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SCALE-BAN TM A Non Chemical Water Treatment Equipment

A Sustainable Solution For Achieving Zero Liquid Discharge (ZLD) Say No to RO Plant and Evaporators (MEE) for achieving ZLD. Utilize R. O. Reject water, ETP Treated effluent and Raw water in cooling tower. Achieve above 20 COC in cooling tower. Maintain Cooling Tower Hardness over 10,000 ppm and TDS over 50,000 ppm. Say No to conventional regenerating Softeners. Say No to expensive Anti - Scaling chemicals. SCALEBAN

SCALEBAN

SCALEBAN installed at Siemens make 130 MW X 3 Nos. Power plant Condenser of M/s BPSL Jharsuguda, Orissa, India

Say No to hard scale permanently in heat transfer equipment. Optimize energy consumption, maximize production and avoid recurring/Hectic maintenance of heat exchangers.

REVOLUTION IN WATER TREATMENT...

BE PROUD TO INDIAN

SCALE-BAN TM A Non Chemical Water Treatment Equipment

PANKAJ KUMAR Managing Director

ABOUT US: SCALE-BAN™ EQUIPMENTS PVT. LTD. (SEPL) was established in the year 1999 with it’s office and manufacturing setup at Indore which is the largest Industrial & Commercial hub in central India. Today, the company has established itself well in the market and is known for it’s commitment, on time Delivery, product performance, customer relations and after-sales-support. We offer customized product for varied applications and with the experience gained in various industrial segments, we have fine tuned our product specification for excellent results. We manufacture patented (Patent Number 2335/MUM/2009) non-chemical water treatment equipment by the name of SCALEBAN. This equipment eliminates deposition of hard scale in the heat exchangers even when RO reject, ETP Treated Effluent or Raw water is used for Cooling purposes. Thus SCALEBAN have proved as the most cost effective and sustainable solution for achieving ZLD. This online equipment which does not require any energy input and is to be installed in the existing cooling water inlet line of heat exchangers. It does not require any regeneration or maintenance and resulting in zero downtime of heat exchangers and zero performance deterioration. Having been in market for over a decade and a half, M/s SEPL have developed a vast data base of satisfied clients, in various sectors like: POWER PLANT/ DISTILLERY PLANT / SOLVENT EXTRACTION PLANT / HVAC / CHEMICAL PLANT / PAPER PLANT etc which have benefitted by achieving substantial operational savings with our proven technology. The client credentials, performance certificates, the projects we have undertaken are listed at our website www.scalebanindia.com. We are very optimistic and confident that SCALEBAN will not only continue to achieve Zero liquid discharge (ZLD) across industrial spectrum but also save huge amount of water across the globe.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

A FACT: Only 0.007% of total water available on earth is potable which is being shared by all types of Industries, Agriculture & House holds.

OUR VISION: Our vision is to provide a Self Sustainable, Most Efficient and Cost Effective Zero Liquid Discharge (ZLD) solution.

OUR MOTTO Optimizing Production Maximizing Water Conservation Minimizing Water Pollution

WATER AND ITS PROPERTIES: Water is nature's most wonderful and most useful substance. It is estimated that two-thirds of earth's surface constitutes water. It also occupies a unique position in industries. It plays a very important role as a coolant in heat exchangers. Water is very complex in nature and it contains a lot of salts and minerals in dissolved form. Calcium and Magnesium salts present in water determine the hardness of water and it is this hardness of water, which is the main cause for insulating HARD SCALE formation in heat exchangers in various industries.

INSULATING PROPERTIES OF HARD WATER SCALING: Scale formation is a common phenomenon in any industry using water as a coolant or for steam generation. Scaling has high thermal insulating properties, thus resulting in poor heat transfer efficiencies (see graph below). Apart from causing this drop in thermal efficiency, it also causes overheating of heat exchange equipment and results in frequent shutdowns because of equipment choking or performance deterioration. The cleaning process is recurring, tedious and it also greatly reduces the life of various heat exchangers. 100

Efficiency Loss In %

90 80

74 60

60 48 38

40 27 18

20 4

7

0.3

0.5

11

0 0.71

3.1

4.7

6.3

9.5

12.7 15.8

Thickness of scale in mm

REVOLUTION IN WATER TREATMENT...

19

SCALE-BAN TM A Non Chemical Water Treatment Equipment

CHEMICAL CHARACTERISTICS OF WATER: EFFECT OF RISE IN TEMPERATURE OF WATER/FLUID ON SOLUBILITY OF CALCIUM AND MAGNESIUM SALTS:

As is known, the main cause responsible for formation of scale inside any equipment is the rise in temperature of water/fluid flowing through it, since at higher temperatures, fluid has a tendency to precipitate dissolved Calcium and Magnesium salts. A graphical representation of solubility of these salts in water vis-a-vis it's temperature indicates that with the rise in temperature of water from T1 to T2 the solubility of these salts reduces from S1 to S2. Thus, with higher temperatures of water/fluid as it comes in contact with any heat exchange surface, Calcium and Magnesium salts precipitate out and form scale on the surface of heat transfer area. SCALEBAN precipitates out these salts much before the water attains this critical temperature due to its coming in contact with the heat exchange surface.

EFFECT OF INCREASE IN THE pH VALUE OF WATER/FLUID ON SOLUBILITY OF CALCIUM AND MAGNESIUM SALTS:

Similar to its tendency to precipitate out dissolved Calcium and Magnesium salts at higher temperature, water/fluid also tends to precipitate out dissolved Calcium and Magnesium salts at its higher pH value i.e. when it tends to be slightly alkaline. A graph plotted above to illustrate solubility of Calcium and Magnesium in water/fluid vis-á-vis it’s pH value indicates that, with the rise in pH value of fluid from P1 to P2, the solubility of these salts reduces from S1 to S2 causing their precipitation at higher pH values.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

HOW DOES SCALEBAN PREVENT SCALING IN YOUR EQUIPMENT?

Cu++

A

++

Zn

H2SO4

WORKING PRINCIPLE: The working principle of SCALEBAN is very simple and proven. It incorporates use of Galvanic Principle, Chemical Characteristics of water/fluid and Fluid Dynamics. SCALEBAN exploits solubility characteristics of Calcium and Magnesium salts in fluid with change in its pH value. SCALEBAN locally increases pH value of water/fluid before it reaches high temperature zone and then precipitates out hardness causing salts as water/fluid flows through SCALEBAN.

HOW DOES SCALEBAN EXPLOIT THESE PRINCIPLES AND CHEMICAL CHARACTERISTICS OF WATER/FLUID? SCALEBAN is an online pipe shaped mechanical device which houses very specially designed core that is Sintered with number of electronegative elements in their order of increasing electronegativity in the direction of water/fluid flow. As feed water/fluid passes through SCALEBAN, it acts as an electrolyte while it comes in contact with the core placed inside SCALEBAN. SCALEBAN makes use of Galvanic principle by locally enhancing the pH value of feed water/fluid. Due to the Galvanic action, the core gets negatively charged and attracts the lightest ions present in the fluid i.e Hydrogen ion towards itself. The relationship between pH of water/fluid and H+ ion is + expressed by the formula pH 1/H .

∝

+

Thus, with the concentration of H ion becoming comparatively less in the water/fluid inside the equipment, pH value increases, there by precipitating Calcium and Magnesium salts before it comes in contact with hot tubes. Consequently, once the precipitation of these hardness causing salts has taken place, further precipitation due to temperature variation is not possible. SCALEBAN precipitates out Calcium and Magnesium bicarbonates in the colloidal form of Argonite crystals much before the water/fluid attains the critical temperature of super saturation due to its coming in contact with hot tubes. These precipitated salts are in the colloidal form (small particles dispersed in another substance) and are suspended in water/fluid, and because of their very small size and lighter weight, the water/fluid flowing through SCALE-BAN carries away these precipitated salts. THE NET RESULT IS TOTAL PREVENTION OF HARD SCALE IN THESE SYSTEMS.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

SAVINGS & BENEFITS a) IMPROVEMENT IN THE PLANT LOAD FACTOR (PLF):- SCALEBAN gives guaranteed zero scale in condenser and other coolers resulting in constantly maintained efficiency of the heat exchangers thus helps in improvement of PLF. Due to it's unique ability to precipitate scale forming salts into very fine particles of colloidal nature, SCALEBAN does not allow the deposition of these salts in heat transfer area, Moreover the precipitated salts get re-dissolve in water/fluid as soon as they reach the zero velocity zone in cooling tower basin, thus keeping the complete cooling tower circuit scale free. b) REMOVAL OF EXISTING SCALE:- Due to the reduction of the free Calcium and Magnesium from solution by the formation of their Carbonate crystals and the solubility being constant, water/fluid can dissolve more salts, which it tends to pick up from the existing scale in the system, thereby desalting scaled up systems. However, it is not marketed as a scale remover, but as a scale preventer. c) REDUCING WATER CONSUMPTION & WATER WASTAGE:- SCALEBAN has been tested successfully to operate at very high level of hardness (10000ppm). This unique ability of SCALEBAN gives freedom to use RO Reject & ETP treated water in Cooling tower as make up water and allows it to increase cooling tower COC above 20, thus reducing blow down quantity almost equivalent to drift and windage loses. This can make a very unique, practical & most economical zero discharge condition. d) PREVENT WATER POLLUTION:- With the reduction in blow down & consumption of effluents like RO Reject & ETP treated water in cooling tower as make up water SCALEBAN provides a great help in minimizing surface water pollution. Further, elimination of dosing of chemicals like anti-scalant and stopping use of Softener, SCALEBAN offers great help in reducing the water pollution. e) ZERO RECURRING & MAINTENANCE EXPENSES:- SCALEBAN does not have any operating & maintenance expenses thus is a “fit & forget system”. Due to special design of the core, SCALEBAN creates heavy turbulence in water/fluid flowing through it, which makes it a self cleaning & maintenance free equipment. Further since SCALEBAN does not incorporate any moving part and any external energy source, it is a totally maintenance free Equipment. f) NO CHANGE IN CHEMICAL COMPOSITION OF WATER:- SCALEBAN does not change the chemical composition of water, but instead, changes the nature of the scaling salts from a dissolved state to a suspended state, thereby preventing scale build up. g) NO RISK OF CORROSION:- Water softeners necessitate use of corrosion inhibitors, as soft water tends to be corrosive. Similarly, chemical dosing reduces the pH of water, thereby increasing the risk of corrosion. SCALEBAN on the other hand has the unique advantage of preventing scale deposition without increasing the risk of corrosion. h) NO INVESTMENT RISK:- SCALEBAN is sold with a 20 years Performance Guarantee. In view of this, there is no investment risk on part of the user of the equipment. It also offers a low pay back period, depending upon the type of industry and present means of water/fluid treatment.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

POWER PLANT SCALEBAN can be very gainfully installed in condensing type thermal power plants. Typically, a 1000 MW power plant would require approximately 98000 M3 of water per day, much of which is wasted resulting in higher operating costs for the plant. SCALEBAN offers a huge saving potential by way of: Saving this precious water. Improving the Plant Load Factor (PLF) by optimizing condenser vacuum thus resulting in higher power generation with better efficiency. Reducing the plant down time required for condenser cleaning. As one might expect, with millions of liters of circulating (cooling) water flowing through the condenser tubes, anything that is contained within the water and flowing through the tubes, can ultimately end up either on the condenser tube-sheet or within the tube itself. Tube side fouling for surface condensers is caused mainly due to SCALING, which are crystalline forms of Calcium and Magnesium salts. Depending on the extent of this fouling, the impact can be quite severe on the condenser's ability to condense exhaust steam coming from the turbine. As fouling builds up within the tubing, an insulating effect is created and the heat transfer characteristics of the tubes are diminished requiring the turbine to be slowed to a point where the condenser can handle the exhaust steam produced. Typically, this can be quite costly to power plants in the form of reduced output, increased fuel consumption and increased CO2 emissions. This "de-rating" of the turbine to accommodate the condenser's fouled or blocked tubing is an indication that the plant needs to clean the tubing in order to regain the turbine's rated capacity.

EFFECT OF EXHAUST PRESSURE/ VACUUM IN POWER PLANT:

100

34.8

99

34.5

98

Turbine efficiency, %

Steam consumption, %

Higher exhaust pressure i.e. lower vacuum, increases the steam consumption in the turbine, keeping all other operating parameters constant. Exhaust pressure lower than that specified, will reduce the steam consumption and improve the turbine efficiency. Similarly exhaust vacuum lower than that specified, will lower the turbine efficiency and increase the steam consumption. Figures below represent the effects of exhaust vacuum on steam consumption and turbine efficiency respectively, keeping all other factors constant for the condensing type turbine.

97 96 95 94 93

34.2 33.9 33.6 33.3 33 32.7

92 0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85

0.84 0.83

0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85

0.84 0.83

Exhaust vacuum, Kg/cm2

Exhaust vacuum, Kg/cm2

1. Effect of exhaust vacuum on steam consumption in condensing type turbine

2. Effect of exhaust vacuum on turbine efficiency in condensing type turbine 2

These figures also indicate that an improvement in exhaust vacuum by 0.014 Kg/cm , reduces the steam consumption in the turbine by about 1.1% and improves in turbine efficiency significantly from 0.24% to 0.4%.

REVOLUTION IN WATER TREATMENT...

REVOLUTION IN WATER TREATMENT... DM / RO REJECT

DM PLANT

BOILER

NEUTRALISATION PIT

SCALEBAN

SCALEBAN

WITH SCALEBANTM

DM / RO REJECT

DM PLANT

BOILER

ASH COOLING

NEGLIGIBLE BLOW-DOWN

PUMP

CONDENSER

AUXILLARIES

ZERO SCALE Guarantee in Condenser / heat exchangers. No efficiency loss and maintained vacuum due to ZERO SCALE.

Ÿ Ÿ

Ÿ Ÿ

Fresh soft water consumption is more due to restricted COC.

Despite use of soft water and anti-scalant chemicals, scale is formed in Condenser / heat exchangers. Ÿ Ÿ

Recurring Expenses for preparation of soft water as make-up-water in Cooling tower.

Cooling efficiency loss and poor vacuum due to scale formation.

Reduced power generation due to scale formation.

No guarantee against scale formation.

Ÿ

Ÿ

Ÿ

Ÿ

Ÿ

Ÿ

20 years performance Guarantee for ZERO SCALE.

Optimum power generation.

Tremendous SAVING of water as our equipment Works on higher COC.

No Recurring and maintenance Expenses.

Already tested up to 10000 ppm Hardness and 50000 ppm TDS. Ÿ

Limitation of hardness & TDS.

Can work on Raw / R.O. Reject / ETP treated / Sea / Bore well water.

15-20COC

COOLING TOWER

RAW WATER

Ÿ

MEE

NEUTRALISATION PIT

RO REJECT WATER

WITHOUT SCALEBANTM

RO PLANT

E.T.P

PUMP

CONDENSER

AUXILLARIES

Ÿ

SOFTNER REJECT

Works only on soft / RO water.

TREATED WATER

BLOWDOWN

4COC

COOLING TOWER

SOFT WATER BOILER BLOWDOWN

SCHEME FOR ZLD WITH SCALE-BAN™ A COMPARISON WITH CONVENTIONAL METHOD

MAKE-UP WATER

Ÿ

MAKE-UP WATER

TO ACHIEVE MOST EFFECTIVE AND ECONOMIC ZERO EFFLUENT DISCHARGE PLANT

SCALE-BAN™

SCALE-BAN TM

A Non Chemical Water Treatment Equipment BOILER BLOWDOWN

SCALE-BAN TM A Non Chemical Water Treatment Equipment

Estimated savings after installation of SCALEBAN Plant Data Power Plant Capacity in MW.

100

Flow of Re-Circulating Water M³/Hr .

20000

Status prior to installation of SCALEBAN: COC Maintained Evaporation Losses (L-e-) @1.5% of circulation rate

5 COC 300 M3 /hr

[A]

e Blow Down from Cooling Tower = {Le / (COC-1)}

[B]

75

Total consumption per hour = [A]+[B]

[C]

375

Total water requirement per Day = [C] x 24 as make up to cooling tower

[D]

9,000

Softener Regeneration Losses @ 5 % of total water requirement

[E]

450

M3 /hr M3/hr 3 M /Day

M3/Day

Status Changed after installation of SCALEBAN: COC Maintained

15

COC

Evaporation Losses (L-e-) @1.5% of circulation rate

[A1]

300

M3 /hr

Blow Down from Cooling Tower = {L e / (COC-1)}

[B1]

21

M3 /hr

Total consumption per hour = [A1]+[B1]

[C1]

321

M3 /hr

Total water requirement per Day = [C1] x 24 as make up to cooling tower

[D1]

7,714

M3 / Day

Total savings of water per day = [D - D1] + E

[E1]

1,736

M3 / Day

Total savings of water per year [E1] x 350 days / year

[F1]

6,07,500

M3 / Year

1. TOTAL DIRECT SAVINGS AFTER INSTALLATION OF SCALEBAN A. Saving due to less consumption of water, stoppage of softener operation and non usage of anti-scaling chemicals Cost of water saved = [F1] x Rs. 15/- per M3

[G]

91,12,500

Rs. Per Year

Cost Saved in ETP and R. O operations by reducing Blow-down for achieving zero discharge = (B-B1) x 24hrs X Rs. 20/- X 350 days

[H]

90,00,000

Rs. Per Year

Cost Saved on Softener Operation @ Rs. 2/-per M³ = D X Rs. 2/- X 350DAYS

[I]

63,00,000

Rs. Per Year

Cost of Resin in softener (Top up)

[J]

2,00,000

Rs. Per Year

Cost of Anti-scaling chemicals saved = Rs. 45000/- per month

[K]

5,40,000

Rs. Per Year

Total Savings per Year (A) = [G+H+I+J+K]

Rs.

2,51,52,500

Rs. Per Year

B. Savings due to proper HEAT EXCHANGE inside condense and lesser consumption of High Pressure steam: Profits reduced due to increase of 0.1Te of steam consumption per MW for an average 75 days in a year due to scaling in condenser. Considering normal consumption of 3Te of steam and cost of Steam @ Rs. 600/- per Te

TOTAL DIRECT SAVINGS = A+B

Rs.

1,08,00,000

Rs. Per Year

3,59,52,500

Rs. Per Year

2. TOTAL INDIRECT SAVINGS AFTER INSTALLATION OF SCALE BAN: Loss of fixed overheads due to forced plant shutdown of 3 days for Descaling: Considering fixed profit to be Rs. 1500/- per MW; Loss of profits = 1500x100MWx24 hrs.X3 days =

Rs.

1,08,00,000

Rs. Per Year

TOTAL [ DIRECT+INDIRECT] SAVING =

Rs.

7,19,05,000

Rs. Per Year

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

DISTILLERY PLANT

RAW WATER DISTILLERY PLANT

Complete quantity of Condensate (Distillery & Sugar plant) / Spent lees water can be consumed as make up water in cooling tower along with RO Reject & raw water. Hence, costly system like CPU can be bypassed & ZLD can be achieved in a sustainable. Most efficient & Cost effective manner with SCALEBAN technology.

SPENT LEES

SPENT WASH MAKE UP WATER

MULTI EFFECT EVAPORATOR

SUGAR MILL

PROCESS CONDENSATE

SUGAR CANE JUICE CONDENSATE

RO PLANT

RO REJECT WATER

SCALEBAN

COOLING TOWER DISTILLERY & CO-GEN PLANT

SCALEBAN

CONDENSER / COOLERS

SCALEBAN

CONDENSER / COOLERS

RO PERMEATE

PROCESS APPLICATIONS

Negligible Blow Down due to high COC. Hence, it can be directly taken for ash cooling / dust suppression.

SCHEMATIC DIAGRAM TO CONSUME CONDENSATE / SPENT LEES IN DISTILLERY & CO-GEN PLANT COOLING TOWER TO ACHIEVE ZERO LIQUID DISCHARGE WITHOUT CPU (ZLD WITH SCALE-BANTM)

Advantages of using SCALEBAN are listed below: Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ

Condensate (Sugar & Distillery) / Spent lees can be directly used in cooling tower as makeup water without treating it further in C.P.U. (Condensate Polishing Unit). Direct use of RO Reject & Raw Water in CT [Cooling Tower] as make up water. Cooling tower will be operated at higher COC of 15-20 resulting in almost NIL blow down. Reduced blow down and use of effluent quality water will reduce water Consumption thus reduced water wastage & reduced water pollution. Higher COC & Use of effluent quality water in cooling tower as makeup water will lead to reduced load to MEE or use of MEE can be eliminated. No need to use Soft water & anti-scalant chemicals in cooling tower. Permanent relief from formation of Hard water scaling in tubes of Condensers & other heat exchangers. Due to scale free condition in condenser; recovery and quality of spirit/ENA is improved. Increase in overall production from Distillery Unit because of better recovery of spirit/ENA and as no shutdown of the plant is required for de-scaling of condenser. No mechanical or chemical de-scaling required for condenser & other coolers; leading to improved plant and machinery life. SCALEBAN has zero operating and maintenance expenses (no electrical power and no spares) and hence is a truly FIT & FORGET equipment.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

REFRIGERATION PLANT Total elimination of hard water Scale in the cooling system of Refrigeration plant by installation of our SCALEBAN Equipment. CONDENSER WATER

COOLING TOWER

Qout

CHILLER

SCALEBAN

CONDENSER REFRIGERANT MOTOR EXPANSION VALVE

COMPRESSOR

EVAPORATOR

VFD

Qin PRIMARY SUPPLY

PRIMARY RETURN

Our Equipment SCALEBAN has been established in the market to give the following savings in Refrigeration plant / cooling tower operation. Ÿ Zero Scale in condensers. Ÿ Optimum Head Pressure maintained in Refrigeration plant.

SCALEBAN Equipment is an online equipment which is fitted just before water cooled condensers/ Heat Exchangers.

A brief description given below, will easily establish the benefits that can be achieved by installing SCALEBAN: Ÿ Ÿ Ÿ Ÿ

Ÿ Ÿ

Ÿ Ÿ

Anti-scaling chemicals are not required in cooling water. Descaling of heat exchangers is not required. No Softening plant is required. No shutdown of plant is required for cleaning of condenser / heat exchanger’s tubes, In conventional water treatment system shut down of plant is required frequently to clean the tubes Chemically / Mechanically, as the case may be. Cost of manpower, Chemicals and Loss of production for a large number of days due to shutdown is saved every year. Due to repeated cleaning of the hard scales in tubes with rod & acid, the tube surface becomes weak and prone to leakages. Any leak in condenser/cooler causes shutdown of plant and adds cost of replacing tubes. Head pressure in Refrigeration plant remains maintained which gives Considerable savings of electricity. Due to scale free system, optimum approach is maintained thus plant runs at optimum efficiency.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

SOLVENT EXTRACTION PLANT

SOFTENER

MAKE UP

RAW WATER / RO WATER REJECT / ETP TREATED WATER

MAKE UP WATER

SCALEBAN

SOFTENER REJECT

EFFLUENT TREATMENT PLANT

COOLING TOWER

CONDENSER / COOLERS

SCALEBAN

CONDENSER / COOLERS

SCALEBAN

CONDENSER / COOLERS

SOLVENT PLANT

SOLVENT PLANT CT BLOWDOWN WATER

COOLING TOWER

CONDENSER / COOLERS

CONVENTIONAL TREATMENT FOR COOLING WATER

SCALEBAN TREATMENT FOR COOLING WATER

Total elimination of hard water Scale in the hexane condenser of extraction unit by installation of our SCALEBAN Equipment.

Advantages of using SCALEBAN: Ÿ Zero Scale in condensers and other coolers. Ÿ Vacuum in condenser in plant remains improved which gives good efficiency of plant

Ÿ Ÿ Ÿ Ÿ Ÿ

Ÿ

Ÿ Ÿ

Ÿ

and better hexane recovery, higher oil extraction with better quality, thus improving profit. Constant vacuum in stripping column. Anti-scaling chemicals are not required in cooling tower. Descaling of heat exchangers is not required. No Softening plant is required. RO reject water can be used as make up water in cooling tower, thus reduction of effluent load of plant and saving fresh water equivalent to RO reject can be used everyday. No shutdown of plant is required for cleaning of condenser tubes, In conventional water treatment system, shut down of plant is required frequently to clean the condenser tubes Chemically (Caustic Circulation) / Mechanical Cleaning, as the case may be. Cost of manpower, Chemicals and Loss of production for large number of days due to shutdown is saved every year. Due to repeated cleaning of the hard scales in tubes with rod, the tube surface becomes weak and prone to leakage. Any leak in condenser/cooler causes shutdown of minimum three days and adds cost of replacing tubes. Due to scale free system, no drop in plant efficiency as happens with conventional water treatment systems & plant continues to works at full loads.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

MULTI EFFECT EVAPORATOR

1st effect

3rd effect

1

SCALEBAN

2nd effect

SCALEBAN

SCALEBAN

Condensate injection

3 2 PUMP

SCALEBAN

Condensate

Concentrate Product

Prevention of Hard Scale in your MULTI EFFECT EVAPORATOR by use of SCALEBAN EQUIPMENT at Fluid / Effluents feed inlet lines and Fluid / Effluents re-circulating inlet lines of Calandrias (each body of evaporator). As Multi Effect Evaporator are the heart and soul of any fluid concentration process plant, any scaling in it’s tubes causes tremendous loss due to excess consumption of Steam / fuel and also reduction in capacity of production. Further descaling of these tubes through CIP (Cleaning In Place) in itself is a time consuming, costly and tedious task. In this context, we have introduced a non-chemical hard scale prevention equipment named SCALEBAN Equipment for preventing hard scale formation in the tubes of Multi Effect Evaporators and thus improving the efficiency of operation and delay the frequency of CIP and time required for CIP. As primary purpose of Multi Effect Evaporator is concentrating or thickening of fluid, preventing hard scale formation result in delayed soft deposition which is very easy to clean.

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

OPERATING GUIDELINES FOR SCALEBAN: Ÿ pH value of the re-circulating cooling water should be maintained between 7.0 to 8.5 for optimal

results of SCALEBAN. Ÿ There should not be any Zero velocity zone between SCALEBAN and heat Exchanger /

Condensers to be protected. Ÿ There should not be any valve or strainer between SCALEBAN and Heat

Exchanger/Condensers. Ÿ Cooling tower sump should be cleaned for any sludge/debris etc. before start of operation. Ÿ Side Stream filter should be operated regularly with open top back wash regularly. Ÿ

Ÿ

pH should be maintained by dosing pH maintaining Chemicals or by commercial grade H2SO4. The Quantity of Sulphuric Acid (H2SO4) dosing can be finalized on commencement of the operation as it is dependent on the Sump holding capacity, quality of water, pH of makeup water, flow rate, evaporation and drift losses etc. Continue with anti corrosive treatment & Bio fouling prevention treatment as per requirement.

PERFORMANCE TEST AFTER SCALEBAN INSTALLATION

Analysis of test result

CHLORIDE TEST FOR SCALING CONFIRMATION

TYPE OF TEST

RAW WATER

RE-CIRCULATED WATER

Total Chloride

C1

C2

Total hardness

H1

H2

Analysis of test result If C2 / C1 = H2 / H1 ± 10%

SAFE; SYSTEM NOT SCALING

C2 / C1 > H2 / H1

UNSAFE; SYSTEM IS SCALING

C2 / C1 < H2 / H1

SYSTEM IS DE-SCALING

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

SCALEBAN INSTALLATION

Ensure that the Heat Exchanger / Condenser is properly De-Scaled and thoroughly cleaned before installation of SCALEBAN.

Identify the location for installation of SCALEBAN, (which should be nearest to the Heat Exchanger / Condenser inlet) and there should not be any valve or strainer between SCALEBAN and heat exchanger.

First measure the length of SCALEBAN to be installed.

Cut the equivalent length from inlet line at a point nearest to the heat exchanger. Weld both the matching flanges provided with SCALEBAN on both cut ends of the inlet line.

Properly place SCALEBAN between these two flanges such that direction arrow on SCALEBAN is in the direction of water flow.

Complete the installation by inserting gaskets and properly tightening all the bolts and nuts supplied with SCALEBAN.

Incase of any query regarding installation please consult us.

REVOLUTION IN WATER TREATMENT...

REVOLUTION IN WATER TREATMENT...

No Power required for operation thus saves the electricity bills.

No pollution.

No space is required as it is Extra space for storing chemicals. installed online.

Limitation

Maintenance

Man Power

Power Consumption

Pollution

Space

Inventory

COC In CT Pay back

Guarantee

3

4

5

6

7

8

9

10

11

12

Disposal of untreated Brine water is a major problem.(increased pollution of water). Space for softener and storage of salt is required.

Needs electrical energy for operation.

Special manpower required for regeneration of resin and operation.

Requires regular maintenance and supervision.

Restricted level of chlorides in re-circulation.

Heavy monthly expenses in procurement, inventory, storage, handling and supervision of chemicals and salts to be dozed.

2 To 6 (depends on Makeup) NIL. NO Performance Guarantee

15 To 20 Low payback period.

20 Years Performance Guarantee for zero Scale.

3 to 5 NIL. NO Performance Guarantee against Scale Formation.

Minimum one month inventory to be Minimum one month inventory to be maintained. maintained

Increases water pollution.

power is consumed to operate dosing pumps.

already tested up to 10000 Limitation varies as per chemical ppm Hardness & 50000 ppm suppliers. TDS. Requires daily maintenance and No maintenance required. check of water quality. No man power required as Requires extra manpower for SCALEBAN is an online monitoring and dosing of chemicals. equipment.

Recurring Cost

No extra inventory to maintain.

Water Softener

Chemical composition of water Chemical composition of water changed. changed due to dosing of chemicals. Nature of water becomes corrosive.

Chemical Dosing

No Recurring Cost Only One Heavy recurring expenses. time investment.

Composition of Chemical composition of water remains same. Water

SCALEBAN

2

1

S.No. Parameters

COMPARISON BETWEEN CHEMICAL DOSING & WATER SOFTENER Vs SCALEBAN

SCALE-BAN TM

A Non Chemical Water Treatment Equipment

SCALE-BAN TM A Non Chemical Water Treatment Equipment

UNSOLICITED LINES OF PRAISE FROM FEW OF OUR MANY SATISFIED CUSTOMERS ON THE BENEFITS OF SCALEBAN EQUIPMENT ACHIEVED BY THEM....

SCALEBAN INSTALLED IN 2 x 490 MW POWER PLANT (UNIT 5 & 6) OF NTPC LIMITED, DADRI (UP), INDIA

SCALEBAN INSTALLED IN 3 X 300TR VAM, VACUUM PUMP, TG-PHE UNIT OF NTPC LIMITED, DADRI (UP), INDIA

SCALEBAN STALL AT NTPC O & M CONFERENCE ON 13-14 FEB, 2015 IN DELHI, INDIA

SCALEBAN INSTALLED IN 130 MW X 3NOS, 60MW, 40MW AND 8MW POWER PLANT OF M/S BPSL (OR), INDIA

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

SCALEBAN INSTALLED IN 45KLPD DISTILLERY UNIT OF M/S OAISIS ALCOHOL LTD., SATARA (M.H.), INDIA

SCALEBAN INSTALLED IN 90KLPD DISTILLERY UNIT OF M/S WAVE INDUSTRIES LTD., ALIGARH (U.P.), INDIA

SCALEBAN INSTALLED IN 1380TR VAM UNIT OF M/S CCL PRODUCTS LTD., DUGGIRALA (AP), INDIA / VIETNAM

SCALEBAN INSTALLED IN 3 X 44TR CHILLER UNIT OF M/S AARTI INDUSRIES LTD., PITHAMPUR (MP), INDIA

SCALEBAN INSTALLED IN 1000TR VAM UNIT OF M/S ALEMBIC LTD., BARODA (GJ), INDIA

SCALEBAN INSTALLED IN MEE UNIT OF M/S YASHASHWI FISH MEAL LTD., MANGALORE (KA), INDIA

REVOLUTION IN WATER TREATMENT...

SCALE-BAN TM A Non Chemical Water Treatment Equipment

SCALEBAN INSTALLED IN 2 X 1350 TPD UNIT OF M/S CHAMBAL FERTILIZER, KOTA (RJ), INDIA

SCALEBAN INSTALLED IN 8MW X 2NOS, 10MW X 1NO & 16MW X 1NO POWER PLANT UNIT OF M/S SHREE BAJRANG POWER & ISPAT LTD., Borjhara, Urla, Raipur (CG), INDIA

SCALEBAN INSTALLED IN 1000, 600 & 400 TON SOLVENT UNIT OF M/S VIPPY INDUSTRIES LTD., DEWAS (MP), INDIA

SCALEBAN INSTALLED IN 3MW POWER PLANT UNIT OF M/S SAINSONS PAPER INDUSTRIES LTD., KURUKSHETRA (HR), INDIA

PERFORMANCE CERTIFICATE

SCALEBAN INSTALLED IN 40MW POWER PLANT UNIT OF M/S BENGAL ENERGY LTD., KHARAGPUR (WB), INDIA

M/S MAHAKALI FOODS PVT. LTD. (SOLVENT PLANT)

REVOLUTION IN WATER TREATMENT...

M/S BALAJI POWER (BIOMASS PLANT)

M/S PEARL DISTILLERY LIMITED

SCALE-BAN TM A Non Chemical Water Treatment Equipment

SELECTION SCALEBAN is selected on the basis of: [A] Water flow (M3 per hour) rate, [B] Diameter of Cooling Water line. Model

Pipe Diameter Minimum Flow Maximum Flow (Inch) (M3/Hr) (M3/Hr)

Model

Pipe Diameter Minimum Flow Maximum Flow

(Inch)

(M3/Hr)

(M3/Hr)

SEB-01

3/8

0.5

1.1

SBE-10

24

2810.0

3475.0

SEB-02

1/2

1.0

1.7

SBE-11

26

3297.8

4078.3

SBB-01

3/4

1.5

3.3

SBE-12

28

3824.7

4729.3

SBB-02

1

3.0

4.8

SBE-13

30

4390.6

5429.7

SBC-01

1-1/4

4.5

8.0

SBE-14

32

4995.6

6177.8

SBC-02

1-1/2

7.5

13.3

SBE-15

34

5639.5

6974.1

SBC-03

2

12.0

21.0

SBE-16

36

6322.5

7818.8

SBD-01

2-1/2

19.0

27.5

SBE-17

38

7044.5

8711.6

SBD-02

3

25.0

44.0

SBE-18

40

7805.6

9652.8

SBD-03

4

40.0

93.0

SBE-19

42

8605.6

10642.2

SBD-04

5

85.0

143.0

SBE-20

44

9444.7

11679.9

SBE-01

6

133.0

210.0

SBE-21

46

10322.8

12765.8

SBE-02

8

198.0

375.0

SBE-22

48

11240.0

13900.0

SBE-03

10

360.0

590.0

SBE-23

50

12169.2

15082.5

SBE-04

12

565.0

850.0

SBE-24

52

13191.4

16313.2

SBE-05

14

820.0

1170.0

SBE-25

54

14225.6

17592.2

SBE-06

16

1135.0

1530.0

SBE-26

56

15298.9

18919.4

SBE-07

18

1490.0

1940.0

SBE-27

58

16411.2

20295.0

SBE-08

20

1880.0

2400.0

SBE-28

60

17562.5

21718.8

SBE-09

22

2320.0

2910.0

NOTES: 1. Approximate Length of SCALEBAN is one meter. 2. SCALEBAN is supplied in flanged or screwed end connections with matching flanges. 3. The equipment is tailor made as per specific requirements of the application.

Manufactured & Marketed by :

SCALE-BAN TM Equipments Pvt. Ltd. 212, 2 nd Floor, Silver Sanchora Castle, 8/2, R.N.T. Marg, Indore, Madhya Pradesh (INDIA), 452001 Phone : 0731 4044059, 3042456, 6542550, Telefax : 0731 4084402, 4041974, Email : [email protected], [email protected] Website : www.scalebanindia.com

REVOLUTION IN WATER TREATMENT...

JV PARTNER