International

International

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.

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.

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.