Professional Documents
Culture Documents
Scaleban Brochure
Scaleban Brochure
SCALEBAN SCALEBAN
Say No to hard scale permanently in heat
transfer equipment.
BE
REVOLUTION IN WATER TREATMENT... PROUD TO
INDIAN
SCALE-BAN TM
A Non Chemical Water Treatment Equipment
PANKAJ KUMAR
Managing Director
ABOUT US:
SCALE-BAN EQUIPMENTS PVT. LTD. (SEPL) was established in the year 1999 with its office
and manufacturing setup at Indore which is the largest Industrial & Commercial hub in central
India.
Today, the company has established itself well in the market and is known for its commitment, on
time Delivery, product performance, customer relations and after-sales-support. We offer
customized product for varied applications and with the experience gained in various industrial
segments, we have fine tuned our product specification for excellent results.
This online equipment which does not require any energy input and is to be installed in the
existing cooling water inlet line of heat exchangers. It does not require any regeneration or
maintenance and resulting in zero downtime of heat exchangers and zero performance
deterioration.
Having been in market for over a decade and a half, M/s SEPL have developed a vast data base of
satisfied clients, in various sectors like: POWER PLANT/ DISTILLERY PLANT / SOLVENT
EXTRACTION PLANT / HVAC / CHEMICAL PLANT / PAPER PLANT etc which have benefitted
by achieving substantial operational savings with our proven technology. The client credentials,
performance certificates, the projects we have undertaken are listed at our website
www.scalebanindia.com.
We are very optimistic and confident that SCALEBAN will not only continue to achieve Zero
liquid discharge (ZLD) across industrial spectrum but also save huge amount of water across
the globe.
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.
OUR VISION:
Our vision is to provide a Self Sustainable, Most Efficient and Cost Effective Zero Liquid
Discharge (ZLD) solution.
OUR MOTTO
Optimizing Production
Maximizing Water Conservation
Minimizing Water Pollution
WATER AND ITS PROPERTIES:
Water is nature's most wonderful and most useful substance. It is estimated that two-thirds of
earth's surface constitutes water. It also occupies a unique position in industries. It plays a very
important role as a coolant in heat exchangers. Water is very complex in nature and it contains a
lot of salts and minerals in dissolved form. Calcium and Magnesium salts present in water
determine the hardness of water and it is this hardness of water, which is the main cause for
insulating HARD SCALE formation in heat exchangers in various industries.
INSULATING PROPERTIES OF HARD WATER SCALING:
Scale formation is a common phenomenon in any industry using water as a coolant or for steam
generation.
Scaling has high thermal insulating properties, thus resulting in poor heat transfer efficiencies
(see graph below).
Apart from causing this drop in thermal efficiency, it also causes overheating of heat exchange
equipment and results in frequent shutdowns because of equipment choking or performance
deterioration. The cleaning process is recurring, tedious and it also greatly reduces the life of
various heat exchangers.
100
90
Efficiency Loss In %
80 74
60
60
48
40 38
27
20 18
11
4 7
0
0.3 0.5 0.71 3.1 4.7 6.3 9.5 12.7 15.8 19
Thickness of scale in mm
As is known, the main cause responsible for formation of scale inside any equipment is the rise in
temperature of water/fluid flowing through it, since at higher temperatures, fluid has a tendency to
precipitate dissolved Calcium and Magnesium salts. A graphical representation of solubility of
these salts in water vis-a-vis it's temperature indicates that with the rise in temperature of water
from T1 to T2 the solubility of these salts reduces from S1 to S2.
Thus, with higher temperatures of water/fluid as it comes in contact with any heat exchange
surface, Calcium and Magnesium salts precipitate out and form scale on the surface of heat
transfer area.
SCALEBAN precipitates out these salts much before the water attains this critical temperature
due to its coming in contact with the heat exchange surface.
Similar to its tendency to precipitate out dissolved Calcium and Magnesium salts at higher
temperature, water/fluid also tends to precipitate out dissolved Calcium and Magnesium salts at
its higher pH value i.e. when it tends to be slightly alkaline. A graph plotted above to illustrate
solubility of Calcium and Magnesium in water/fluid vis--vis its pH value indicates that, with the
rise in pH value of fluid from P1 to P2, the solubility of these salts reduces from S1 to S2 causing their
precipitation at higher pH values.
A ++
Cu++ Zn
H2SO4
WORKING PRINCIPLE:
The working principle of SCALEBAN is very simple and proven. It incorporates use of Galvanic
Principle, Chemical Characteristics of water/fluid and Fluid Dynamics. SCALEBAN exploits
solubility characteristics of Calcium and Magnesium salts in fluid with change in its pH value.
SCALEBAN locally increases pH value of water/fluid before it reaches high temperature zone
and then precipitates out hardness causing salts as water/fluid flows through SCALEBAN.
SCALEBAN makes use of Galvanic principle by locally enhancing the pH value of feed water/fluid.
Due to the Galvanic action, the core gets negatively charged and attracts the lightest ions present
in the fluid i.e Hydrogen ion towards itself. The relationship between pH of water/fluid and H+ ion is
expressed by the formula pH 1/H .
+
+
Thus, with the concentration of H ion becoming comparatively less in the water/fluid inside the
equipment, pH value increases, there by precipitating Calcium and Magnesium salts before it
comes in contact with hot tubes. Consequently, once the precipitation of these hardness causing
salts has taken place, further precipitation due to temperature variation is not possible.
SCALEBAN precipitates out Calcium and Magnesium bicarbonates in the colloidal form of
Argonite crystals much before the water/fluid attains the critical temperature of super saturation
due to its coming in contact with hot tubes.
These precipitated salts are in the colloidal form (small particles dispersed in another substance)
and are suspended in water/fluid, and because of their very small size and lighter weight, the
water/fluid owing through SCALE-BAN carries away these precipitated salts. THE NET RESULT
IS TOTAL PREVENTION OF HARD SCALE IN THESE SYSTEMS.
b) REMOVAL OF EXISTING SCALE:- Due to the reduction of the free Calcium and
Magnesium from solution by the formation of their Carbonate crystals and the solubility
being constant, water/fluid can dissolve more salts, which it tends to pick up from the
existing scale in the system, thereby desalting scaled up systems. However, it is not
marketed as a scale remover, but as a scale preventer.
d) PREVENT WATER POLLUTION:- With the reduction in blow down & consumption of
efuents like RO Reject & ETP treated water in cooling tower as make up water
SCALEBAN provides a great help in minimizing surface water pollution. Further,
elimination of dosing of chemicals like anti-scalant and stopping use of Softener,
SCALEBAN offers great help in reducing the water pollution.
e) ZERO RECURRING & MAINTENANCE EXPENSES:- SCALEBAN does not have any
operating & maintenance expenses thus is a t & forget system. Due to special design of
the core, SCALEBAN creates heavy turbulence in water/fluid owing through it, which
makes it a self cleaning & maintenance free equipment. Further since SCALEBAN does
not incorporate any moving part and any external energy source, it is a totally maintenance
free Equipment.
POWER PLANT
SCALEBAN can be very gainfully installed in condensing type thermal power plants.
Typically, a 1000 MW power plant would require approximately 98000 M3 of water per day,
much of which is wasted resulting in higher operating costs for the plant. SCALEBAN
offers a huge saving potential by way of:
Saving this precious water.
Improving the Plant Load Factor (PLF) by optimizing condenser vacuum thus resulting in higher
power generation with better efficiency.
Reducing the plant down time required for condenser cleaning.
As one might expect, with millions of liters of circulating (cooling) water flowing through the
condenser tubes, anything that is contained within the water and flowing through the tubes, can
ultimately end up either on the condenser tube-sheet or within the tube itself. Tube side fouling for
surface condensers is caused mainly due to SCALING, which are crystalline forms of Calcium
and Magnesium salts.
Depending on the extent of this fouling, the impact can be quite severe on the condenser's ability
to condense exhaust steam coming from the turbine. As fouling builds up within the tubing, an
insulating effect is created and the heat transfer characteristics of the tubes are diminished
requiring the turbine to be slowed to a point where the condenser can handle the exhaust steam
produced. Typically, this can be quite costly to power plants in the form of reduced output,
increased fuel consumption and increased CO2 emissions. This "de-rating" of the turbine to
accommodate the condenser's fouled or blocked tubing is an indication that the plant needs to
clean the tubing in order to regain the turbine's rated capacity.
100 34.8
99 34.5
Steam consumption, %
98
34.2
Turbine efficiency, %
97
33.9
96
33.6
95
33.3
94
33
93
92 32.7
0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83
SOFT RAW
AUXILLARIES BOILER AUXILLARIES SCALEBAN BOILER
WATER WATER
CONDENSER SCALEBAN
SCALE-BAN TM
MAKE-UP WATER
MAKE-UP WATER
COOLING PUMP COOLING PUMP
TOWER DM / RO TOWER DM / RO
SOFTNER REJECT
REJECT REJECT
BOILER BLOWDOWN
BOILER BLOWDOWN
4COC 15-20COC
NEUTRALISATION
TREATED
WATER RO PLANT MEE ASH COOLING
RO
REJECT
WATER
Works only on soft / RO water. Can work on Raw / R.O. Reject / ETP treated / Sea / Bore well water.
Limitation of hardness & TDS. Already tested up to 10000 ppm Hardness and 50000 ppm TDS.
Recurring Expenses for preparation of soft water as make-up-water in Cooling tower. No Recurring and maintenance Expenses.
Fresh soft water consumption is more due to restricted COC. Tremendous SAVING of water as our equipment Works on higher COC.
Despite use of soft water and anti-scalant chemicals, scale is formed in Condenser / heat exchangers. ZERO SCALE Guarantee in Condenser / heat exchangers.
Cooling efficiency loss and poor vacuum due to scale formation. No efficiency loss and maintained vacuum due to ZERO SCALE.
No guarantee against scale formation. 20 years performance Guarantee for ZERO SCALE.
SCALE-BAN TM
A Non Chemical Water Treatment Equipment
Total savings of water per year [E1] x 350 days / year [F1] 6,07,500 M3 / Year
Cost Saved in ETP and R. O operations by reducing Blow-down for achieving [H] 90,00,000 Rs. Per Year
zero discharge = (B-B1) x 24hrs X Rs. 20/- X 350 days
Cost Saved on Softener Operation @ Rs. 2/-per M = D X Rs. 2/- X 350DAYS [I] 63,00,000 Rs. Per Year
Cost of Resin in softener (Top up) [J] 2,00,000 Rs. Per Year
Cost of Anti-scaling chemicals saved = Rs. 45000/- per month [K] 5,40,000 Rs. Per Year
Total Savings per Year (A) = [G+H+I+J+K] Rs. 2,51,52,500 Rs. Per Year
B. Savings due to proper HEAT EXCHANGE inside condense and lesser consumption
of High Pressure steam:
DISTILLERY PLANT
SPENT WASH
MAKE UP WATER
MULTI EFFECT PROCESS
EVAPORATOR CONDENSATE SCALEBAN
COOLING
SUGAR MILL SUGAR CANE JUICE TOWER
CONDENSATE
RO PERMEATE
Negligible Blow Down due to high CONDENSER
COC. Hence, it can be directly taken SCALEBAN
for ash cooling / dust suppression. / COOLERS
PROCESS
APPLICATIONS
SCHEMATIC DIAGRAM TO CONSUME CONDENSATE / SPENT LEES IN DISTILLERY & CO-GEN PLANT
COOLING TOWER TO ACHIEVE ZERO LIQUID DISCHARGE WITHOUT CPU (ZLD WITH SCALE-BANTM)
REFRIGERATION PLANT
Total elimination of hard water Scale in the cooling system of Refrigeration plant by
installation of our SCALEBAN Equipment.
CONDENSER WATER
COOLING
TOWER
CHILLER
Qout
SCALEBAN
CONDENSER
REFRIGERANT
MOTOR
EXPANSION
VALVE COMPRESSOR
EVAPORATOR
VFD
Qin
PRIMARY SUPPLY PRIMARY RETURN
Our Equipment SCALEBAN has been established in the market to give the following
savings in Refrigeration plant / cooling tower operation.
Zero Scale in condensers.
Optimum Head Pressure maintained in Refrigeration plant.
SCALEBAN Equipment is an online equipment which is fitted just before water cooled
condensers/ Heat Exchangers.
A brief description given below, will easily establish the benefits that can be achieved
by installing SCALEBAN:
Anti-scaling chemicals are not required in cooling water.
Descaling of heat exchangers is not required.
No Softening plant is required.
No shutdown of plant is required for cleaning of condenser / heat exchangers tubes, In
conventional water treatment system shut down of plant is required frequently to clean the
tubes Chemically / Mechanically, as the case may be.
Cost of manpower, Chemicals and Loss of production for a large number of days due to
shutdown is saved every year.
Due to repeated cleaning of the hard scales in tubes with rod & acid, the tube surface becomes
weak and prone to leakages. Any leak in condenser/cooler causes shutdown of plant and adds
cost of replacing tubes.
Head pressure in Refrigeration plant remains maintained which gives Considerable savings of
electricity.
Due to scale free system, optimum approach is maintained thus plant runs at optimum
efficiency.
REVOLUTION IN WATER TREATMENT...
SCALE-BAN TM
A Non Chemical Water Treatment Equipment
MAKE UP
MAKE UP RAW WATER / RO WATER
WATER REJECT / ETP
SOFTENER TREATED WATER
SCALEBAN
SOFTENER
REJECT COOLING COOLING
TOWER CONDENSER TOWER SCALEBAN CONDENSER
/ COOLERS / COOLERS
SOLVENT PLANT SOLVENT PLANT
EFFLUENT
TREATMENT PLANT
CT BLOWDOWN WATER
CONDENSER SCALEBAN
CONDENSER
/ COOLERS / COOLERS
CONVENTIONAL TREATMENT FOR COOLING WATER SCALEBAN TREATMENT FOR COOLING WATER
Total elimination of hard water Scale in the hexane condenser of extraction unit by
installation of our SCALEBAN Equipment.
Condensate
injection
SCALEBAN
SCALEBAN
1
3
2
PUMP
SCALEBAN
As Multi Effect Evaporator are the heart and soul of any fluid concentration process plant, any
scaling in its tubes causes tremendous loss due to excess consumption of Steam / fuel and also
reduction in capacity of production. Further descaling of these tubes through CIP (Cleaning In
Place) in itself is a time consuming, costly and tedious task.
In this context, we have introduced a non-chemical hard scale prevention equipment named
SCALEBAN Equipment for preventing hard scale formation in the tubes of Multi Effect
Evaporators and thus improving the efficiency of operation and delay the frequency of CIP and
time required for CIP.
pH value of the re-circulating cooling water should be maintained between 7.0 to 8.5 for optimal
results of SCALEBAN.
There should not be any Zero velocity zone between SCALEBAN and heat Exchanger /
Condensers to be protected.
There should not be any valve or strainer between SCALEBAN and Heat
Exchanger/Condensers.
Cooling tower sump should be cleaned for any sludge/debris etc. before start of operation.
Side Stream filter should be operated regularly with open top back wash regularly.
pH should be maintained by dosing pH maintaining Chemicals or by commercial grade H2SO4.
The Quantity of Sulphuric Acid (H2SO4) dosing can be finalized on commencement of the
operation as it is dependent on the Sump holding capacity, quality of water, pH of makeup
water, flow rate, evaporation and drift losses etc.
Continue with anti corrosive treatment & Bio fouling prevention treatment as per requirement.
SCALEBAN INSTALLATION
Cut the equivalent length from inlet line at a point nearest to the
heat exchanger. Weld both the matching flanges provided with
SCALEBAN on both cut ends of the inlet line.
Composition of Chemical composition of Chemical composition of water Chemical composition of water changed.
1 changed due to dosing of chemicals. Nature of water becomes corrosive.
Water water remains same.
SCALE-BAN TM
No extra inventory to Minimum one month inventory to be Minimum one month inventory to be
9 Inventory
maintain. maintained maintained.
10 COC In CT 15 To 20 2 To 6 (depends on Makeup) 3 to 5
11 Pay back Low payback period. NIL. NIL.
20 Years Performance NO Performance Guarantee against Scale
12 Guarantee NO Performance Guarantee
Guarantee for zero Scale. Formation.
SCALE-BAN TM
A Non Chemical Water Treatment Equipment
SCALEBAN INSTALLED IN 2 x 490 MW POWER PLANT SCALEBAN INSTALLED IN 3 X 300TR VAM, VACUUM PUMP,
(UNIT 5 & 6) OF NTPC LIMITED, DADRI (UP), INDIA TG-PHE UNIT OF NTPC LIMITED, DADRI (UP), INDIA
SCALEBAN STALL AT NTPC O & M CONFERENCE SCALEBAN INSTALLED IN 130 MW X 3NOS, 60MW, 40MW
ON 13-14 FEB, 2015 IN DELHI, INDIA AND 8MW POWER PLANT OF M/S BPSL (OR), INDIA
SCALEBAN INSTALLED IN 90KLPD DISTILLERY UNIT OF SCALEBAN INSTALLED IN 45KLPD DISTILLERY UNIT OF
M/S WAVE INDUSTRIES LTD., ALIGARH (U.P.), INDIA M/S OAISIS ALCOHOL LTD., SATARA (M.H.), INDIA
SCALEBAN INSTALLED IN 1380TR VAM UNIT OF SCALEBAN INSTALLED IN 1000TR VAM UNIT
M/S CCL PRODUCTS LTD., DUGGIRALA (AP), INDIA / VIETNAM OF M/S ALEMBIC LTD., BARODA (GJ), INDIA
SCALEBAN INSTALLED IN 2 X 1350 TPD UNIT OF SCALEBAN INSTALLED IN 8MW X 2NOS, 10MW X 1NO & 16MW X 1NO
M/S CHAMBAL FERTILIZER, KOTA (RJ), INDIA POWER PLANT UNIT OF M/S SHREE BAJRANG POWER & ISPAT LTD.,
Borjhara, Urla, Raipur (CG), INDIA
SCALEBAN INSTALLED IN 3MW POWER PLANT UNIT OF SCALEBAN INSTALLED IN 1000, 600 & 400 TON SOLVENT UNIT OF
M/S SAINSONS PAPER INDUSTRIES LTD., KURUKSHETRA (HR), INDIA M/S VIPPY INDUSTRIES LTD., DEWAS (MP), INDIA
PERFORMANCE CERTIFICATE
SCALEBAN INSTALLED IN 40MW POWER PLANT UNIT M/S MAHAKALI FOODS PVT. LTD. M/S BALAJI POWER M/S PEARL DISTILLERY LIMITED
OF M/S BENGAL ENERGY LTD., KHARAGPUR (WB), INDIA (SOLVENT PLANT) (BIOMASS PLANT)
SELECTION
SCALEBAN is selected on the basis of:
[A] Water flow (M3 per hour) rate,
[B] Diameter of Cooling Water line.
Pipe Diameter Minimum Flow Maximum Flow Pipe Diameter Minimum Flow Maximum Flow
Model Model
(Inch) (M3/Hr) (M3/Hr) (Inch) (M3/Hr) (M3/Hr)
NOTES:
1. Approximate Length of SCALEBAN is one meter.
2. SCALEBAN is supplied in flanged or screwed end connections with matching flanges.
3. The equipment is tailor made as per specific requirements of the application.