ntpc netra's conference on r&d for energy...

Revolution in Water Treatment…

A Fit & Forget System

NTPC NETRA's Conference on R&D for Energy Sustainability

Presentation on Non-chemical Technology for High COC Operation with Scale

Inhibition for achieving “ZLD” 31st March 2016

NETRA

SCALE-BANTM A Sustainable solution

for Zero Liquid Discharge (ZLD)

A Fit & Forget System…

Continuously improving the possibilities to Innovate the conservation of natural resources….

A Non Chemical Water Treatment…



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.



Vision

To provide a Self Sustainable, Efficient and Cost Effective Zero Liquid Discharge

(ZLD) solution for Industries.



Optimizing Generation through Scale free operations

Maximizing Water Conservation

A Sustainable Zero Liquid Discharge (ZLD) Solution

MISSION



SCALE-BANTM equipment has been developed by years of

hard researches & trials and in commercial production since

1999. The technology is proven and well tested. The

references of its successful running in more than 200

industries and applications have been established.

“SCALE-BANTM is an online non chemical static mechanical

equipment which reduces 30% to 40% water consumption in

thermal power plants besides total prevention of hard water

scale in condensers/heat exchangers in cooling water

services.”

Genesis



Impacts of scaling:

Loss of Vacuum/Generation & Increased steam consumption

Increased water consumption and water pollution

Problems & Concerns

SCALING IN CONDENSER/HEAT EXCHANGER

To meet above guidelines, conventional systems like RO & Multi Effect Evaporator (MEE) are very costly to install & operate. RO & MEE operations are cumbersome.

Zero Liquid Discharge (ZLD) & Specific Water Consumption in Thermal Power Plants as per New Gazette Notification (7th Dec. 2015) issued by Government of India-MOEF to be mandatorily achieved



“Scale of even 0.5 mm causes an energy loss of 7%”

Impact of Scale in Heat Exchangers

11 27 48 90

0.3

0.71

4.7

9.5

4

Efficiency Loss in %



RO & MEE

Chemical Treatment

Online Ball Cleaning System

Softener Plant

Conventional SCALE-BAN

Non-Chemical Static Mechanical Equipment

Available methods for ZLD & Scale Prevention

Restricted level of hardness (300ppm) and TDS (1500ppm) in cooling water causing Heavy Blow Down from cooling tower.

Blow down water can be consumed only after treatment through

RO followed by MEE.

Recurring Expenses on RO+MEE operations, Online Ball Cleaning System, anti-scalant chemical dosing & softener operation in cooling tower.

No guarantee for zero scale (Generation losses).

Frequent de-scaling of condenser/heat exchanger.

Limitations of Conventional Systems for achieving ZLD & Scale free Operations

Cooling tower can be operated at very high hardness (10000ppm) and TDS (50000ppm), Unbelievable COC level of 15 to 20 already achieved.

Reduction in blow down by more than 80% to 90% (ZLD achieved with zero recurring expenses).

Elimination of RO+MEE system for achieving ZLD.

Complete elimination of Online Ball Cleaning System, Softener & anti-scaling chemical.

Zero scale is guaranteed for 20 years.

De-scaling of Condensers/heat exchangers is not required.

Operations with SCALEBAN

Working Principle of

SCALE-BANTM “Innovation

evolved from problem”

SOLUBILITY CHARACTERISTICS OF WATER S O

L U

B I

L I

T Y

Temperature

S1

S2

T1 T2

Ca++

Mg++

Relationship of pH & Solubility of Ca2+ and Mg2+in Liquid

Relationship of Temperature & Solubility of Ca2+ and Mg2+ in Liquid

S O

L U

B I

L I

T Y

pH Value

S1

S2

P1 P2

Ca++

Mg++

SCALEBAN

IN HEAT

EXCHANGER IN SCALEBAN

GALVANIC PRINCIPLE



Working process of SCALE-BANTM



VIDEO ON SCALEBAN AT NTPC DADRI



SCALE-BAN Installation In a Power Plant



DESIGN OF A SELF SUSTAINABLE, EFFICIENT AND COST EFFECTIVE ZERO LIQUID

DISCHARGE MODEL

ZERO LIQUID DISCHARGE (ZLD) WITHOUT SCALEBAN

COOLING TOWER --------------------------------

-------------------------------------------------------------

CONDENSER/ COOLERS

CONDENSER/ COOLERS

Make up water CLARIFIED WATER

EFFLUENT TREATMENT PLANT

CT Blow Down water

RO PLANT

COOLING TOWER/PROCESS

APPLICATIONS

RO PERMEATE

ETP TREATED WATER

MULTI EFFECT EVAPORATOR

(MEE)

2-3 COC

ZERO LIQUID DISCHARGE (ZLD) WITH SCALEBAN

COOLING TOWER ----------------------------------------------------------------

-----------------------------

CONDENSER/ COOLERS

CONDENSER/ COOLERS

Make up water CLARIFIED WATER

EFFLUENT TREATMENT PLANT

RO PLANT

COOLING TOWER/PROCESS

APPLICATIONS

RO PERMEATE

ETP TREATED WATER

MULTI EFFECT EVAPORATOR

Negligible Blow Down due to high COC. Hence can be directly taken

for ash handling/ coal handling

15-20 COC

COOLING TOWER ---------------------------------------------------------------------------------------------

CONDENSER/ COOLERS

CONDENSER/ COOLERS

SCALEBAN

SCALEBAN

Make up water

FINAL SCHEME WITH SCALEBAN FOR ACHIEVING ZERO LIQUID DISCHARGE (ZLD)

Negligible Blow Down due to high COC. Hence can be directly taken for ash

handling/coal handling

CLARIFIED WATER

15-20 COC



SCALEBAN V/S CONVENTIONAL SYSTEM FOR ZLD AND SCALE PREVENTION

SCALEBAN SOLUTION CONVENTIONAL SYSTEM

It can handle very high hardness (10,000 PPM) & very high TDS (50,000 PPM).

Restricted low level of hardness (300 PPM) & TDS (1500 PPM).

No effect of seasonal or annual variation of water quality.

Chemical treatment and RO are water quality dependent.

Life time zero recurring cost for operation and maintenance.

Daily recurring expenses, Heavy opex for MEE & life of RO Membrane maximum 3 years.

Zero Scale Guarantee in Condensers. No Guarantee of Zero Scale.

Better life of Condenser Tubes. Acid and High Pressure jet cleaning shorten the life of tubes.

Additional Plant availability of 10-15 days enhancing PLF by 3% to 4%.

Downtime required for condenser/heat exchanger de-scaling.

Minimum 1% steam saving as condenser vacuum maintained at higher side.

Vacuum deteriorate over time leading to plant shutdown.

No land space for installation. Large shed required for RO & MEE Plant.

No power Consumption. Minimum 2 MWH power consumption.

ROI Maximum 2 years. Only Expenses, No ROI

No need of EVAPORATORS for achieving ZLD EVAPORATORS are required for achieving ZLD



• pH value of re-circulating water should be maintained

between 7.0 to 8.5

Working Parameters of SCALE-BANTM



Started as a concept in late 90’s - Now a proven technology and continuously proving the potential as the most efficient, cost effective & sustainable solution for Zero Liquid Discharge (ZLD) with Zero Scaling.

Year 2000: SEP

200 Plus Satisfied Clients

Year 2014: NTPC 1000MW power plant



SCALEBAN CASE STUDY AT NTPC, DADRI 2X490MW TPP



The ground work for the implementation of Scaleban at NTPC power plants started in 2012 by approaching to the then RED Mr. A. K. Jha (Director Technical), who advised to demonstrate Scaleban technology to NETRA.

BACKGROUND



Presentation made to NETRA in May 2012 followed by NETRA’s visit to 3X130MW CPP of Bhushan Power and Steel ltd. Sambalpur (Orissa) to study Scaleban performance.

After satisfactory visit to BPSL Sambalpur, NTPC formed a team consisting of members from NETRA, OS & Dadri station.

Introducing Scaleban



NTPC Dadri issued work order to Scaleban in November 2013.

Scaleban was commissioned in April 2014 on all the heat exchangers of Unit -5 and on Unit-6 in May 2015.

Project Implementation



2X490MW NTPC, DADRI TPP

SCALEBAN INSTALLATION IN 490MW POWER PLANT CONDENSER (NTPC DADRI)



“Scaleban offered all the equipment for unit-5 and unit-6 free of cost as a salute to our

Nation”



From October 2014 Plant COC started increasing from average 2.5 to average 6 till December 2014 and passed bore well water circulation test.

Performance comparison was carried out by opening a Plate heat exchanger (PHE -5b) of Unit-5 which is fitted with Scaleban and a PHE of Unit-6 which was then operating without Scaleban.

Performance Evaluation

No scale

UNIT 5 PHE PLATE - After Scaleban

UNIT 6 PHE PLATE – Without Scaleban

Very hard Scale



Impressed with the 10 months of performance, NTPC Dadri showcased the Scaleban Technology at their annual O&M conference during 13th to 15th February, 2015 and had presented a paper.



NTPC DADRI STALL AT NTPC O&M CONFERENCE 13th-15th FEBRUARY 2015



One pass of Unit 5 condenser opened on July 22, 2015 and found Scale free after

15 months.

Unit 5 condenser tube condition before installation of Scaleban



1. Average 8 COC to be maintained during the month of December 2015 .

2. pH to be maintained beyond 8.3 during the entire month.

3. Vacuum loss due to dirty tube was recorded as 14.52 mm Hg on 28.11.2015.

4. The Criteria for success of Scaleban performance is if vacuum loss due to dirty tube remains within 3 mm of Hg.

Final Performance Test Parameters



PHE 5b Opened for physical inspection

Before Concluding on 30.12.2015



1. With Installation of Scaleban no scale has been observed during the complete test.

2. Calculated water saving of 31.44%, anti-scaling chemical saving of 100% and considerable reduction in sulfuric acid consumption and pumping power.

3. NTPC Dadri shall further increase COC to 10 in next 3 months for achieving ZLD.

SCALEBAN PERFORMANCE RESULTS



In line with the environment (protection) amendment rule 2015 and the goal of National Water Mission for “Increasing water use efficiency by 20%” in existing and upcoming Power Plants, SCALE-BAN™ EQUIPMENT is the only technology available on self sustainable basis for achieving Zero Liquid Discharge along with ensuring Zero Scaling in Condensers/Heat Exchangers with lucrative ROI without any recurring cost.

With Scaleban, the cost of water can be reduced up to 40%, associated water treatment cost, electricity cost will be reduced & saving on chemical consumption. Scaleban is environmentally sustainable & helps achieving NATIONAL GOALS OF WATER CONSERVATION.

Conclusion



BHUSHAN POWER & STEEL LTD., Sambalpur (Orissa)

Power Plant : P.O.Date : 01 May 2011 1. 130MW X 3 Nos. 2. 60MW X 1 No. 3. 40MW X 1 No. 4. 8MW X 2Nos.

CSP Plant : P.O.Date : 01 May 2011

Oxygen Plant : P.O. Date : 01 May 2011



Bengal Energy Ltd., Kharagpur (WB) 40MW CPP (Installation in March 2014)

Condenser tubes at 15 COC



Thank You!

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