Since 2000, TISCO has also outsourced
the comprehensive water management of the CRM complex to
IEI including operation & maintenance of the water
and waste water treatment plants and the management of
the cooling tower and cooling water treatment
programme.
Our team of 25 includes a
plant-in-charge, shift supervisors,  process engineers,
operation and maintenance staff, lab chemists and
labourers. Our scope of service involves round the clock
operation of the plant, maintenance of the mechanical/
electrical/instrumentation equipment of the plant (water
treatment, waste water treatment, recirculation pump
house), supply and monitoring of the cooling tower
chemical system, laboratory analysis at plant site and
submission of consumables consumption report.
Our personnel run t he plants are
effectively run by our personnel, with planned
periodical maintenance in place. Required stocks of
spares and chemicals are maintained by TISCO in close
coordination with us, ensuring trouble free operation
and maintenance schedules. When necessary, visits by
OEMs are also planned in consultation with TISCO to
ensure smooth running of the various
equipment.
Awarding the entire water management
and services to a specialist has enabled the customer to
concentrate on the core area of steel making. In
addition, there has been tremendous value addition
through savings in consumption of chemicals, improved
plant efficiency and consistent quality & quantity
of treated water.
We also worked closely with
TISCO in maintaining quality systems as well as in ISO
14001 certification audits. Thus, our association with
TISCO in the total water management at the CRM complex
is like a partnership, and this customer's satisfaction
is evident by the renewal of our contracts, twice over.
Our personnel have also been commended by TISCO for
their performance, knowledge and quality services. |
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