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Transcript of RALEX® - WATER TREATMENT Company General Presentation Aquatech India Tomas Dornik, MEGA a.s., Czech...
RALEX® - WATER TREATMENT
Company General Presentation
Aquatech India
Tomas Dornik, MEGA a.s., Czech Republic
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Our mission
To be preferred supplier of electro-chemical membrane processes providing
superior solutions and services with maximum respect to the environment.
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Company profile
We are innovative and constantly growing private company with more than 25 years of experience in the production of ion-exchange membrane and supply of membrane technologies
Family owned company (Mr. Lubos Novak, Ph.D.) author or co-author of patents (>20), research reports (>100)
especially in the field of membrane processes, president of Czech Membrane Platform, founder of electro-membrane processes in CR
Core business is production of ion-exchange membranes, spacers, membrane stacks and supply of complex electro-membrane technologies on the basis of own know-how
Processes and products are certificated by ISO (EU standards) and GOST-R (Russian Standards)
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History
1995 2012
1975 – 1981: Central laboratories of uranium industry (CSUP)
1981 – 1990: Research and Development Institute of CSUP
since 1985: Industrial production of membranes RALEX®
1991 – 1992: MEGA - VVÚ s.p. – state company
• since April 1992: MEGA a.s.
• 2000: MEGA-TEC s.r.o.
• 2007: MEGA ProfiLine
• 2008: MemBrain
• 2012: MEGA Ukraine
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Production Plant in Straz pod Ralskem
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MEGA Group
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MemBrain s.r.o. R&D (research and development)
Subsidiary of MEGA a.s., Quick transfer of results of research works to industrial applications
Headquarters: Stráž pod Ralskem, Czech Republic
Founded: 2008
Employees: 56 Activities are mainly focusing into:
- the latest processing trends in the field of membrane processes
- electro-membrane processes
- hybrid membrane processes
- bipolar membranes
- gas separation
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Membrane Innovation Center (MIC) is a unique Center focusing on research and innovation in membrane processes, which provides:
new infrastructure for research and innovation activities
modern equipment of analytical, technological and mobile laboratory
net of industrial and academic organizations
more than ten years experience in R&D
support for education and popularization of the field
MemBrain s.r.o. Membrane Innovation Center (MIC)
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Our Offer in Membrane Processes
Products Heterogenous ion-exchange RALEX membranes® (
www.ralex.eu) Electrodialysis equipment (laboratory, pilot, industrial) Electrodeionization equipment Electrophoretic cells (flat, tubular)
Membrane technologies (turn-key delivery) Electrochemical (ED(R), EDI) Complex process lines (integrated membrane processes)
R&D and other services Consultancy, expertise, designing Laboratory and pilot scale trials Guarantee and post-guarantee service Staff training
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Main Products & Applications
Processes
ED, EDR, EDI, (RO)
Segment Water Food Special Apps Replacement E-coat
Product EWTU, HPWU, (RWTU)
EWDU ELPU RALEXEL, RALEX EFC
Application
Sludge lake water
treatment
Whey demineralization
L-carnitineDesalination
Membranes(GE-Ionics, Schekino)
Anode cell tubular
Ammonium nitrate
condensate
Mother liquor demineralizatio
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Gama–butyrobetain desalination
Spacers(GE-Ionics)
Anode cellflat
TertiaryTreatment
UF permeate demineralizatio
n
Purification of organic solution
Electrodes(GE-Ionics)
Membrane tube
Brackish water
desalination
Lactulose syrup demineralizatio
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Glycol purification ED Stacks(Eurodia)
Membrane roll
Waste waterRe-use
Skim-milkde-ashing
XyloseDesalination
Ultra-pure water
production
Re-use of rinse water from
galvanizing plant
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Strategic partners:
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Electrodialysis (ED) is an electrically-driven method of removing dissolved ionic compounds
- Dissolved solids may exist in a form of ions that are either positively or negatively charged (cations or anions)
- When an electrical potential is applied across the ion-selective membrane, cations migrate towards the negative electrode (cathode) and anions migrate towards positive electrode (anode)
- The driving force is DC electric field
Definition of Electrodialysis
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Ions are nothing more than atoms or molecules that have gained or lost an electron(s).- Generated by salts, acids or alkalies dissociation in water
- Both types – organic and inorganic
- Independent movement in solution
Definition and Characteristics of Ions
Cation is a positively charged (loosing of electron) ion- Cations migrate to the cathode
Anion is a negatively charged (gaining of electron) ion - Anions migrate to the anode
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Ion-exchange membranes present ion-selective barries
Cation-exchange membranes (CM)- Selective transport of cations
- Anionic transport blocked
- Permselectivity about 96 %
Anion-exchange membranes (AM)- Selective transport of anions
- Cationic transport blocked
- Permselectivity about 96 %
Ion-exchange Membranes
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Basic characteristics- Series of alternating ion-exchange membranes separated by
spacers
- One cation and one anion exchange membrane plus two spacers = cell pair
- Spacers are alternately connected to internal manifolds for proper liquids distribution
- Platinum-coated titanium electrodes
Electrodialyzer – Heart of the ED Process
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Electrodialyzer – Heart of the ED Process
1- Manifolds with built-in collectors
2 - Electrodes
3 - Ion exchange membranes
4 - Spacers
5 - Tie-rods, washers and nuts
6 - Assembly pins
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Membrane Stack ED/EDR-II
Membrane stack EDR-III
RALEX EDR stacks for industrial applications
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Small capacity EWT technology units
P-series - EWTU P10 and EWTU P20 are compact, fully autonomous processing
units for small size projects till 15 m3/hour (EWTU P10) and 20 m3/hour (EWTU P20); also suitable for piloting and/or testing
- Both single pass and batch process applicable
- Up to three stacks in series (for single pass mode)
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Medium-capacity EWT technology units
M-series - M45 and M90 are compact, fully autonomous processing units for
medium-capacity size projects till 45 m3/hour (EWTU M45) and till 90 m3/hour (EWTU M90);
- Operating in single-pass through mode- M45 - arrangement in one line ; up to three stacks in series- M90 - arrangement in two lines; up to three stacks in series a s
standard, can be designed with 2 concentration loops as four stages technology
RALEX® EWTU M45 RALEX® EWTU M90
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Large scale EWT technology units
TwinLine90 12L/3S (approx. 500 m3/hour of product)
TwinLine90- Inlet hydraulic skid with reversal valves, pneumatic actuated- Two EDR lines, 2, 3 or 4 stages- Outlet hydraulic skid- Pipe collectors
One TwinLine90
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MEGA industrial applications of ED/EDR in Water Reuse and Desalination
Water Reuse - of biologically pretreated waste waters to produce water for
agricultural or landscape irrigation- of discharged water from industry to reuse it back to a process
(as process water, make up water for cooling towers, RO brine recovery)
- treatment of waste condensates from fertilizer industry to reuse ED concentrate back in the production process and diluate in water management of the company
- …
Desalination- of tailing ponds (mining industry) - of gas well waters- of brackish waters to produce drinking water- …
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MEGA industrial applications of ED/EDR in Water Reuse and Desalination
0,1 $/m3
1 $/m3
10 $/m3
M
B C
IX/A
IX
1 g/L 10 g/L 100 g/L
BWRO
SWRO
EDI
ED
R
EDR
Reverse Osmosis
Evaporation
Ion Exchange
E-Separation
ROEDRIX
EDR Evap
TDS
Cost
Desalination cost of various technologies
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MEGA projects in Water Reuse: Project “Depurbaix” Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation
Client: BEFESA/ACSA
Project: Municipal waste water (tertiary) treatment to produce irrigation water
Locality: Barcelona, Spain
Commissioning: 2010
Feed specification: Municipal wastewater after biological and mechanical pre-treatment; 3200 microS/cm
Quality of Product: < 750 microS/cm
Capacity of product: 4x 12.000 m3/day (4x 500 m3/hour)
MEGA technology: RALEX EWTU TwinLine90 48L/2S (EDR-III/600)
Mode: Single pass, water recovery 86%
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MEGA projects in Water Reuse: Project “Depurbaix”Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation
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Process block scheme
Feed into wetland areasFeed into river Llobregat
Tailing pond K II
Filtration
ED
Secondary settler
WWTP Actiflo®
Coagulation, Injection,
Maturation, Lamella Clarifier
Discfilter
Disinfection
UV
Cartridgefiltration
Agricultural Irrigation
UF, RO, Ultraviolet
Injection into aquifer to prevent saline intrusion
Sand filtration
hypochlorite
MEGA projects in Water Reuse: Project “Depurbaix” Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation
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MEGA projects in Water Reuse: Project „A.R.P.C.“Desalination of biologically pretreated waste water to produce make up water for cooling towers
Client: GEMWATER/ ARAK PETROCHEMICAL CORPORATION
Project: Desalination of biologically pretreated waste water from petrochemical
plant to produce make up water for cooling towers
Locality: Arak, Iran
Commissioning: 2010
Feed specification: Wastewater after biological and mechanical pre-treatment, 1800 microS/cm
Quality of Product: 85% of desalination degree (approx. 200-250 microS/cm)
Capacity of product: 210 m3/hour
MEGA technology: RALEX EWTU 6L/3S (EDR-III/500)
Mode: Single pass, water recovery 85%
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Tailing pond K I
MEGA projects in Water Reuse: Project „A.R.P.C.“Desalination of biologically pretreated municipal waste water to produce make up water for cooling towers
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Process block scheme
MEGA projects in Water Reuse: Project „A.R.P.C.“Desalination of biologically pretreated municipal waste water to produce make up water for cooling towers
Waste water from Complex
Activated sludge
Sand filters + Carbon filters
Cooling tower make up
EDRDAF
Clarifier
Evaporation pond
Cartridge filters
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Client: DIAMO s.p., zavod GEAM
Project: Desalination of tailing ponds created by uranium mining
Locality: Dolni Rozinka, Czech Republic
Commissioning: 1986, extension 1995, extension 2007
Feed specification: Alkaline tailing pond waters from uranium mining with approx. 35 g/l TDS, containing, especially anions SO4
2- (20 g/l), NO3-, NO2-, cations NH4 , Na+, Ca2+, Mg 2+, other metals as Mo, organic matters, uranium U
Pretreatment: Addition of lime and soda ash to precipitation Ca2+ and Mg2+ , sand filtration sorption of heavy metals and uranium on ionexchange colon
filled by LEWATIT, sorption of organic solids on acivated carbon
Capacity, composition: ED (membrane stacks ED-II) in Feed&Bleed mode- Feed: 65 m3/h, TDS approx. 35 g/l- Diluate: 50 m3/h, TDS 12-15 g/l; Concentrate: 15 m3/h, TDS
min. 100g/l
RO- Feed: 50 m3/h, TDS 12 g/l- Permeate: 35 m3/h, TDS less than 0,5 g/l; Retentate: 15 m3/h,
TDS cca 40 g/l
Quality of Product: Desalinated stream is discharged after pH controlle to a river, concentrate is evaporated to the final commercial product of pure Na2SO4
MEGA technology: Combination of ED and RO; ED: RALEX EWTU 30xED-II/200
ED Mode: Feed&Bleed
MEGA projects in Desalination: Project „GEAM“Desalination of tailing ponds (mining industry)
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Tailing pond K I
Tailing pond K II
MEGA projects in Desalination: Project „GEAM“Desalination of tailing ponds (mining industry)
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Tailing pond K II
Tailing pond water
Sand filtration
GAC Filtration (sorption of
organic solids)
ED
Drainage water Ca and Mg
precipitation
Lime,Na2CO3
Sorption of heavy metals and U (on ion
exchange columns)
RORiver
Evaporation, Na2SO4
crystalization
Process block scheme
MEGA projects in Desalination: Project „GEAM“Desalination of tailing ponds (mining industry)
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Project: Desalination of tailing ponds created after production of aluminium oxide
Locality: Ziar nad Hronom, Slovakia
Commissioning: 2003
Feed specification: Very high alkalinity waters (pH 13-14) from red mud tailing pond (nearly 10g/l of free NaOH, containing anions OH-, CO3
2-, cations Na+, K+, metals as Al (1g/l), heavy metals Cr, As, Mo, V and some organic matters)
Pretreatment: Neutralisation with H2SO4 and precipitation using FeSO4 plus floccculant, sedimentation and filtration, additional acidification and double filtration before electrodialysis itself
Capacity, composition: Feed: 14,4 m3/hr at 37 g/l TDS ; Diluate: 11,8 m3/hr at 6 g/l TDS; Concentrate: 2,6 m3/hr at 180 g/l TDS
Quality of Product: Desalinated stream is discharged after pH controlle to a river, concentrate is evaporated to the final commercial product of pure Na2SO4
MEGA technology: ED: RALEX EWTU 12xED-II/200
Mode: Feed&Bleed
MEGA projects in Desalination: Project „ZSNP“Desalination of tailing ponds (mining industry)
DIV
ISO
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ANE
PRO
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MEGA projects in Desalination: Project „ZSNP“Desalination of tailing ponds (mining industry)
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Tailing pond water
Floculant
Sedimentation Sand and anthracite filtration I
Decarbonation
(by air)
ED
NaClO2 (disinfection)
RiverNeutralization,
As and Cr precipitation
H2SO4,
FeSO4
H2SO4,
NaClO2 (disinfection)
Sand and anthracite filtration II
Bag and Cartridge filtration
Evaporation, Na2SO4
crystalization
MEGA projects in Desalination: Project „ZSNP“Desalination of tailing ponds (mining industry)
Process block scheme
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Project: Small capacity unit - treatment of gas well waters
Locality: Alberta-Calgary, Canada
Commissioning: 2008
Feed specification: Gas well water, TDS in range 10 000 – 18 000 mg/l
Quality of Product: Drinking water for hog barns, TDS under 500 mg/l
Capacity of product: approx. 40 m3/day
MEGA technology: RALEX EWTU P10 1xEDR-II/200-0.8;
Mode: Batch
MEGA projects in Desalination: Project „GRP“Desalination of gas well waters
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MEGA projects in Desalination: Project „GRP“Desalination of gas well waters
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MEGA projects in Desalination: Project „GRP“Desalination of gas well waters
Process block scheme
Gas well water
Bag
filtration 1 µm
GAC Filtration (sorption of
hydrogencarbons)
EDR
Drinking water
Feed tank 1
Feed tank 2
EDR
Brine tank
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Project: Pilot unit - treatment of river water to produce drinking water
Locality: Abrera, Barcelona, Spain
Commissioning: 2008
Feed specification: River water, < 2 000 microS/cm, problem s with high level of Trihalomethanes
Quality of product: Potable water, 400-500 microS/cm
Capacity of product: 10-12 m3/hour
MEGA technology: RALEX EWTU P10 2xEDR-III/150-0.8
Mode: Single pass
MEGA projects in Desalination: Project „Llobregat-Abrera “Desalination of brackish waters to produce drinking water
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MEGA projects in Desalination: Project „Llobregat-Abrera “Desalination of brackish waters to produce drinking water
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MEGA projects in Desalination: Project „Llobregat-Abrera “Desalination of brackish waters to produce drinking water
Process block scheme
Llobregat
River
KMnO4 Coagulant Floculant
Sedimentation
ClO2
Sand filtration
GAC Filtration (dechlorination)
RemineralizationCO2 CO2
Cl2 Cl2
Drinking water
EDR
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MEGA projects in Chemical Industry: Project „JSC Minudobreniya “Treatment of waste waters from fertilizer industry
Client: JSC MINUDOBRENIYA – Rossosh,
Project: Treatment of waste waters from production of NPK in order to reuse ED concentrate back in the production process. Diluate stream is used in water management of the company.
Locality: Rossosh, Russia
Commissioning: 2012
Feed specification: 60 m3/hour of wastewater from ammonia nitrate production, 1,7 g/l (mainly NO3, NH4
+)
Requirement for product: ED concentrate approx.100 g/l (1 m3/h), diluate approx. 0,05 g/l (59 m3/h)
MEGA technology: Pretreatment - Sand filtration plus microfiltration
RALEX® EWTU М90 2L/4S EDR-III/600; RALEX® EWTU P15 2xED-II/250;
Mode: 1. part: Basic demineralization on RALEX® EWTU M90 2L/4S EDR-III/600 operating in one-pass mode
2. part: The concentration on the two units RALEX® EWTU P15 2xED- II/250 operating in batch mode
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MEGA projects in Chemical Industry: Project „JSC Minudobreniya “Treatment of waste waters from fertilizer industry
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MEGA projects in Water Reuse: Project „JSC Minudobreniya - Rossosh“Treatment of waste waters from fertilizer industry
Pretreatment
EWTU M90 2L/4S
EDR-III/600
Sand filtration
MF
2 x EWTU P15
ED-II/250
Electromembrane processes
Buffer tank
Product 1: Diluate
TDS = 0,05 g/lFeed water
TDS = 1,7 g/l
Product 2: Concentrate
(NH4NO3) TDS above 100 g/l
Process block scheme
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Unit A25
Nominal Parameters
feed 25 m3.h-1, TDS 3.0 g.l-1 (as NH4NO3), temp. 20 – 40°C
diluate TDS 0.10 – 0.25 g.l-1
concentrate TDS 100 – 200 g.l-1
energy consumption 3.5 kWh.m-3 (of upper defined feed)
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Unit A25
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Unit A25
Advantages in Comparison to the Conventional ED Concept
without intermediate tanks, pumps and instrumentation
compact footprint
optimized membrane area
the same spare parts for both types of membrane stacks
all main components doubled
possibility to have 1 line in operation and 1 line in repair or CIP
fast start to full production with constant products quality
no waste production even during CIP (reprocessing by A25)
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MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“Treatment of waste waters from fertilizer industry
Client: AO KUYBYSHEV AZOT
Project: Treatment of waste waters from production of NPK in order to reuse ED concentrate back in the production process. Diluate stream is used in water management of the company.
Locality: Togliatti, Russia
Commissioning: 2013
Feed specification: 60 m3/hour of wastewater from ammonia nitrate production, 2,9g/l
Requirement for product: ED concentrate approx.120 g/l, diluate approx. 0,04 g/l;
MEGA technology: RALEX® EWTU М90 2L/4S EDR-III/600; RALEX® EWTU 4xED-II/250; 2xRALEX® EWTU HPW P32 8xEDI-X
Mode: 1. part: Basic demineralization on RALEX® EWTU M90 2L/4S EDR-III/600 operating in one-pass mode
2. part: The concentration on the two units RALEX® EWTU 4xED-II/250 operating in batch mode
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MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“Treatment of waste waters from fertilizer industry
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MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“Treatment of waste waters from fertilizer industry
Pretreatment
EWTU M90 2L/4S
EDR-III/600
MF
Electromembrane processes
Buffer tank
Product 1: Diluate TDS = 0,04 g/l
Feed water
TDS = 2,9 g/l
Product 2: Concentrate
(NH4NO3) TDS above 120 g/l
EWTU HPW P32 8xEDI-X
EWTU 4xED-II/250
Process block scheme
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Client: VWS Brasil Ltda
Project: Desalination pretreated industrial waste water after MBR to prepare water for further industrial usage in a petrochemical complex
Locality: Itaboraí – Rio de Janeiro, Brasil
Commissioning: supposed 2014
Feed specification: Industrial waste waters after MBR; TDS 1200mg/l
Quality of Product: TDS 210 mg/l
Capacity of product: 425 m3/hour
MEGA technology: RALEX EWTU TwinLine90 12L/3S (EDR-III/550)
Mode: Single pass, water recovery 85%
MEGA projects in Water Reuse: Project „Petrochemical Complex - Comperj “Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage
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MEGA projects in Water Reuse: Project „Petrochemical Complex - Comperj “Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage
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Process block scheme
MEGA projects in Water Reuse: Project „Petrochemical Complex - Comperj “Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage
MBR
Waste water from Complex
Nut schell filter
Carbon filters
Mix Bed
Oil separator
RO
Boiler feed
EDRDAF
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MEGA projects in Water Reuse: Project „Achinsk“Desalination of mechanically and biologically pretreated industrial waste water to achieve the limits for discharge
Client: BIOTECHPROGRESS
Project: Desalination of mechanicaly and biologically pretreated industrial waste water to achieve the ecological limits for discharge to watercourse
Locality: Krasnoyarsk, Russia
Commissioning: supposed 2014-2015
Feed specification: Industrial waste waters after biological and mechanical pretreatment; TDS 1300mg/l
Quality of Product: TDS 500 mg/l
Capacity of product: 500 m3/hour
MEGA technology: RALEX EWTU TwinLine90 12L/2S (EDR-III/550) + 6L/2S
Mode: Single pass, water recovery 85%
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Process block scheme
MEGA projects in Water Reuse: Project „Achinsk“Desalination of mechanically and biologically pretreated industrial waste water to achieve the limits for discharge
Tailing pond K II
EDR
Organic removal
MBR
Bag filtration (TSS removal)
Feed water TDS = 1,3 g/l
RO
Diluate TDS = 0,37 g/l
Concentrate TDS = 7 g/l
Crystalization
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Project: Drinking water supply
Locality: Belkhir, Tunisia
Commissioning: supposed 2014
Feed specification: Well water, TDS 2500 mg/l
Quality of Product: Drinking water, TDS under 1000 mg/l
Capacity of product: approx. 2x 800 m3/day
MEGA technology: 2x RALEX EWTU M45 2xEDR-III/500-0.8;
Mode: Single pass, water recovery 85%
MEGA projects in Desalination: „Project Belkhir“Desalination of well waters to produce drinking water
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Process block scheme
Well water 2,5 g/l
Sand filters
Drinking water supply < 1 g/l
EDR
Evaporation pond 12,2 g/l
Cartridge filters
MEGA projects in Desalination: „Project Belkhir“Desalination of well waters to produce drinking water
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EDI Process – How does it work
The EDI process uses ion-exchange membranes in combination with ion-exchange resin to provide a high purity water.
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MEGA Pure means MPureM36 Product Requirements
Application: industrial high purity water
Reduce system complexity and cost
Equal or better DI & Silica performance vs. state-of-the-art EDI
Improved mechanical construction
Improve stack robustness
Cost competitive also for large flow rates
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M36 Product Requirements
Flow rate 10-15 m3/h per stack
Interconnection up to 3 stacks
High Recovery
Hardness Tolerance
Low system cost
Competitive with MB
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GEAM Demonstration Unit
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Mpure Three Stack System
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Mpure Three Stack System
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Why consider MEGA as supplier?
EXPERIENCE: MEGA has long-term experience in developing, designing, manufacturing and supplying of electrodialysis (since 1985).
PROVEN AND REASONABLE: MEGA has a significant market position in electrodialysis supply for different applications and industries (reference list upon request)
KNOWLEDGE: MEGA has long-term R&D co-operation with reputable institutions concerning whey treatment and MEGA ProfiLine develops new dairy products based on demineralized whey. R&D subsidiary MemBrain Ltd. received budget approval for building and operation of Membrane Innovative Centre in the Czech Republic.
EU ORIGIN, SHORT DELIVERY TIME (for European & CIS customers): MEGA manufactures all key components for ED (membranes, spacers, stacks, equipment) based on own know-how in plant located in Central Europe. MEGA ProfiLine keeps main spare parts and consumables in local warehouse in Russia.
RALEX® - WATER TREATMENT
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Thank you for your attention.