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Mettlesome Service at JSW
Simbhaoli Sugar Mills Group, Uttar Pradesh
Tata Chemicals Ltd. – Fertilizer Works at Barbala


Mettlesome Service at JSW

Production capacity at the Jindal South West (JSW) semi-integrated steel plant at Bellary is 2.4 million metric tons (MMT), enhanced from 1.6 MMT two years ago. JSW is poised to enter a new growth phase, with production targetted at 4 MMT in 2006-07 with the commissioning of the second blast furnace, almost doubling to 7.0MT by March 2008 and then to 10 MMT with a fourth - among India's largest - blast furnace.

To strengthen focus on their core competency of making steel, the strategy of the JSW group is to outsource all high tech, non-core activities that specialist vendors are in an expert position to handle.

Water is like the bloodline of a steel plant. Approximate consumption of water at JSW Bellary is is 4.0 to 4.5 m3/tonne. If it doesn't flow, production will stop. Even a small change in process water quality will affect the quality of production, particularly in the Basic Oxygen Furnace - Continuous Casting (BOF-CCP) plant. IEI News met with JSW Bellary (earlier known as Jindal Vijayanagar Steel Limited or JVSL) to discover how our TWM & O&M teams have delivered the desired results. Read on.

The beginning
The starting point of the JSW-IEI relationship was our total water management (TWM) contract for the entire JSW plant in 2004 - the scope of work was mainly chemical supply for cooling water treatment, providing manpower for services, setting up the infrastructure for daily water analysis in our own laboratory, maintaining the raw water treatment plant with all supplies and services, and consultancy services for overall water management inside the plant.

Performance pays
As time progressed, performance and reliability of service built up JSW's confidence level in IEI, resulting in several orders for water treatment equipment, including auto valveless gravilty filters and pressure sand filters for the COREX and Blast Furnace #1 plant, Their completion ahead of schedule gained IEI orders for demineralisatiion (DM) and softening plants for Blast Furnace#2. Then, in July 2005, came the first O&M contract for a compeitor's DM plant in Blast Furnace #1, covering supply of basic chemicals for the DM plant and softening plant, supply of specialty chemicals, manpower supply for O&M of DM plant and softener, and dosing, monitoring of cooling water chemicals, followed by an O&M contract for Blast furnace #2 in July 2006. Currently, IEI has emerged as JSW's preferred vendor for all water treatment products and services.

Why outsource?
JSW's prime objective in off-loading these TWM services to one party was

  • To reduce cost of operations by increasing the volume of business to a single party
  • To freeze the cost of water treatment per MT of steel production i.e. HRC / HM / Slab etc.
  • To make a single party accountable for the whole plant, from the raw water treatment to other process plants, to avoid confusion.
  • To eliminate time, effort, and hassles of supervision, operation and maintenance of the water utility, so that JSW could concentrate on its core activity of steel making.


  • Benefit to business
    After taking over TWM at JSW, IEI was able to resolve many critical process problems in their plant.

    Problem Solving: The COREX GCP thickener used to have a high raker load problem due to large floating un-burnt carbon particles on the surface. (Raker load is the torque developed at the center of the scraper arm in a thickener. An increase in raker load increases the driver load/trips the prime mover, causing unpredictable breakdowns.) The introduction of a polymer flocculant by IEI did an excellent job by decreasing scum formation on the thickener water surface, reducing the raker load and thereby downtime. This also lessened the carry-over of unburnt coal from the thickener and as well as reduced nozzle choking in the GCP circuit. COREX is one of the most satisfied departments at JSW.

    Introducing Improvments: Trials with various polymers resulted in another improvement in HSM(hot strip mill) thickner performance by reducing corrosion rate in the system. Yet another substantial improvement initiated was the spray circuit of BOF-CCP with the introduction of new methods. GCP scrubber performance was also improved with proper monitoring and lab-trials on the slurry.

    The result was a high degree of customer satisfaction, with appreciation certificates from all these departments.

    Specialist consultancy: Consultancy on various other aspects also gave them considerable improvement. Our recommendation of an auto gravity valveless filter (AVGF) for their blast furnace cooling tower reduced TSS in the system thereby saving water loss due to excess cooling tower blowdown; they not only saved water but water but system corrosion also reduced substantially with incorporation of an AVGF and of course, our chemical treatment programme. Corrosion rate which used to be around 25 - 30 MPY earlier with competitor treatment was reduced to just <2 MPY.

    Trouble shooting: There was a major problem in Blast Furnace #1 DM plant operation due to frequent increases in differential pressure (DP). Organic fouling had created a problem in the SBA. To tackle this, chlorination was stepped up which led to slippage of residual chlorine which started affecting the SAC column. When this problem was referred to IEI's site personnel, their suggestion of soaking in the SBA column eliminated the problem. We also recommended crosschecking the free residual chlorine after the activated carbon filter, to prevent resin damage due to its presence in feed water. Implementation of these suggestions resulted in excellent improvement and the frequency of DP increase dropped from once a week to once in 45 days. It was satisfaction with this solution that led JSW to opt for our first O&M contract in Blast Furnace #1.

    The water treatment chemical business is built mainly on mutual trust and deliverables at service end. Product and technology offered by all the leading companies may be the same - it is service that is the differentiator, it is trust and commitment that count with the customer. While IEI's first contract was awarded on price, demonstrated commitment and service resulted in repeat orders. Particularly appreciated by JSW is IEI's dedicated service and commitment to continuously try to incorporate improvements that will in turn benefit the customer's business and help fire up its steel production and achieve JSW's ambitious expansion plans.
    Badarpur Thermal Power Station (NTPC)

    Simbhaoli Sugar Mills Group, Uttar Pradesh

    The Simbhaoli Sugar Mills Group has two sugar mills in Uttar Pradesh, one at Simbhaoli and the other at Chilwaria, with a combined crushing capacity of 11,000 TCD ; it laso has a 40 KLPD distillery at Simbhaoli. The Group's speciality sugar product range, marketed under the brand TRUST, includes cubes, sachets (white & brown), icing sugar, table sugar and pharma sugar, besides refined sugar in packing of 1, 5 and 50 kgs.

    The sugar mill at Simbhaoli, one of the modern sugar mills in India with refined sugar production of 750 TPD, commands a major share of the institutional market. It decided to go in for sugar decolourisation in crushing season 2003 - 2004 and selected our INDION ion exchange process for the project. Our system, designed for sugar melt flow rate of 48 m3/h and comprising two resin columns, enables production of refined sugar of <45 ICUMSA.

    Dr. CS Rao

    Dr G.S.C. Rao, Executive Director (GSCR) and Mr. A.K. Srivastava (AKS), General Manager (Projects) of the Simbhaoli Sugar Mills Group talk about their experience with our sugar decolourisation process as well as with the company, as we have also serviced a number of contracts for water treatment equipment and sugar process chemicals over the years.

    What triggered the decision to go in for the sugar decolourisation?
    GSCR: The globalisation of the Indian economy has opened new markets and opportunities for the sugar industry. Sugar decolourisation, we were convinced, would help us to encash this opportunity, adding value to our existing business -through economy of scale, product cycle, and change in the entire manufacturing process, thereby delivering quality products.

    How exactly will this project be of benefit ?
    GSCR: I believe that by producing quality refined sugar (< 45 ICUMSA) as compared to conventional sugar (100 - 150 ICUMSA), we will be able to carve a niche into the speciality sugar market. We would also be able to reach institutional buyers with our product - the institutional market is 50 - 55%, and yet to be tapped. Also, this project will help in running the plant for the entire year with processing of raw sugar.

    What made you select our ion exchange process over others?
    AKS: World over two processes are adopted for decolourisation of sugar remelt i.e. carbonation followed by activated carbon, and phosflotation followed by ion exchange process. Based on our extensive research, we concluded that the ion exchange technology is the best suited for Indian conditions, as the plant and resins used in this process are manufactured indigenously, thereby offering the advantage of low recurring cost.

    What is your experience with the performance of our system validate its selection?
    GSCR: We are indeed happy and very satisfied with its performance; the technology is quite adaptable; we are also satisfied with the system engineering. Commissioning, after sales service and support from Ion Exchange India has been very good.

    What is the company's current production of refined sugar using our sugar decolourisation process?
    AKS: We have had a total production of 750 tons per day of refined sugar for 300 days during the crushing season 2004 - 2005.

    What are the other products of our company that Simbhaoli Sugar uses?
    GSCR: We use several of your sugar refining chemicals, including the INDION 1951 colour precipitant and INDFLOAT 100 Floatation Polymer. We you're your demineralisation plant supplied along with annual maintenance contract, and we are also procuring resins and spares from you.

    What do you look for in a vendor? How would you rate Ion Exchange India?
    GCSR: Qualities that we look for in a good vendor include

    • Transparency in working
    • Commitment to execute and deliver
    • Good reputation and technological backup
    • Long term relationship

    We give weightage to quality more than merely price.

    Being a professional organisation, Ion Exchange India meets our expectations well and we enjoy a good relationship with your company. If ever a problem does crop up, it is solved promptly.

    If you had to zero in on one point about our company that makes a favourable impression, what would that be?
    GCSR: The fact that Ion Exchange India is very professional, customer commitment runs high through the organization and people at all levels deliver.


    What status does Simbhaoli enjoy in the sugar industry? What are the company's plans?
    GCSR: The sugar industry can be classified into two categories, based on the number of factories. There are those that have more than than four factories like Birla Sugar, Bajaj Hindustan, Balrampur Chini Mills, Triveni Engineering. The second category comprises those with two factories such as the DSCL Group and SIEL. We are comfortably positioned in this second group.

    Currently we have two sugar mills, one at Simbhaoli and the other at Chilwaria, in Uttar Pradesh, with a combined capacity of 11,000 TCD. We are planning to expand production to 15,500 TCD for the next crushing season. We are also thinking of starting sugar decolourisation at Chilwaria.


    Tata Chemicals Ltd.
    – Fertilizer Works at Barbala

    The Problem The DM plant - two strong acid cation exchangers in series - had been manufactured, erected & commissioned by the client using resins supplied by IEI. The scheme was based on the expected water quality at site. However, during commissioning, it was found that the acid consumption was very high and the actual water analysis showed high M-alkalinity and hardness; and the sodium to total cation ratio was differing from the design. As the original resins were supplied by Ion Exchange India (IEI), the matter was referred to them. During the visit for troubleshooting, IEI suggested that, based on the actual water quality, the scheme of two strong acid cation in series required review and the resin in the first vessel needed to be replaced with weak acid cation resin to improve regeneration efficiency. The original scheme envisaged such flexibility for changeover in future if necessitated by water quality.
    Solution IEI immediately offered weak acid cation resin with short delivery.
    Challenge The amount of saving estimated was such that the client was not fully convinced, as it seemed too good to be true. IEI then supported the proposal with thorough design calculations and guaranteed the implementation of the project all of which helped the client to decide to try it in one of the three streams.
    Results The scheme, when implemented in the first vessel, was an immediate success. Based on the savings achieved, the client immediately placed an order for the balance two streams.These also gave similar results.
    Savings The total cost of Rs.2.7 million involved in the project was received in a period of just six months. The unit is benchmarked in the industry for low chemical consumption.


    Badarpur Thermal Power Station
    (NTPC)

    The Problem Due to pretreatment problems on account of high suspended solids, muck and turbidity, the middle collector system frequently failed. Because of this the system had to be operated in co-flow mode – resulting in high acid consumption, high sodium slip and inconsistent quality.
    Solution A new type of a much sturdier middle was specifically designed to tackle the problem. With the new collecting system, the client could go back to countercurrent operation and obtain full benefits of the countercurrent system such as consistently low sodium slip and reduced acid consumption. After much followup with the client, our proposal was accepted on condition that it be first tried in only one of the four vessels.
    Results The system was implemented in one of the strong acid cation vessels, executed while the plant was in operation, within the stipulated time. The vessel was commissioned and the system ran successfully without any problem.
    Savings The client was able to achieve a 30% reduction in chemical cost due to implementation of this project. The cost of Rs.600,000, incurred in modifying one vessel, was recovered in one year’s time due to savings in chemical consumption. Additional benefits were consistent quality. And low sodium slip resulting in lower silica slips from strong base anion.
    The client decided to go in for a similar modification in the balance three vessels and the system has now been successfully commissioned in al four vessels.


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