International

RO Plant for Petroleum Development of Oman
Petroleum Development of Oman (PDO) awarded us a prestigious Build-Own-Operate (BOO) contract for four containerised reverse osmosis plants, which have been installed at four remote oil drilling sites in Oman.

Manufactured at our Hamriya facility in UAE in a record time of 12 weeks, the plants will be operated & maintained by Ion Exchange for seven years, and thereafter purchased by the client. Our revenue is on the basis of cubic metre of water produced. Around forty personnel will be stationed at the sites for O&M.

Apart from water purification, treatment will also remove traces of boron from the raw water. The water produced will be used for process and other requirements such as drinking water at the PDO sites water in excess of the client’s requirements will be supplied to the surrounding habitats.

Supply and installation of a 4 m3/h solar powered sea water reverse osmosis plant, along with supply of solar panels, for a beach front tourist development complex in Abu Dhabi. Intended to publicise and promote energy saving, the 35 KWH power generated is used for running the plant, the high pressure pump and all the control systems.

Repeat Contracts from Indonesia
At PT Indah Kiat Pulp & Paper, Indonesia 6 x 150 m3/h demineralisation plant and 3 x 175 m3/h condensate polishing unit; both were repeat contracts after successful performance of the plants supplied in 2002.

At PT South Pacific Viscose, Indonesia 500 m3/h pretreatment using ultra high rate clarifier and dosing systems, This was an additional unit to the 2500 m3/h pretreatment with lamella clarifier and continuous sand filter, supplied in 1996. Order for 2x50 m3/h automatic UF, RO and mixed bed system from White Nile Sugar, Sudan.

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Contract for the Escravos gas to liquid project for Chevron, Nigeria
A contract, for the Escravos gas to liquid project for Chevron, Nigeria, for a condensate polishing package consisting of filtration, twin bed and mixed bed demineralization. The consultant is KBR, USA.

Filter stream: Condensate from the heat exchangers is polished in a series of cartridge, de-oiling and activated carbon filters, for removal of free/ dissolved oil. It is designed to produce a net flow rate of 49.9m3/h of treated condensate (one train working + one standby).

Fully automatic, it can however also be operated in semi auto and manual modes.

Twin bed demineraliser: Provides polishing of process condensate from the plant. The main stream consists of ctaion and anion demineralisers in series. Net flow rate is 238 m3/h (one train working + one standby); there are two trains in parallel, with the same components.

Mixed bed demineraliser: This is the final treatment stream for the treated condensate of the above two streams stored in the condensate tank. Net flow rate is 273 m3/h, with one working and one standby.

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3150 m3/day MBR for Reef Island, Bahrain
Ion Exchange was awarded the prestigious contract, against international bidding, for the membrane bio reactor based sewage treatment plant for the Reef Island Development Project - our first such plant overseas. Reef Island, previously known as Lulu Island, is a man-made island being built on the coast of Al Manama, in the Kingdom of Bahrain. The US$ 1.2 billion freehold development project will cover an area of 579,000 square meters (6.23 million square feet). is being constructed as a joint venture between the Bahrain government and the Bahrain-based Mouawad Group Real Estate Development Company. The development was designed by Australian-based Spowers and Pentago. The consultant for the project is SCOTT WILSON UK and the civil contractor is AMA, Bahrain.

Our contract scope included design, engineering, supply, erection and commissioning of the membrane bio-reactor, with a project value of USD 1.5 million. The original capacity of the plant was 2300 m3/day, later upgraded to 3150 m3/day. The plant uses flat sheet membrane modules and the scheme consists of automatic screens, equalisation tank, anoxic tank, aeration tank with MBR membranes and post disfinection system along with membrane cleaning systems. The plant is automatic with PLC controlled operation. We will also be undertaking operation and maintenance of the plant.

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MBR for Sewage Treatment at Jebel Ali, Dubai
Our GCC operations - Ion Exchange, UAE successfully commissioned the membrane bioreactor based sewage treatment plant in Jebel Ali, Dubai, for Wade Adams, a major civil contracting company in Dubai. The MBR treats sewage water from the labour accommodation of the client and the treated water is used for concrete curing and mixing at the client’s construction sites. Ion Exchange was also awarded the contract for O&M contract of the plant.

Another 500 m3/day MBR and a fluidized media reactor (FMR 200 ) have been supplied to this client.

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For KSI, Cambodia

For Copper Mining Company, Zambia

5000 m3/day RO plant for Tiger Woods Project, Dubai
The real estate & zoning department of Tatweer, a Dubai Holdings company, awarded the contract for the construction of a golf course in Dubai to Tiger Woods. Tiger Woods Dubai is a massive 55 million square feet development with the 18-hole golf course alone accounting for 13 million square feet. The latter has retained Confluence as their project management company while grass cultivation on the course has been contracted to Desert Landscape group, Dubai. Treated sewage water from Dubai Municipality, after tertiary treatment will be used for grass cultivation in the nursery as well as main golf course.

The complete design , supply, erection & commissioning package for the interim 5000 m3/day RO based treatment plant for the golf course was awarded to Ion Exchange, Hamariya. The plan will treat the sewage for the immediate requirement of the nursery and watering of the golf course until completion of the main treatment plant. Treated sewage water from Dubai Municipality will be transported in tankers to the site and stored in a lagoon. The water from the lagoon will be chlorinated treated in a 2 x 2500 m3/day RO plant consisting of cartridge filters, high pressure pumps and RO units, operating at 75% recovery ratio.

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Prestigious EPC project from Technip Malaysia
A prestigious order for 27 m3/h pretreatment and two stage 11 m3/h sea water reverse osmosis and EDI plant of 4 m3/h mounted on 10 containers, from Tecnip, Malaysia for a project in Turkministan.

1. Design Temp : -17 deg C to 45 deg C ; design Pr - 45 bar RO and 14 BAR filtration
2. The plant is fully containerized & fully automatic, , with 1600 dia. filters mounted inside containers. Top level of automation with latest features, using distributed IO philosophy, which minimizes cabling and provides more operating space to operator; automation is supplemented with power backu, mounted within the containers.
3. The containers are equipped with heavy duty HVAC designed for handling outside temperatures of 17 - 45 deg C while maintaining inside temperature at 25 Deg C, with automatic adjustment through temperature controllers.
4. Sodium hypo required for RO is generated inside the containers from sea water, capacity 2 kg/h, concentration 0.2 %
5. Instrument air required for automation is also generated in the containers - this system is specially designed for handling suction air temperature of 17 - 45 deg C ; the compressors are provided with auto on off and with dryers to suit instrument air requirement.
6. All chemicals dosing systems are within the containers.
7. EDI units for producing high purity water were dispatched,fully assembled, from our fabrication facility in Hosur.

All three 85 m3/h streams of the SWRO plant were successfully commissioned and the treated water produced to desired parameters. The plant will assist the customer to achieve self-sufficiency in meeting the current water requirement of its 1.2 million tonne capacity cement plant.

The mixed bed units are installed after the DM water storage tanks to meet the specifications of flow rate of 200 m3/h with conductivity < 0.1 micro siemens and pH of 7.

We installed the PLC based fully automatic mixed bed polishing unit after the DM water storage line and before supply to their gas turbine system. The plant performance test carried out successfully in Feb 2010. With large savings on the fuel cost, the payback period for the customer is less than a year. The O&M of this plant is also with Ion Exchange.

Indirect Cooling Water (ICW) System, 1100 m3/h for Furnace: hot and cold wells, pumps and motors, piping work, side stream filtration, cooling towers and emergency overhear tank, electrical (MCC etc.), instruments (gauges, transmitters etc.) and automation (PLC) system.

ICW System, 2200 m3/h, for Mills: indirect cooling water (ICW) circuit of mills (wire and bar rod) comprises cold well, pumps and motors with associate piping, side stream filtration, cooling towers, electrical (MCC etc.),instruments (gauges, transmitters etc.) and PLC system.

Direct Cooling Water (DCW) System. 5000 m3/h, for Mills: cold well, pumps, motors with associate piping, scale pit with pumping system, settling tank, pump house with piping, pressure filtration system (dual media filters) with allied air blower and dosing system, cooling towers, sludge scrapers, sludge handling system comprising thickener with rake mechanism, sludge transferring by positive displacement pumps & filter press, electrical (MCC etc.), instruments (gauges, transmitters etc.) and PLC system.

Make up cum Drinking Water, Soft Water & DM Plant Filling Water Supply & Distribution System through Overhead Tank: 120 m3/raw water treatment plant , 100 m3/softening plant, 20 m3/h drinking water plant and 3 m3/h demineralization plant for complete cooling water system.

Given the worsening water scarcity in Mumbai city on account of the monsoon failure, Ion Exchange took the initiative to organize a press meet in March on Solutions & Technologies for Mumbai’s Water Needs. Addressing members of the press, Mr. Ajay Popat, CEO, Ion Exchange Waterleau, presented various alternative sources of supply such as sea water for industrial process use and potable/drinking water; industrial effluent for industrial process applications, sullage and sewage for secondary purposes (toilet flushing, gardening, vehicle washing, etc.) and rain water for drinking and secondary purposes. Among the solutions to augment and conserve water supplies, desalination of sea water and treatment and recycle of sewage in particular provoked a lot of interest and interaction, and a lengthy and interesting Q&A session followed the presentation, with the press fraternity eager to know more about the technologies, cost-benefit etc.

Ion Exchange Asia Pacific Pte. Ltd. participated in Singapore International Water Week 2009, putting up a display stand at the Water Expo at Suntec Singapore International Convention & Exhibition Centre. The week’s events included various business forums; Mr. Rajesh Sharma, Vice Chairman & Managing Director, Ion Exchange (India) Ltd., participated in the Indian Business Forum at which he made a presentation on ‘Business of Water in India: Building Sustainable Growth’ which focussed on investment opportunities in water.

Confederation of Indian Industry’ s Water Equipment & Management Division, of which Mr. Sharma is Chairman, organised a national seminar on Water for All in New Delhi. Ms. Sheila Dikshit, Hon’ble Chief Minister, Government of National Capital Territory of Delhi, was the Chief Guest at the seminar. Mr. Rajesh Sharma chaired the inaugural session of the national seminar on Water for All where he shared his views on Sustainable Water Security during his welcome remarks and introduction of seminar theme.

Ion Exchange Wins Water Awards, 4th Consecutive Year

03/04/2010

The Ion Exchange contribution to the water industry was once again recognized with the prestigious 2009-10 Water Awards for the fourth consecutive year awarded by Water Digest in association with UNESCO & PHD Chambers.

Receiving the award, Mr. Rajesh Sharma, Vice Chairman & Managing Director, said” It is our company’s continuous endeavor to use technology innovatively to offer solutions to improve the quality of life and protect our earth’s most vital resources for a sustainable future. Receiving the award, Mr. Rajesh Sharma, Vice Chairman & Managing Director, I said” It is our company’s continuous endeavor to use technology innovatively to offer solutions to improve the quality of life and protect our earth’s most vital resources for a sustainable future. This has led us to develop products and technologies to create a capability to provide integrated, cost-effective solutions for all sectors - industrial, institutional, municipal, homes and communities. It has led us to extend our capabilities to encompass water, air, waste and renewable energy. We have pioneered solutions for recycle of industrial effluent and domestic sewage, to conserve water and natural resources. Our Zero B purifiers provide safe drinking water to all consumer segments at every price point and include innovative solutions to treat water contaminated with fluoride, iron, arsenic and nitrates. We are grateful to our customers, stakeholders and vendors for their continued support and to our employees for their valuable contribution.”

The Frost & Sullivan Environment Excellence Awards recognise the exemplary achievements, business winning strategies and innovative best practices of companies operating in the highly dynamic and competitive environment industry. These recognitions culminate in Frost & Sullivan Awards and are regarded as benchmarks for excellence in the given industry segment.

This award to Ion Exchange follows several other prestigious Water Awards by Water Digest in association with UNESCO such as for Best Water Company, Best Domestic RO Purifier, Best Water Treatment Chemicals and Best Water Conserver.

Desalinated water is fed to the 13 x 388 m3/h demineralisation plant consisting of mixed bed units to demineralise the water boiler water turbine and process use. The 3 x 388 m3/h condensate polishing unit treats the return condensate at the refinery complex and captive power plant. The condensate after treatment is returned to the plant for reuse as polished feed water with low pressure and higher pressure steam generator. The return condensate is treated for removal of oil traces and low levels of dissolved suspended solids by activated carbon filtration and ion exchange process.

The waste water treatment is carried out in a dedicated state-of-art completely automated & PLC operated effluent treatment plant (ETP) supplied by Ion Exchange Waterleau . The effluent treatment area is designed to contain and treat all internal process/utility waste water and storm/firewater, with the objective of zero discharge from the new refinery complex. The treated water is recycled back to the high total dissolved solids treatment train or guard tanks, as required.

The low total solids (LTDS) stream is treated to an effluent quality adequate for reuse for cooling water make up, fire water make up and irrigation water for development and maintenance of the local green belt.

The high total dissolved solids (HTDS) stream is is treated to an effluent quality adequate for re-use as partial make up in a sea water cooling tower.

The treated oily water sewer (OWS) effluent is used for horticulture.

By-product streams generated during the treatment of refinery waste water - skimmed or slop oils; oily sludge and biological sludge. Skimmed oil is chemical and heat treated, with recovered oils transferred back to the refinery for reprocessing. Oily sludge is thickened and then transferred back to the delayed coker unit for reprocessing. Biological sludge is thickened, stabilised, dewatered and disposed off to landfill.

The effluent treatment plant is treating 100% effluent generated by the refinery since its commissioning in December 2008 and consistently producing treated effluent (pH 6-8.5, Sulphide < 05.ppm, COD < 50 ppm, Oil & Grease < 5 ppm, Phenol < 0.35 ppm) meeting guarantee parameters for re-use for various applications mentioned earlier.

The waste streams from the cation and anion plants, and the utility waste like boiler blowdown and DM regeneration effluent, are segregated based on their constituent impurities and treated separately. The acidic water, wash water, boiler blow down, DM plant waste from both the plants are treated through a process which incorporates the INDION high rate solids contact clarifier (HRSCC), hollow fibre ultra filtration and reverse osmosis. The water recovered from these streams is taken back for process uses.

The other stream comprising TBC,PVA , scrubber, chloro and amination effluent, and the other biodegradable waste from the toilets are combined and treated by a process involving chemical treatment, HRSCC , advanced oxidization, and the state-of-art submerged membrane bio-reactor to recover water for reuse.

The complete treatment philosophy was determined after extensive studies and piloting to arrive at the most suitable technology for implementation. The plants have all been commissioned and are performing at expected levels thereby reducing fresh water consumption in the plant as well as reducing the discharge of waste to the environment.

O&M at Gujarat Mineral Development Corporation

Annual operation & maintenance (O&M) contract from Gujarat Mineral Development Corporation (GMDC), for sea water treatment plant at the 2 x 125 MW Akrimota Thermal Power Station. This comprises 2 x 1800 m3/h PT, 2 x 50 m3/h sea water desalination plant, 2 x 40 m3/h demineralisation plant & 2 x 50 kg/h electro-chlorination plant.

O&M for Gas Turbine Power Station

Gas Turbine Power Station (GTPS) located in New Delhi is a gas based power plant owned by the Delhi Government. The plant uses fresh water from the Yamuna river which is highly contaminated due to various untreated effluents being discharged to the river. Ion Exchange has been awarded the O&M contract for the complete water system which includes pre-treatment by chlorination, clarification and sand filtration followed by demineralization. The three-stream plant was supplied by the competition and the O&M team will have to ensure that treated water quality from the exit of the mixed bed unit meets the high purity requirement of the power plant irrespective of the quality of intake from the Yamuna. Ion Exchange has taken over the O&M since January 2010.

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O&M at Angeripalaym CETP

After successful commissioning of one of India’s largest textile recycling plants using membrane bio-reactor (MBR) technology, for the Angeripalayam common effluent treatment plant (CETP) project at Tirupur, Tamil Nadu, Ion Exchange was awarded the contract for operating and maintaining this state of the art system on a long term basis. The 10 MLD zero discharge treatment plant incorporates several unique technologies including MBR, ion exchange conditioning filters for removal of colour and organics, two-stage reverse osmosis and nano filtration. Our operations team will carry out comprehensive O&M of this complete process with a team of over 70 people located at site. The team will ensure that the combined effluent from around 80+ industries which comes into the plant is treated in order to maximise the recovery of water and salt solution. The recovered water and the salt solution are then sent back to the processing units for reuse. Managing the treatment process as well as ensuring quality consistently will be the responsibility of this team.

Major O&M Contracts

1. Additional O&M order from Chennai Petroleum Corporation Ltd., Chennai for their 2.5 MGD sewage reclamation project plant-2.
2. From JSW Bellary’s CRM unit at Karnataka renewal of O & M contract for DM and effluent treatment plants.
3. Three year O&M contract from Areva, Hosur along with order for water and sewage Treatment system The comprehensive O&M contract will include supply of manpower and chemicals & consumables for their uninterrupted quality supply of water at the unit .

IESL-KBL Tie-up for Customer Care
Kirloskar Brothers Ltd. (KBL), largest pump manufacturer and turnkey water project contractor in India with global pump business & Ion Exchange Services Ltd. (IESL),entered into a strategic service tie-up to expand and enhance customer service in the building and construction segment in India. The tie-up will offer comprehensive pumping solutions backed by 24x7 service support to this segment which primarily comprises hotels and resorts, malls, multiplexes and cinema halls, hospitals, airports, metros, large residential and all commercial complexes including SEZs.

IMC RBNQ Award For Ion Exchange Services Ltd.

Ion Exchange Services Ltd. (IESL) of the Ion Exchange Group was awarded a Commendation Certificate under the Indian Merchant Chambers – Ramakrishna Bajaj National Quality Awards (IMC-RBNQA) for 2007,in the Service Category.

Mr. Montek Singh Ahluwalia, Deputy Chairman, Planning Commission, Government of India presented the award to Mr. Dinesh Sadasivan, Executive Director & CEO, IESL at the award function in Mumbai. Congratulating the companies who qualified for the awards, Mr. Ahluwalia said it is indeed an achievement to pass through the exhaustive award criteria covering all aspects of business

IESL provides a complete spectrum of After Sales Services & Products including Operation & Maintenance and Build-Own-Operate/Transfer Contracts to users of Water & Waste Water Treatment Equipment across diverse industries & institutions. Headquartered at Bangalore, the ISO 9001:2000 company with a NABL Certified Laboratory has the largest Service Network in the Indian Water Treatment Industry with 25 Branches, 75 Territories & 1000 Service Personnel spread across India covering over 12000 customers. IESL has also extended its operations to neighboring countries like Nepal & Bangladesh and is poised to enter other Asian countries.

The IMC-RBNQA committee identified the following as benchmark practices of IESL:

• Total Water & Waste Water Management Solutions business approach to optimise use and recycle of water
• Multilevel Customer Feedback & Satisfaction Monitoring Reports
• Knowledge Management Systems & Training Initiatives by Top Management
• Employee Welfare & Recognition methods – Achievers Club
• Corporate Social Responsibility – Supporting under-privileged children of convicts for education & drinking water.

Modelled on the Malcom Baldrige National Quality Award (USA), the IMC-RBNQA is one of India’s most prestigious quality and business excellence awards since 1996. Applicants are judged by a panel of specially trained experts, on the critical framework of Leadership, Strategic Planning, Customer and Market Focus, Measurement – Analysis and Knowledge Management, Human Resources a Focus, Process Management and Business Results.

Acknowledging this recognition, Mr. Dinesh Sadasivan said "The RBNQA application & site visit of the examiners covered every aspect of our Service Business. The need to integrate corporate goals to the key deliverables of each and every employee, benchmarking best practices in Service Operations, and capturing the voice of all stakeholders helped tremendously in more closely aligning the organisation towards Business excellence. We shall remain committed to provide prompt, cost effective and value added quality services through continual improvement, customer orientation and employee involvement.”

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Total O&M of Tertiary Effluent Facilities for CPCL

Considering our expertise in operating and maintaining more than 2,000 water systems, cooling tower systems and other utilities for industrial customers in India, Chennai Petroleum Corporation Ltd. (CPCL), following a process of competitive bidding, awarded Ion Exchange the complete O&M of all the waste water treatment and recycling facilities. The contract includes comprehensive O&M services for all the tertiary effluent treatment systems supplied by us as well as by our competitors. The plants being operated & maintained by Ion Exchange in the complex include

1. Sewage Recovery Plant , 11 MLD
2. Zero Discharge Plant, 4.8 MLD
3. Reject Handling Plant, 1 MLD
4. Pilot Plant, 1 MLD

This complex network of various plants treating sewage from Chennai city and recycling process effluents are operated by a team of over 100 professionals from Ion Exchange headed by an overall plant manager/assisted by different sectional heads. This O & M contract is for the single largest advanced recycling facilities being operated in the country and is responsible for producing almost 14 million litres of recycled water every day (14 MLD).

O&M for Sea Water Desalination Plant at GMDC

Gujarat Mineral Development Corporation (GMDC) had a multi-effect distillation plant for desalination of sea water at their facility in the remote coastal area of Bhuj. The contract for O&M for this desalination plant, constructed using MED technology, was awarded to Ion Exchange mid 2007. The plant generates treated water for use in all processes and for drinking. The MED plant was operating at 60% of rated capacity at the time of our taking over the O&M; it has now been ramped up to the designed capacity after taking over its operation and proper monitoring, and taking care of all necessary maintenance activities.

The O&M of the complete bottling plants of IRCTC are being managed by Ion Exchange since 2002 at the Nangloi facility near Delhi and since 2004 at Danapur near Patna. Each plant currently produces over 66000 bottles/day of the hugely popular bottled water brand ”Railneer”. Our O&M scope includes the state-of-art water treatment plant, the bottle blowing and bottle filling machine, conveyors, capping, labeling, packaging, etc. the O&M also manages all the required utilities and sub system required for operation including chillers, compressors, chemical and microbial laboratory etc. The plants produce water of the highest quality meeting the stringent standards of regulations in India and worldwide. Currently the IRCTC plant at Nangloi near Delhi is being expanded by Ion Exchange and the expanded facility will increase production from the current 66,000 bottles to 1,02,000 bottles/day.

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Apart from the contract for treating 125 m3/h waste water and operating and maintaining the plant for a period of 10 years, JSW has also awarded the O&M contract for the water and waste water treatment plants constructed by us for their CRM complex in Bellary. This contract involves 24 x 7 maintenance of all systems including the 2 x 35 m3/h plant and the two effluent treatment plants, total 2200 m3/day capacity. The effluent treatment plants will treat waste water generated from the CRM complex and make it suitable for discharge.

Ion Exchange Services has set up a testing and calibration laboratory in Bangalore which is certified by the National Accreditation Board (NABL).

The demand for our O&M services keeps growing, with a number of new contracts as well as contract renewals, from:

Renewals
· ACC Chaibasa
· BKTTP
· Rail Neer, Danapur

New Contracts
· Vasavadutta Cements - AP
· Satyam Computers - Hyderabad
· HT Media, Mumbai
· Rajshree Sugars
· Indian Overseas Bank
· Ashok Leyland
· Motherson Automotive
· Le Royal Meridien
· Aqua Pure Enterprises
· Safdarjung Hospital
· BHEL Karmachari Sehkari Awa Samiti
· Danzong Breweries
· Reserve Bank of India - Chennai

Zero B Hat-Trick!

Zero B won the prestigious Mera Brand award for Best RO Water Purifier (2007), awarded for the third consecutive year on the basis of a poll conducted in 6 metros, 225 suburban towns and 25 state capitals.