The feed water, depending on its source, may contain various concentrations and sizes of suspended solids and dissolved matter. The objective of the feed water pretreatment process is to improve the quality of the feed water to the level which would result in reliable operation of downstream equipment. Depending on the treatment requirements, pre-treatment systems are designed to get rid of troublesome impurities first. Fine suspended solids, colloids or silt can be removed by coagulation method where as some sparingly soluble salts such as fluoride, silica, iron etc can be removed by chemical precipitation method in Pretreatment plants. Marcuras provides following processes to make feed water suitable for the downstream processes:
- Flocculators
- Tube Settlers /Lamella Clarifiers
- HRSCC / Clarifiers / Clari-Flocculators
- Dosing Systems
- Flash Mixers
- Static Mixers
Clarifiers
These clarifiers settle the suspended matter from pre-flocculated water or effluent. The clarifiers are constructed in Metal as well as RCC depending on the size and are equipped with scrapers, scraper drives, stationary or moving bridge, collecting launders, wear plates, V-notch boxes etc.
A variant in this equipment called Clari-flocculator combines flocculation zone along with the conventional clarifier mechanism. This eliminates the need of having a separate equipment for flocculation. The settling is aided by virtue of gravity with carefully designed hydraulic flows and the sludge blanket formed with TSS also traps finer particles to provide clear water at the outlet.
Commonly known as HRSCC, these are next generation technologies that achieve higher throughput in a smaller footprint than conventional clarifiers - resulting in cost savings and improved performance. The sludge formed in the settling process is re-introduced to feed water so that the process of floc formation is better. HRSCC suits best for varying or even low turbidity loads and optimizes the chemical costs.
The design features of the solids contact type clarifier provide the three zones necessary for proper clarification:
Rapid mix zone, where raw water, recirculated precipitates and fresh reagents are rapidly mixed together.
Slow mix zone or flocculation zone, where gentle mixing permits floc formation and brings the floc into intimate contact with the suspended impurities.
Clarification or settling cone, where the upward flow (rise rate) is reduced to a low value to permit the precipitation to settle out.
This ensures a higher clarified water quality and greater tolerance to variations in inlet conditions. Marcuras is involved in producing HRSCC, which is very reliable and cost-effective.
- Tube Settler
- Plate (Lamella) Settler
Both these devices use the principle of high surface contact area and countering upward velocity with inclination of surface. The specific angle (60 0) results in lowering the upward velocity of particle thereby allowing higher rise rates and lower cross-sectional area. Plates and Tubes used in these devices are available in various lengths, profiles and MOCs to suit specific applications.
Marcuras is engaged in design, manufacturing and supply of Inclined plate (lamella) clarifiers, tube settlers, which are based on innovative technologies that increase basin settling area by creating an inclined settling surface. Overall plant footprint can be reduced substantially using these technologies.
Floculators
Flocculators are used as preceding equipment to settling devices such as clarifiers or settlers. The main function of floculator is to allow contact of flocculated particles with each other to form a larger floc which is easier to settle or trap than individual small particles. Floculators can be used for making flocs of suspended solids as well as chemical precipitates. This equipment allows time for reaction and to allow particles to come in contact with each other with slow speed agitation. These can be constructed in metal as well as RCC and are equipped with floculator shaft, blades and drives.
Other Supplementary Equipment
Dosing System : Dosing systems are provided to dose chemicals, coagulants, flocculants required for reactions. The systems consist of Dosing pumps of different types and MOCs, Dosing Tanks, Agitator and mounting skids.
Flash Mixers : Flash mixers are used for rapid mixing of chemicals before flocculation and are usually high speed mixers with a small retention tanks.
Static Mixers : Sometimes, depending on the nature and criticality of process, inline static mixers can be used for mixing chemicals for rapid reaction. These are inline devices with internal baffle construction to increase turbulence for chemical mixing. Obviously there is no running cost as there are no electrical or moving parts.
A water filter removes impurities from water by means of a fine physical barrier from a chemical process or a biological process. Filters can be used for suspended solids removal, removal of organics, odour, oil& grease, iron etc by selecting the right type of medium for filtration. We offer a wide range of water filtration systems that provide you clean & healthy water to use. Designed to meet the stringent requirements of clients these include. The entire ranges of filter are available in different MOC like FRP, MS, MSRL, SS etc. They are available in fully automatic, remotely operated, manually operated or with multiport valves.
Our filters work on the principal of depth filtration. The principal media in these filters is quartz grade sand and anthracite. Other supporting media include pebbles of various sizes, crushed gravel and silex. The major advantage of this kind of filters is that anthracite which provides for coarse filtration is lighter than filtering sand. Due to which one stage of coarse filtration takes place on the anthracite bed and the next stage takes place on the sand bed. Thus, depth filtration is achieved. Since both media (viz sand and anthracite) are employed the dirt loading capacity of these filters is twice that of pressure sand filters. Hence these type of filters are more capable and give high performance.
The principal media in these filters is activated carbon. Other supporting media include pebbles of various sizes, crushed gravel and silex. The activated carbon is a highly porous media. This property of carbon allows it to adsorb the free chlorine in raw water. Also organic matter present in colloidal form, oil & grease is adsorbed in these pores. Thus odour emanating from raw water on account of these colloids is reduced. The activated carbon present in the standard range has an iodine value of 450. This carbon is also available in iodine values of 600, 900 and 1200.
The principal media in these filters is manganese dioxide. Other supporting media include pebbles of various sizes, crushed gravel and silex. Manganese dioxide catalyses precipitation of iron and holds back the precipitated matter on the filter bed. These are used to remove iron from ground waters.
For larger flow rates where pumping is a constraint, we suggest gravity filter, also known as rapid sand filters, usually at the outlet of pretreatment plant. This reduces pumping requirement and can be a good choice where space availability is not a constraint. AVGF is a boon for places which are remotely located where operators can not attend on regular basis. Automatic Valve-less Gravity Filter comes with a unique feature of initiating backwash based on pressure drop and it does not involve any automation product such as auto-valves, controllers, PLCs etc. It operates on gravity and backwashes purely on delta-P using simple hydraulic principles. AVGFs are Ideally suited for village water supply schemes and remote locations.
Marcuras is involved in offering an exhaustive range of ion exchangers that is best known for its high quality & high performance. Our range includes softening plants, demineralization plant, mixed bed etc. The entire ranges of plants are available in different MOC like FRP, MS, MSRL etc. They are available fully automatic, remotely operated, manually operated or with multiport valves.
- Softeners
- De-Mineralizers and Mixed Bed Polishers
- Condensate Polishers
- De-Alkalizers
- Specialty Applications
- Nitrate Removal
- Fluoride Removal
- Organic Scavenger / Colour Removal
Ion exchange water softening products remove calcium and magnesium from hard water to produce softened water. A water softener uses sodium to help replace calcium and magnesium ions. Unlike hard water, softened water will not leave any residue or scale on contact surfaces. Marcuras provides softening solutions for various applications such as boiler feed, cooling tower, heat exchangers, mould cooling, process, component washing, laundry, domestic use and pretreatment to RO, where hardness can cause considerable damage to process or equipment involved. We have interesting technologies to use weak acid cation resins in softeners as well as utilization of spent brine for better performance at lower cost.
We design, manufacture and supply DM plants and mixed bed polishers. Ion Exchange process utilizes ion exchange resin for the removal of dissolved salts in surface and groundwater sources to meet industrial water standards. Dimeralization plants are used for the purpose of TDS reduction to required levels. In these plants, impurities are replaced by hydrogen and hydroxyl ions, and the water that is produced is extremely pure.
We carefully design DM plants considering various aspects of salt composition and suggest best schemes including combinations of SAC, WAC, SBA, WBA and layered bed units for capex and opex optimization.We use resin manufacturer graphs and guidelines of Regeneration levels, Exchange capacities, velocities, bed depth, bed expansion, pressure drops, various ratios of impurities etc to optimize resin performance and regeneration chemical consumptions through selection of up-flow, down-flow, co-current and counter-current regeneration techniques.
A condensate polisher is a device used to treatwater condensed from steam as part of the steam cycle. Our superior condensate polishing ion exchange resins excel in capturing corrosion products in the condensate stream. This polishing typically involves ion exchange technology for the removal of trace dissolved minerals and suspended matter. It is generally used as part of a power plant's condensate system and prevents premature chemical failure and deposition within the power cycle which would have resulted in loss of unit efficiency and possible mechanical damage to key generating equipment.
CPU reduces treatment cost drastically as it contains minimal impurities and hence economical than treating raw water where dissolved impurities are high. Specialty resins are also available for treating the condensate at elevated temperatures which reduce the heat loss there by reducing fuel cost for the end customer.
De-alkalizers are used typically in small boilers or specific applications where apart from softening, alkalinity (carbonates and bicarbonates) also has to be reduced. Usually a split-stream de-alkalizers are very commonly used wherein one stream passes through a softener and one stream through SAC, followed by degasser tower for removing CO2 from water. Partial TDS reduction is possible in this scheme to the extent of alkalinity present in water.
Marcuras has developed top-notch expertize in designing, manufacturing and supplying a comprehensive range of Membrane technology products.
These are :
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Reverse Osmosis Plants(RO)
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Nano Filtration Plants(NF)
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Ultra Filtration Plants(UF)
Membrane technology is gaining high importance in the water treatment industry because it is easy to understand and guarantee efficient and environment-friendly purification with a minimal use of chemicals. Marcuras is involved in manufacturing and supplying of a comprehensive range of reverse osmosis plants, ultra filtration plants, nano filtration plants, water treatment system, RO systems, containerized water treatment plants, water purification systems etc.
We at Marcuras carefully design the plants taking into consideration various aspects such as source of water, SDI, fouling potential, temperature, desired flux rates for specific applications, scaling potentials, hydraulic balancing, type of membranes, beta factor, LSI, pretreatment, automation etc. so that the plants run smoothly for long durations.
Reverse osmosis plants are quite exclusively constructed by installing spiral wound membranes. They work with medium-high pressure depending on the type of application (6 - 70 bar) and they are applied to separate the dissolved salts from aqueous solutions by means of semi-permeable membranes. In this case the dimension of membrane pores are very small so that the resistance to the passage of water is higher.
Our strength is designing an optimum system which can operate smoothly for longer durations. We provide Reverse Osmosis solutions for
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Brackish Water
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Sea Water Desalination
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Effluent Recycle
Nano filtration plant are generally constructed by installing spiral wound membranes. They have a medium-high working pressure (4-30 bar) and they are normally used to reduce water hardness, to recover salts from dying baths, to remove colour and to recover acids and caustic soda. As against RO, the NF membranes remove only multi-valent ions and hence can be used for softening. The operating costs of NF are much lower than RO due to low operating pressure of NF membranes.
UF plants are gaining huge popularity as pre-treatment to RO since it saves RO membranes from variety of foulants. Surface water and treated waste water is pre-treated in UF prior to feeding it to RO as it allows RO to do its job of removing dissolved salts effectively. Absence of UF in such cases results in frequent failures, CIP requirements and consequential losses for the end user.
Ultra-filtration plants can be constructed by employing hollow fiber membranes or spiral wound membranes. They work with a pressure of about 1-5 bar and they are suitable to separate higher Molecular weight particles present in water. The ultrafiltration plants have established a position in the drinking water sector due to the fact that they filter water to such an extent that it is virtually free of solids. Bacteria, parasites and viruses are not killed off, but entirely removed from the drinking water.
The technology and process involved are relatively simple, membranes representing very fine filters, which act like sieves through which water is either pressed or sucked. Any content, which is larger than the microscopic pores, is separated out and depending on the fineness of the filter, a differentiation is made between micro-, ultra- and nanofiltration. Reverse osmosis is an additional variation, in which only water molecules pass through the membrane. Marcuras has been using this membrane process in combination with conventional cleaning processes for many years and due to this experience and in-house innovations, has built up a pool of comprehensive expertise. We offer a diversity of membrane processes and select the best and lowest-cost variation for each application.
Other advantages of our membrane filtration are:
- Modular design
- Membranes as absolute barriers
- Low space requirement
- Easy to operate.
Zero Liquid Discharge Plants are designed and developed in accordance with latest market requirements. We offer turn-key solutions to make ZLD work efficiently, by conducting overall study of site about the water balance, sources of water, consumption points of water and their quality requirements, economics, cost of operation. We audit the water plants and suggest avenues for reducing waste water thereby optimizing of evaporator capacity to reduce costs.
Marcuras Water Treatment India Pvt. Ltd. is involved in offering Zero Liquid Discharge Plant, We supply systems based on either membrane processes, evaporative processes or a hybrid combining the two processes to achieve Zero Liquid Discharge from the plants in a cost-effective manner. Zero Liquid Discharge System is a fully integrated automated system incorporating a multiple effect evaporator, crystallizer, and associated accessories.
Sewage Treatment Plant is a facility designed to receive the waste from domestic, commercial and industrial sources and to remove impurities that damage water quality and compromise public health and safety when discharged into water receiving systems. Today, technological progress is increasingly broadening the range of possibilities offered by classic environmental protection. The ecological focus is on water protection and the multiple use of waste water.
Marcuras is involved in offering an entire range of Sewage Treatment Plants to clean the water. We use a combination of innovative treatment processes. We facilitate the utilization of wastewater for industrial and municipal purposes and thus the conservation of resources.
Our proven and advanced processes include amongst others:
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MBBR - Moving Bed Bio Reactor
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SBR – Sequencing Batch Reactor
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MBR – Membrane Bio Reactor
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UASB- Upflow Anaerobic Sludge Blanket
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Advanced Oxidation
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Photo-Cell
Marcuras offers an exhaustive range of Effluent Treatment Plants that is highly efficient. The effluent treatment plant is designed to treat the effluent coming from different areas of the plant. The treatment of different effluents varies with the type of effluent. Industrial wastewater contains a diversity of impurities and therefore for this reason alone, its treatment constitutes a special task. Our expertise is advantageously employed for the technical and economic optimisation of every subsequent facility. The treatment process may contain mechanical, biological and chemical physical process steps.
Our capabilities include solutions for following industries Textile, Paper & pulp, Dairy, Food & Beverages, Electroplating, Pharmaceutical, Chemical, Semi-conductor, Automobile, Rice mills, Distilleries, Tanneries, Hospitals, Slaughter houses, Metal processing, Surface coating, cooling tower blowdowns, Soap & Oil industries and many more.
Some processes followed by us are:
Primary Treatment
- Screening and Grit removal
- Oil & Grease Traps
- Clarification – Coagulation and /settling
- Physio-Chemical precipitation
- DAF – Dissolved Air Flotation
Secondary Treatment
- Aerobic Reactor
- MBBR
- SBR
- ASP
- SAFF
- Aeration lagoons
- Anearobic Reactors
- UASB
- Digestors
- Septic Tanks
- Physio-Chemical Precipitation
- Chemical Dosing Systems
- Flocculator / Flash Mixer
- Tube & Lamella Settlers
- Clarifiers, HRSCC
- Reaction Tanks & Agitators
- Batch Reactors
- Aerobic Reactor
Tertiary Treatment
- Filtration
- Gravity, Media, Sand, Carbon etc
- Micron Filtration
- Ultra Filtration
- MBR
- Disinfection
- Ozonation
- UV
- Chlorination
- TDS Reduction
- Reverse Osmosis
- De-Mineralizers
- Filtration
We are involved in manufacturing the RO plant as per AAMI standards that is used for kidney dialysis machines in hospitals & kidney dialysis centers. The treated water from RO plant is used while performing the kidney dialysis. Manufactured using advanced technology the plant is basically used whenever salt removal or deionization is required. It helps in removing more than 97%-99% of the total mixed solids along with bacteria, organics, and other particulates. We manufacture both, Online and Offline systems along with PEX piping for distribution.
Features and Benefits Dialysis RO Plant :
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Advanced system design
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Complete system automation capabilities with Remote Monitoring System
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Stops bacterial contamination with UV and Endotoxin filters
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Integrated micron pre-filtration
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Integrated membrane cleaning system
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Simple in operation and easy maintenancen
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Assured quality and consistent performance
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Continuous membrane and pump protection
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Reliable performance and operation flexibility
Ultrapure water is the water purified to highest purity levels as required by some critical applications required in biotechnology, pharmaceutical, semiconductor and power plant applications. Pure water is a bad conductor of electricity and we have the capability and experience of delivering 18 megaOhm resistivity which is highest practically possible resistivity.
Pharmaceutical Water
We design purified water generation systems for pharmaceutical applications as per prescribed standards of pharmacopeia, USP grades. Water is a very critical resource in pharma industry and could turn into a nightmare if it fails to perform as desired. With Marcuras you can sit back and relax and experience a world class system designed to eliminate all problematic issues. We take utmost care while executing such projects with proper selection of Pre-treatment, Filtration, micro and ultrafiltration, Nano-Filtration, Softening, Two pass RO system, Advanced EDI system, Ultraviolet sterilisers, Endo-Toxin filters etc.
Chemical sanitized and heat sanitized systems are supplied with careful selection of MOCs that involve SS-316L, electro-polished, orbital welded pipes and TC fittings, sanitary zero-lag valves etc. We have excellent project execution capabilities and knowledge to execute distributions systems at site to ensure sterile water supply at user points.
Semiconductor and other applications
For other application like semi-conductor or power plant industries, similar systems are designed with other features such as nitrogen blanketing for avoiding air contact with purified water and a continuous recirculation through a pre-regenerated nuclear grade Mixed Bed resin to maintain the resistivity of water.
Our aim is to increase the operational efficiency of the RO Plants and reduce operational/service costs. Real time status parameters of all RO Plants anywhere in India can be done from a single location.
Why Remote Monitoring?
Problems with the Current Systems:
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Plant operators are not well versed with the technical aspects of the RO plant and cannot interpret instrument values such as flow, pressure, conductivity and pH.
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A site complaint is received only when the flow reduces drastically (or) the plant completely breaks down.
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Site Operators do not backwash sand/carbon filters timely nor do they change cartridges when required.
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Site Operators may throttle the reject control valve too much to get better permeate flow.
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Site Operators may not ensure antiscalant dosing pumps operation
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Log books are rarely maintained at site.
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Service calls are always an emergency. The cost of providing the service has to borne by the supplier providing the service or any material consumed.
CROWN
CROWN is a software application, provides central supervisory ‘control and monitoring’ of water treatment equipment. CROWN communicates to LCU on the site for control operations.
Key Features:
Create / Edit Remote Site configurations (MPV's, Instruments, Digital I/O etc.) & Client details
Simultaneous data logging from various sites using GSM(SMS) technology
Instantly start Backwash/Regeneration Cycles of Remote Sites. Change service/backwash timings as per requirement.
Receives status messages based on three options
- Status based on preset time.
- On-Demand status
- In case of alert conditions at site
Generates SMS alerts in case of critical problems at Site
Generates alerts to service technicians in case of device value is beyond safe operational range. (Ex: Pressure, Conductivity etc)
Provides history of plant operational status, commands issued for a selected site.
Option to export status information to excel sheets.
Provides Graphical summary for instrument readings
Operational summary notifications to concerned persons
We have excellent technical knowledge and Project Execution Management capabilities to execute turn-key projects involving end to end solutions. We have a team of dedicated engineers, resources and skills in Electrical, Mechanical, Civil, Instrumentation and process to design, manufacture, supply, install and commission small, medium and larger projects in water and waste water treatment. Our professional team is eager to execute challenging projects successfully and within the aggressive time schedules. We undertake turn-key projects in Pre-Treatment, Filtration, Softening, RO, UF, DM, MB, EDI, ETP, STP, ZLD etc for variousindustrial applications.
Marcuras marks the Year 2016-17 as a year of Contribution towards the global initiative of “Right to Water”.
UNESCO stated that ‘non-discriminatory access to water and sanitation is regarded […] as a pre-requisite for the realisation of several other human rights, such as the rights to life, dignity, health, food, and an adequate standard of living and education.’
In The year 2015 Government of India has played a vital role in the recognition of the human right to clean drinking water and sanitation. Marcuras got the opportunity to serve the Indian community with Small Reverse Osmosis plant for drinking water for around 1000 villages in Maharashtra, Karnataka & Rajasthan region.
The advent continues in pace with the Government & other private bodies to reach every village in India....
Save water! Save life!
