Case Studies Archives - ScaleBan Equipments Private Limited https://scalebanindia.co.in/category/case-studies/ Company Website Tue, 31 Dec 2024 11:40:18 +0000 en-GB hourly 1 https://scalebanindia.co.in/wp-content/uploads/2023/10/SCALEBAN--150x150.png Case Studies Archives - ScaleBan Equipments Private Limited https://scalebanindia.co.in/category/case-studies/ 32 32 “SCALEBAN” CASE STUDY – PROJECT AT INDORAMA PETROCHEM LTD(IRPL), Thailand https://scalebanindia.co.in/2023/10/indorama/ Fri, 13 Oct 2023 06:46:29 +0000 https://scalebanindia.co.in/?p=3967 SYNOPSIS IRPL, Thailand (Petrochemical Plant, PET) Successfully achieved WaterConservation & ZLD objectives with “SCALEBAN Technology” on Sustainablebasis without installing conventional technologies Like wastewater RO & MultiEffect Evaporator (MEE) and Saved High CAPEX, OPEX and Space by using200m3/day treated wastewater directly in process plant cooling tower in Placeof Fresh Water ABOUT INDORAMA PETROCHEM LTD., THAILAND Indorama […]

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SYNOPSIS

IRPL, Thailand (Petrochemical Plant, PET) Successfully achieved WaterConservation & ZLD objectives with “SCALEBAN Technology” on Sustainablebasis without installing conventional technologies Like wastewater RO & MultiEffect Evaporator (MEE) and Saved High CAPEX, OPEX and Space by using200m3/day treated wastewater directly in process plant cooling tower in Placeof Fresh Water

ABOUT INDORAMA PETROCHEM LTD., THAILAND

Indorama Ventures is a world-class chemicals company with a global integrated leader in PET and fibers serving major customers in diversified end-use markets. IVL is world’s leading Petrochemicals producer having 119manufacturing plants in 33 countries globally. 

Being listed in Dow Jones Sustainability Indices (DJSI), they were exploring sustainable solutions for achieving Water Conservation & ZLD objectives by reusing their waste water within the plant. When it came to adopt available conventional technologies globally, high CAPEX & OPEX besides operational difficulties were serious concerns for them.

IRPL heard about Indian “SCALEBAN technology” and after thorough technical discussion and visiting different client sites for reference purpose, IRPL management decided to implement “SCALEBAN technology” at one of their PET plant in Thailand in July 2019 to validate the performance & claims of “SCALEBAN technology” in-house.

ACHIEVEMENTS of the Scaleban PROJECT

  • Achieved Water Conservation and ZLD objectives on a sustainable basis.
  • Successful utilization of 200m3/day wastewater in cooling tower.
  • 100% saving of fresh water in cooling tower.
  • Saved high CAPEX of CONVENTIONAL TECHNOLOGIES.
  • Saved high OPEX of CONVENTIONAL TECHNOLOGIES.
  • Zero footprints being an online technology.
  • High COC (25) operation of cooling tower.
  • Reduction in cooling tower blowdown by 95%.
  • Improved plant performance because of zero scale, corrosion & biofouling
    free operation of the entire cooling tower circuit.
  • Reduction in CO2 emission as “SCALEBAN” technology does not require
    energy to operate.
  • Saved Environment IRPL contributed in achieving UN sustainable development goal no. 6,7,13,14

TYPICAL wastewater handling SCHEMe BEFORE & AFTERSCALEBAN IMPLEMENTATION

PARAMETERS OF MAKEUP & CIRCULATIONWATER WITH SCALEBAN TECHNOLOGY

GRAPHICAL REPRESENTATION OF TDS

GRAPHICAL REPRESENTATION OF TDS

POST OBSERVATIONS

PROCESS PLANT COOLING TOWER RUNNING WITH WASTEWATER

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]]> “SCALEBAN” CASE STUDY – Project at Distillery plant Gulshan Polyols https://scalebanindia.co.in/2023/06/case-study-scaleban-project-at-80-kld-grain-based-distillery-plant-of-gulshan-polyols-for-optimizing-water-conservation-zld-objectives-on-a-sustainable-basis/ Fri, 02 Jun 2023 09:40:31 +0000 https://scalebanindia.co.in/?p=2389 SYNOPSIS SCALEBAN PROJECT AT 80 KLD GRAIN BASED DISTILLERY PLANT OFGULSHAN POLYOLS FOR OPTIMIZING WATER CONSERVATION & ZLDOBJECTIVES ON A SUSTAINABLE BASIS. Gulshan Polyols have implemented “SCALEBAN” technology at ethanol distillery division, Chhindwara, MP for their 80 KLD grain based distillery plant to utilize their wastewater directly at distillation & evaporation plant cooling towers to […]

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SYNOPSIS

SCALEBAN PROJECT AT 80 KLD GRAIN BASED DISTILLERY PLANT OFGULSHAN POLYOLS FOR OPTIMIZING WATER CONSERVATION & ZLDOBJECTIVES ON A SUSTAINABLE BASIS.

Gulshan Polyols have implemented “SCALEBAN” technology at ethanol distillery division, Chhindwara, MP for their 80 KLD grain based distillery plant to utilize their wastewater directly at distillation & evaporation plant cooling towers to stop operation of wastewater RO and Multi Effect Evaporator.

OBJECTIVE WITH “SCALEBAN” TECHNOLOGY

Gulshan Polyols Ltd is India’s leading manufacturer of ethanol/bio-fuel, grain and mineral based specialty products. At their distillery plant at Chhindwara 350-400 m3/day wastewater is generated which is presently being treated through available conventional technologies like wastewater RO and Evaporator (MEE) for achieving ZLD

Challenges for Gulshan:

Due to high operating cost of wastewater RO and Evaporator (MEE) to treat RO reject besides their operational difficulties, Gulshan management was searching for a sustainable solution to stop operation of these conventional technologies.

Gulshan Approach:

While searching right solution for their problem, Gulshan management came across “SCALEBAN” technology and after verifying the performance with our existing clients in India.

In the first phase, Gulshan management awarded contract to “Scaleban” to implement “SCALEBAN” technology at their distillation and evaporation plant cooling towers to utilize 200m3/day treated wastewater (wastewater RO Feed)in place of fresh water to reduce load on wastewater RO and Evaporator (MEE)to treat RO reject. This project was implemented in the month of August 2022and till date we are successfully using their wastewater in cooling towers at high COC and achieved zero scale, corrosion and bio-fouling free operation of the entire cooling tower circuit and stopped operation of wastewater RO &MEE. We implemented “SCALEBAN” equipment at the inlet of all the condensers/coolers of Distillation plant including at the inlet of surface condenser of Evaporation plant.

"SCALEBAN" water conservation & ZLD Scheme

DETAILS OF COOLING TOWERS

PARAMETERS OF WASTEWATER (MAKEUP) / COOLINGTOWER RECIRCULATION WATER

ACHIEVEMENTS OF THE “SCALEBAN” PROJECT

  • Successful utilization of wastewater in Distillation & Evaporation plant cooling tower.
  • High COC operation of cooling tower.
  • Reduction in cooling tower blowdown by 90%.
  • Elimination of soft water makeup in cooling tower.
  • Saving in fresh water consumption in Distillation & Evaporation plant cooling tower.
  • Achieving water conservation and ZLD objectives on a sustainable basiswithout conventional technologies like wastewater RO and MEE.
  • Saving in high operating cost of wastewater RO and MEE for achieving ZLD.
  • Zero scale, corrosion & bio fouling free operation of Distillation & Evaporation Condensers/Coolers.
  • Improved plant performance.
  • No downtime of the plant.
  • Reduction in Carbon footprint.
  • Gulshan contributed in achieving UN sustainable development goal no.6,7,13,14

Cooling TowerS USING WASTEWATER

"SCALEBAN" Installation at the inlet ofCondensers/Coolers

"SCALEBAN" FILTERATION SYSTEM with glass media to control TSS in cooling tower circulation water

We are thankful to Gulshan Polyols Ltd, for implementing “SCALEBAN” Technology.

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]]> “SCALEBAN” CASE STUDY – PROJECT AT JUBILANT PHARMOVA LTD, NANJANGUD​ https://scalebanindia.co.in/2023/06/case-study-scaleban-zld-project-at-jubilant-pharmova-ltd-nanjangud/ Fri, 02 Jun 2023 09:22:18 +0000 https://scalebanindia.co.in/?p=2380 SYNOPSIS Jubilant Pharmova Ltd, Nanjangud Plant has optimised water conservation and ZLD (Zero Liquid Discharge) objectives on a sustainable basis by implementing unique, revolutionary , sustainable, “SCALEBAN ” technology by minimising load on costly conventional technologies like RO & MEE. Background of ‘SCALEBAN’ Project: Jubilant Pharma Limited is a global integrated pharmaceutical company offering a […]

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SYNOPSIS

Jubilant Pharmova Ltd, Nanjangud Plant has optimised water conservation and ZLD (Zero Liquid Discharge) objectives on a sustainable basis by implementing unique, revolutionary , sustainable, “SCALEBAN ” technology by minimising load on costly conventional technologies like RO & MEE.

Background of ‘SCALEBAN’ Project:

Jubilant Pharma Limited is a global integrated pharmaceutical company offering a wide range of products and services to their customers across geographies. Jubilant has its pharma business into three segments i.e.
‘Specialty Pharmaceuticals’ comprising Radiopharmaceuticals (including Radiopharmacies) and allergy therapy products.

CONCERN for Jubilant

High operating cost of existing ZLD system was the concern for Jubilant

JUBILANT Approach:

Jubilant came across ‘SCALEBAN’ Technology through their industrial references/ interactions with our existing clients, to gain further confidence on our non conventional ‘SCALEBAN’ technology, Jubilant team visited few of our client sites. After verifying the performance of “SCALEBAN” technology, Jubilant implemented ‘SCALEBAN’ technology to utilize their 100m3/day wastewater in MEE cooling tower in place of fresh treated water at high COC for optimizing water conservation and ZLD (zero liquid discharge) objectives on a sustainable basis.

Achievements of the “SCALEBAN” Project

  • Reduction in load on conventional technologies like wastewater RO and
    MEE.
  • Saving in high operating cost of wastewater RO and MEE.
  • Completed project in 6-8 weeks.
  • Considerable reduction in Carbon footprint.
  • 100% Saving in fresh water consumption in the cooling tower.
  • High COC operations of the cooling tower.
  • Reduction in cooling tower blowdown quantity by 90%.
  • Zero scale, corrosion and biofouling free operation of the entire cooling
    tower circuit including heat exchangers.
  • No down time of the plant.
  • By implementing Scaleban technology Jubilant contributed in achieving
    UN sustainable development goal no. 6,7,13,14

After successful operation of the ‘SCALEBAN’ project, Jubilant awarded repeat order to implement ‘SCALEBAN’ technology at their another facility i.e. Jubilant Ingrevia Ltd at Gajraula (UP), India to utilize 150m3/day wastewater at pyridine plant cooling tower.

In ‘SCALEBAN’ process at Jubilant, Nanjangud, we are using 100 m3/day RO reject water (MEE feed) in cooling tower at very high COC (15-20) and saved high operating cost of MEE (Evaporator).

system details

Parameters of wastewater (Makeup) / cooling tower Recirculation water

‘SCALEBAN’ Installation AT HEAT EXCHANGERS

We are thankful to JUBILANT group for implementing “SCALEBAN” Technology for achieving water conservation and ZLD system.

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]]> “SCALEBAN” CASE STUDY – “PROJECT AT TGV SRAAC LIMITED, KURNOOL​ https://scalebanindia.co.in/2023/06/case-study-scaleban-zld-project-at-tgv-sraac-limited-kurnool/ Fri, 02 Jun 2023 09:12:27 +0000 https://scalebanindia.co.in/?p=2370 SYNOPSIS TGV SRAAC LIMITED (formerly Sree Rayalaseema Alkalies and Allied ChemicalsLtd.) is the flagship company of the TGV Group. It is the leading producer ofChlor-Alkali products and also manufactures Castor Derivatives and FattyAcids. TGV OBJECTIVE WITH “SCALEBAN” TECHNOLOGY Due to high operating cost of conventional technologies such as Evaporator for achieving ZLD objective. TGV SRAAC […]

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SYNOPSIS

TGV SRAAC LIMITED (formerly Sree Rayalaseema Alkalies and Allied ChemicalsLtd.) is the flagship company of the TGV Group. It is the leading producer ofChlor-Alkali products and also manufactures Castor Derivatives and FattyAcids.

TGV OBJECTIVE WITH “SCALEBAN” TECHNOLOGY

Due to high operating cost of conventional technologies such as Evaporator for achieving ZLD objective. TGV SRAAC management was looking for an alternative cost effective sustainable solution.

TGV Approach to adopt “SCALEBAN” technology:

TGV SRAAC came across “SCALEBAN” Technology through their industrial references/interactions with our existing clients in India and outside India. After getting good performance feedback of “SCALEBAN” Technology with our clients in India & abroad, In the 1st Phase, TGV SRAAC awarded contract to implement ‘SCALEBAN’ technology at their 500TPD Caustic Soda Evaporation plant cooling tower to utilize their 250m3/day Final RO reject in cooling tower at high COC for optimizing water conservation and ZLD objectives on a sustainable basis.

After its successful implementation at 500 TPD caustic soda Evaporation plant cooling tower, TGV SRAAC LTD. awarded repeat order for their 200 TPD caustic soda Evaporation plant cooling tower to use balance quantity of RO reject to optimize ZLD objective on a sustainable basis.

With the implementation of “SCALEBAN” technology, we have successful eliminated the need of Evaporator for the treatment of wastewater RO reject  and saved high CAPEX and OPEX for achieving ZLD objective.

Details of 500TPD Caustic Soda Evaporationplant Cooling Tower

Parameters of makeup and circulation of 500TPD Evaporation Plant Cooling Tower

PICTURE OF COOLING TOWER AND "SCALEBAN" Installation

Achievements of the “SCALEBAN” Project:

  • Achieved water conservation and ZLD objectives on a sustainable basis.
  • Saving in high CAPEX of MEE (Evaporator).
  • Saving in high OPEX of MEE (Evaporator).
  • 100% saving of fresh water consumption in cooling towers.
  • Completed project in 6-8 weeks time.
  • Considerable reduction in Carbon footprint.
  • High COC operations of the cooling tower.
  • Substantial reduction in cooling tower blowdown quantity.
  • Zero scale, corrosion & biofouling free operation of the condensers/coolers.
  • By implementing Scaleban technology TGV contributed in achieving UNsustainable development goal no. 6,7,13,14

We are thankful to TGV SRAAC team for implementing ‘SCALEBAN’ Technology for achieving water conservation and ZLD system on a sustainable basis.

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]]> “SCALEBAN” CASE STUDY : PROJECT AT ADITYA BIRLA CHEMICALS THAILAND LTD. https://scalebanindia.co.in/2023/06/zld-plant-case-study-project-at-aditya-birla-chemicals-thailand-ltd-3/ Fri, 02 Jun 2023 09:04:06 +0000 https://scalebanindia.co.in/?p=2360 Background of Aditya Birla Chemicals (ABCTL),Thailand Aditya Birla Chemicals (Thailand) (ABCTL) is a part of the Aditya Birla Group’s chemicals business. Aditya Birla Chemicals (Thailand), Sulphites Division located at Saraburi, Thailand and manufacturing Sodium Sulphites and Sodium Meta-Sulphites products. Challenges for ABCTL ABCTL is generating 250 m3/day Process wastewater having TDS of 20,000 ppm. As […]

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Background of Aditya Birla Chemicals (ABCTL),Thailand

Aditya Birla Chemicals (Thailand) (ABCTL) is a part of the Aditya Birla Group’s chemicals business. Aditya Birla Chemicals (Thailand), Sulphites Division located at Saraburi, Thailand and manufacturing Sodium Sulphites and Sodium Meta-Sulphites products.

Challenges for ABCTL

ABCTL is generating 250 m3/day Process wastewater having TDS of 20,000 ppm. As per Thai Pollution Control Board norms, ABCTL had to recycle this effluent for reuse and to achieve Zero Liquid Discharge (ZLD). Quality of this effluent was not suitable for RO hence they had no other option but to install Multi Effect Evaporator (MEE) for achieving ZLD objective. High CAPEX & OPEX was the serious concern for them to treat 250 m3/day process wastewater through Evaporator (MEE)

“SCALEBAN” Solution

ABCTL installed 27 nos. of “SCALEBAN” equipment at the cooling water inlet of different process plant heat exchangers in Feb 2019 to utilize 250 M3/Day process effluent (Waste Water) as makeup in place of fresh water at their main process plant cooling tower. After implementation of “SCALEBAN” Equipment at the inlet of 27 nos. process heat exchangers (PHEs) and by using “SCALEBAN” Specialty chemicals in cooling towers,  ABCTL is successfully using wastewater in their process plant cooling tower and operating it at 3,00,000 PPM TDS(30%). Due to high COC operation of cooling tower ABCTL is giving only 20 m3/day blowdown having 30% TDS which they are sending to authorized agency in Thailand to handle it separately. ABCTL could manage to achieve ZLD objective on a sustainable & most cost-effective basis by installing “SCALEBAN” technology without implementing costly conventional evaporation (MEE) technology.

ABCTL observed smooth operations of the plant with respect to heat exchange coefficient due to zero scaling in heat exchangers even at such high TDS level besides saving 250M3/Day fresh water. ABCTL also observe corrosion and biofouling free operation of the entire cooling tower circuit.

Achievements of the “SCALEBAN” Project

  • Achieved water conservation and ZLD objectives on a sustainable basis.
  • Saving in high CAPEX of MEE (Evaporator).
  • Saving in high OPEX of MEE (Evaporator).
  • 100% saving of fresh water consumption in cooling towers.
  • Completed project in 6-8 weeks.
    Considerable reduction in Carbon footprint.
    High COC operations of the cooling tower.
  • Substantial reduction in cooling tower blowdown quantity.
  • Zero scale, corrosion & biofouling free operation of the condensers/coolers
  • By implementing Scaleban technology ADITYA BIRLA contributed in
    achieving UN sustainable development goal no. 6,7,13,14

After successful operation of the “SCALEBAN” project, ABCTL awarded repeat order to “SCALEBAN” for their another facility in Thailand. “SCALEBAN” Technology is handling 300m3/day process waste water and other cooling tower blowdown in process plant cooling tower successfully and achieving their water conservation and ZLD objectives on a sustainable basis.

Details of Process plant Cooling Tower

Parameters of wastewater (Makeup) & cooling tower Re-circulation water

“SCALEBAN” ZLD SCHEME

"SCALEBAN" Installation

Appreciation of "SCALEBAN" technology at ABCTL, Thailand:

We are thankful to ABCTL, Thailand for implementing  “SCALEBAN” Technology for achieving water conservation and ZLD objectives on a Sustainable basis.

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]]> “SCALEBAN” CASE STUDY – PROJECT AT BIOCON BIOLOGICS, MALAYSIA https://scalebanindia.co.in/2023/05/case-study-scaleban-zld-project-at-biocon-biologics-malaysia/ Fri, 26 May 2023 08:09:25 +0000 https://scalebanindia.co.in/?p=2293 SYNOPSIS BIOCON BIOLOGICS is an Indian company and has a large insulin manufacturing facility in Malaysia. As per DOE (Department of Environment) norms in Malaysia, they were allowed to discharge only 400 m3/ day treated wastewater outside the plant after achieving discharge limit parameters, because of this restriction and variation in the raw wastewater parameters, they were not able […]

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SYNOPSIS

BIOCON BIOLOGICS is an Indian company and has a large insulin manufacturing facility in Malaysia. As per DOE (Department of Environment) norms in Malaysia, they were allowed to discharge only 400 m3/ day treated wastewater outside the plant after achieving discharge limit parameters, because of this restriction and variation in the raw wastewater parameters, they were not able to achieve their full production. Due to this serious issue they were searching for technologies to recycle their 400 m3/day wastewater within the plant to utilize optimum capacity of the plant.

BIOCON OBJECTIVE WITH “SCALEBAN” TECHNOLOGY

Due to variation in the wastewater parameters, No technology supplier was able to provide a solution to treat their wastewater, as all available conventional technologies are designed on the basis of fixed design wastewater parameters thereby recycling of wastewater project was getting delayed and affecting the plant production.

BIOCON Approach to adopt “SCALEBAN” technology:

BIOCON came across “SCALEBAN” Technology through their industrial references/interactions with our existing clients in India and outside India. After getting good performance feedback of “SCALEBAN” Technology with our
clients in India & abroad, BIOCON Biologics, awarded a contract to “Scaleban” to utilize their 400m3/day high TDS wastewater at 5Nos. x 1060TR Chiller condenser Cooling Towers in place of fresh water for achieving water
conservation and ZLD on a sustainable basis. This project was commissioned in the month of August 2021.
After successful operation of the “SCALEBAN” project, BIOCON awarded repeat order to “SCALEBAN” for their another facility in Malaysia to utilize 200m3/day utility RO reject in the Chiller and SRP Cooling Tower.

“SCALEBAN” technology is handling total 600m3/day wastewater in all the Cooling Towers successfully and achieving their water conservation and ZLD objectives on a sustainable basis ,also saving equal amounts of fresh water. In the “SCALEBAN” process we are operating a cooling tower at very high COC (20-25) with wastewater and maintaining 80,000 ppm ;of TDS in cooling tower recirculation water and giving only 15 m3/day concentrated blowdown, which Biocon is handling separately.

Details of Process plant cooling tower

Parameters of wastewater (makeup) / cooling tower recirculation water

"SCALEBAN" water conservation & ZLD Scheme

Achievements of the “SCALEBAN” Project for Biocon

  • Achieved water conservation and ZLD objectives on a sustainable basis.
  • Saving in high CAPEX of MEE (Evaporator).
  • Saving in high OPEX of MEE (Evaporator).
  • 100% saving of fresh water consumption in cooling towers.
  • Completed project in 6-8 weeks.
  • Considerable reduction in Carbon footprint.
  • High COC operations of the cooling tower.
  • Substantial reduction in cooling tower blowdown quantity.
  • Zero scale, corrosion and biofouling free operation of the entire cooling tower circuit including chiller condensers.
  • Maintained chiller approach.
  • Saving in energy consumption.
  • No down time of the plant.
  • By implementing Scaleban technology Biocon contributed in achieving UN
    sustainable development goal no. 6,7,13,14.

Chiller cooling tower circulation TDS

WATERFRESH WATER CONSUMPTION TREND AFTER “SCALEBAN” technology implementation

"SCALEBAN" Installation

Zero Liquid Discharge

Cooling TowerS USING WASTEWATER

Appreciation of "SCALEBAN" technology at BIOCON Malaysia

SUSTAINABILITY REPORT : Biocon Biologics Sets a New Standard in Sustainability by Reducing Freshwater Consumption by 30%

We are thankful to BIOCON Biologics, Malaysia for implementing “SCALEBAN” Technology for achieving water conservation and the ZLD  system.

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