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WABAG offers sustained solutions for special customer needs through a comprehensive range of services and innovative technologies.

Oil and Gas

Upstream: Produced Water Treatment


Project

Suplacu Oil field, Romania

Client

OMV Petrom, Romania

Location

Suplacu, Romania

State-of-the-art plant with an innovative, multi-stage treatment system and a biological process for the first time combined with filtration systems for produced water treatment plant. WABAG was responsible for the design & engineering, construction, delivery, installation and commissioning of this essential project.

Package

  • Storage and settlement tanks
  • Dissolved-air-flotation (DAF)
  • Cooling towers
  • Biological treatment based on the activated sludge process
  • Lamella clarifiers
  • Two-layer filtration with flocculation and coagulation and activated carbon filtration
  • Sludge dewatering
  • Service water station

Complete Water Solutions


Project

Dangote Refinery and Petrochemical Project

Client

Dangote Oil Refining Company Ltd.

Location

Lagos, Nigeria

Complete water package with first of its kind advanced processes and technologies like HHP Wet Air Oxidation, Bioremediation, Bardenpo Process based BNR, Thermal Oxidiser, BIOPUR® and Reject meeting TN standards.

WABAG’s scope of work includes design, engineering, procurement, supervision of installation and commissioning & testing of an effluent treatment plant with reverse osmosis, demineralisation & condensate polishing and raw water treatment package. Dangote Oil Refining Company is the largest single train refinery in the world.

Package

  • Package 01: Effluent Treatment plant
  • Package 02: Reverse Osmosis, Demineralisation and Condensed Polishing Unit plant
  • Package 03 : Raw Water Intake
  • Package 04: Raw Water Treatment Plant

Effluent Treatment


Project

RAPID Complex

Client

PETRONAS

Location

Johor, Malaysia

A state-of-the-art treatment system which ensures the reduction of contaminants in the effluents of the complex to well below the regulatory discharge limits. Run-off water and effluents from all sources in RAPID (Refinery and Petrochemical Integrated Development Project), as well as Cogen Plant are collected and segregated so that specific treatment can be applied. The ETP is the largest in Asia.

Package

  • Integrated ETP for new RAPID Complex
  • Treating a total capacity of 102,864 m3/d
  • Effluents from seven different types of wastewater streams are treated exclusively
  • Customized multi-stage ETP including sludge and VOC treatment
  • EPC – turnkey-execution

Water Reclamation


Project

Panipat Refinery

Client

IOCL

Location

Panipat, Haryana, India

India’s first refinery wastewater recycling system based on membrane technology. One of the world‘s largest plants with 90% recovery.

Package

  • Clarification
  • Filtration
  • Ultrafiltration
  • Reverse Osmosis and Demineralisation
  • Recycling for reuse as boiler feed water

Complex Effluent Treatment & Recycling


Project

Dahej Manufacturing Division

Client

Reliance Industries

Location

Dahej, Gujarat, India

WABAG has set up a plant to treat a cocktail of PTA process effluent streams generated from expansion of the PTA and PET plants in Dahej, Gujarat. It is the largest recycling plant for PTA Effluent in India. A tailor-made, advanced process design was employed, combining the activated sludge process (MBR) and anaerobic treatment (UASB) in a single unit.

The recycling plant comprises ultrafiltration and reverse osmosis technologies; purified water is reused as utility water (80% recovery rate). The biogas generated during anaerobic treatment (34,000 m3/d) is used as flue gas for plant utility purposes providing about 40% savings in heating costs.

Package

  • Module 1 – Converting effluent streams like process effluents from Polyester Staple Fibre plant, oily water stream, sanitary wastewater and treated effluent from existing effluent treatment plant & cooling tower blow down to reuse quality with 80% recovery.
  • Module 2&3 – Process effluents from Poly Terephthalate Acid (PTA) and Poly Ethylene Terephthalate (PET) production & demineralisation water effluent treated to reuse quality with Up-flow Anaerobic Sludge Blanket Reactor (UASB), Membrane Bio Reactor (MBR), Ultra Filtration and Reverse Osmosis.

Refurbishment and Upgrade


Project

Petrobrazi Refinery

Client

OMV PETROM SA

Location

Brazi, Romania

Update of an existing plant to state-of-the-art ETP (30,000 m3/d) implementing a comprehensive technological optimisation and upgrading programme. The modernisation process commenced in 2010 and was realised in two phases during continuous plant operation. In addition, a self-washing filtration system was installed for enhanced water reuse.

Package

  • Slop Oil Recovery – API
  • Dissolved Air Flotation – DAF
  • Activated Sludge Process
  • Slop and Sludge Tri-canters
  • VOC Odour Treatment

Compact Effluent Treatment Solutions


Project

KAR Refinery

Client

Unirecycling SRL

Location

Erbil, Iraq

To meet more stringent environmental standards a containerized solution comprising multi treatment steps was designed and built. Commissioning was completed on site.

Package

  • Oil separators (CPI)
  • DAF (Dissolved Air Flotation)
  • Low footprint Lamella separators
  • Activated sludge treatment

High Salinity Raw Water Treatment


Project

Dahej Manufacturing Division

Client

Reliance Industries

Location

Dahej, Gujarat, India

The project acted as a solution to the issues faced by the client due to salinity in the intake water from Narmada river. The project was completed in a record breaking time of 8 ¾ months including engineering, supply, construction, testing and commissioning.

Package

  • Basket Strainer
  • Ultrafiltration
  • Reverse Osmosis
  • Reject Reverse Osmosis, achieving high recovery rate of 80 – 85%

Balance of Plant


Project

1 X 600 MW Rayalseema Thermal Power Plant

Client

Andhra Pradesh Power Generation Corporation (APGENCO)

Location

Kadapa, Andhra Pradesh, India

Complete Balance of Plant for 1 X 600 MW Rayalaseema Thermal Power Project Stage IV Unit 6

Package

  • Coal Handling
  • Ash Handling
  • Cooling Tower
  • Chimney
  • Water Systems
  • Compressed Air
  • Fire Protection Air-conditioning and Ventilation
  • Railway Siding

Sea Water Treatment


Project

Mundra Thermal Power Plant

Client

Adani Power Limited

Location

Mundra, Gujarat, India

Continuous production of RO treated water despite variation in feed water TDS load. Reduction in operating expenditure using energy recovery device. Efficient brine discharge mechanism for low impact on the environment

Package

  • Sea water intake system
  • Pre-treatment (Plate settler, Gravity Dual Media Filter and Pressure Sand filter for fine filtration)
  • RO Based Desalination process
  • Energy Recovery Device: Turbocharger
  • Plant Control – Automatic operation with PLC based Control System

ETP & Recycling Solutions

 

Project

Captive Power Plant

Client

Rashtriya Ispat Nigam Ltd., Vishakhapatnam

Location

Vishakhapatnam, India

Turnkey contract for Plant Water System and Balance of Plant including a wastewater treatment plant as part of the expansion of the Rashtriya Ispat Nigam Limited power plant in Vizag, India.

Highlight being the downstream ultrafiltration and reverse osmosis systems which facilitate efficient water recycling. The reclaimed water is re-used as make-up water for cooling tower.

Demineralisation / Condensate Polishing Unit


Project

Krishnapatnam Power Plant

Client

Andhra Pradesh Power Development Company Limited (APPDCL)

Location

Krishnapatnam, Andhra Pradesh, India

Objectives

  • Continuous production of polished condensate
  • Removal of corrosion residuals
  • Reduction of operating costs
  • Low impact to the environment

Package

  • High Pressure Condensate Polishing Unit
  • Resin Transfer to Regeneration area
  • Cation and Anion Resin Separation
  • Cationic Regeneration
  • Anionic Regeneration
  • Resin Transfer to Service Vessel Area
  • PLC Based automatic operation

Water Treatment Plant

 

Project

Ostrava Steel Plant

Client

Arcelor Mittal

Location

Ostrava, Czech Republic

WABAG blazed through intense competition to upgrade the water filtration plant for ArcelorMittal Ostrava a.s., the largest steelmaker in the Czech Republic and part of the world’s largest steel and mining group ArcelorMittal.

Package

  • Upgrade of Water Treatment Plant: two-chamber sand pressure filters, filtration and wastewater pumps incl. chemical dosing and sludge treatment.

Complete Water Solutions

 

Project

Vishakhapatnam Steel Plant

Client

Rashtriya Ispat Nigam Ltd., Vishakhapatnam

Location

Vishakhapatnam, India

Turnkey contract for Plant Water System and Balance of Plant including a wastewater treatment plant as part of the expansion of the Rashtriya Ispat Nigam Limited power plant in Vizag, India.

Highlight being the downstream ultrafiltration and reverse osmosis systems, facilitates efficient water recycling. The reclaimed water is to be re-used as make-up water for cooling tower.

At the Visakhapatnam steelworks, secondary effluent from the municipal wastewater treatment plant is further treated by means of ultrafiltration followed by Reverse Osmosis. The purified water is reused as cooling water in the steelworks.

Package

  • Cooling towers
  • Pumping Station
  • Ultrafiltration
  • Reverse Osmosis
  • Demineralisation
  • Wastewater Treatment Plant

Water Reclamation Plant

 

Project

Smederevo Steel Works

Client

SIGMA DIZ spol. s r.o.

Location

Smederevo, Serbia

The project comprised of the water treatment in cooling circuit ZPO. The aim was the reuse of the recycled water for the steel works. To meet the strict requirements WABAG implemented a system mainly consisting of two piping flocculators, one flotation unit and five two-chamber sand filters. Capacity is 48,000 m3/d.

Package

  • Flotation
  • Piping flocculators
  • Flotation unit
  • Filter installation
  • Two-chamber sand filters max. flow rate 5 x 400 m3/h
  • Chemical system

Raw Water Treatment Plant

Project

Raw water treatment plant

Client

DANGOTE Fertilizer Plant

Location

Lagos, Nigeria

Raw water treatment plant for Nigeria’s largest fertiliser complex using a combination of biological treat-ment (SBR) and membrane filtration – ultrafiltration & reverse osmosis – as a tertiary treatment.

Package

  • Biological treatment system
  • Dual Media Filter
  • Ultrafiltration system
  • Pre-treatment, Filtration, Backwash
  • Chemical enhanced backwash (CEB)
  • UF permeate tank
  • RO system
  • Cartridge filters
  • RO membranes
  • CIP system
  • Reject discharge system
  • Outfall piping & sub-sea diffuser piping for reject disposal

Water Treatment Plant

Project

Water Treatment Plant

Client

Indorama Eleme Fertilizer & Chemicals Ltd

Location

Port Harcourt, Nigeria

Objectives

  • Reliable operation
  • Continuous production of Demineralized water
  • Reduction of operating costs
  • Low impact to the environment

Package

  • Decarbonators
  • Filtration (Auto backwash filter)
  • De-cationization (SAC)
  • De-Anionization (SBA)
  • Mixed bed Exchanger (MB)
  • Potable water filters (ACF)
  • Neutralization Pit ( N. Pit)

Wastewater Treatment for Dairy effluents

Project

Effluent treatment for dairy “Tunisie Lait”

Client

Tunisie Lait

Location

Sidi Bou Ali, Tunisia

WABAG has realized a wastewater treatment plant for the purification of effluents emanating from the dairy “Tunisie Lait” located in Sidi Bou Ali (25 km from Sousse). The project included the design, detail engineering, supply, installation and commissioning of the equipment for the industrial wastewater plant. The process employed is a low-load activated sludge treatment which enables the achievement of the required treated effluent quality.

Package

  • Screen, homogenization, grease removal
  • Biological reactor with anoxic tank
  • Degassing zone
  • Secondary sedimentation tank
  • Sludge thickening and dewatering Sludge beds in safety

Wastewater Treatment Plant for Beverages Production


Project

Refurbishment of Dragon WWTP

Client

Pepsi Co. International

Location

Bucharest, Romania

Modernisation of industrial effluent treatment plant based on the MBBR process (FLUOPUR®) with a capacity of 2,550 m3/d. The new design was successfully tested on the spot for several months using a pilot prior to full-scale installation. Turnkey completion followed by 15 months O&M.

Package

  • Pre-treatment
  • Ph control
  • Biological treatment (MBBR process)
  • Sludge dewatering (new)
  • Design, engineering, supply, installation, commissioning
  • O&M

Wastewater Treatment Plant for Snack Production


Project

Modernisation & Upgrade of Kashira WWTP

Client

Pepsi Co. International

Location

Moscow, Russia

The Kashira plant is one of the largest and most modern snack manufacturing sites both in Russia and continental Europe. In line with PEPSI Co‘s intention to increase the production capacity, it awarded WABAG Romania with the refurbishment and extension of the WWTP with a capacity of 1,460 m3/d (average).

Package

  • Increase of capacity from 45 m3/h to 60 m3/h (peak 105 m3/h)
  • Renewal and extension of the electro-mechanical equipment
  • Design, equipment supply, installation, commissioning and start-up.

Al Kharj Industrial City


Project

Water Reclamation Plant for new industrial park

Client

Alkhorayef Water & Power Technologies comp. Ltd.

Location

Al Kharj, Saudi Arabia

Realisation of an effluent treatment plant with the target of the reuse of industrial effluents emanating from various production facilities – including wood and metal industries, construction material production as well as chemical and petroleum industries. Employment of a multi-stage-treatment system with a capacity of 10,000 m3/d.

Package

  • Pre-treatment
  • Chemical Precipitation
  • Primary Sedimentation
  • Equalization
  • Biological Treatment
  • Disc Filtration
  • Disinfection
  • Sludge treatment
  • Odor treatment

UJAMS Industrial Park


Project

Wastewater treatment & Reclamation Plant

Client

UWTC (JV, leaded by WABAG) , for the City of Windhoek.

Location

Windhoek, Namibia

The first Industrial Wastewater Treatment & MBR along with Reuse situated in Namibia. Based on MBR this plant completely recycles a crucial influent which comprises of wastewater blends from a tannery, a brewery, an abattoir and a chocolate factory. The plant showcases state of the art MICROPUR-MBR® technology supported in the later phases by UV, sludge treatment and exhaust air treatment.

The plant is a prime example of WABAG‘s technological knowhow when it comes to Industrial Water Reclamation. This project received the Distinction Award for the “Industrial Water Project of the Year 2015” at the Global Water Summit in Athens, Greece.

Package

  • Pre-treatment
  • Dry weather buffer tank including pH correction
  • Fine sieving by MICROPUR®
  • Membrane Bioreactor – MBR
  • UV-Disinfection
  • Clear water tank
  • Sludge treatment
  • Odour treatment

Tobacco Industry – ETP for Otopeni factory


Project

Wastewater treatment & Reclamation Plant

Client

Philip Morris International

Location

Otopeni, Romania

The state-of-the-art factory of Philip Morris International (PMI) in Otopeni, located very close to Bucharest, is to be expanded by y new production line which requires also a respective effluent treatment plant. A tailor-made multi-stage treatment plant employing advanced technologies to meet all requirements will be installed. The plant is designed for a capacity of 800 m3/day with additional treatment possibility of 800 m3/day for utilities wastewater to make it suitable for discharge or reuse.

Package

  • Dissolved Air Flotation (DAF)
  • Biological treatment – the WABAG FLUOPUR® process (MBBR technology)
  • Dual Media Filter
  • Activated Carbon (GAC) Filtration
  • Odour control system

IOCL Paradip ETP: outstanding contribution in water efficiency & conservation

Initial state

The port town of Paradip in Jagatsinghpur district, Odisha was facing acute drinking water shortage due to over exploitation of groundwater resources by industries surrounding the town. The port town is home to about two lakh people.

IOCL’s refinery at Paradip is also one among the industries relying on the water sources available around Paradip. A refinery requires huge amount of water for its daily operations. The water crisis became more severe during the summer. Realizing the fact that “Drinking water is the fundamental right of living beings”, IOCL decided to set-up an effluent treatment and water reclamation plant inside its premises to reduce the dependency on external water sources and to prioritize freshwater for the residents of Paradip.

Challenges

Efficient treatment and recycle of the complex effluent generated by the refinery. Need for a proven and innovative blend of processes based on the variation and contamination in the effluent. To attain more efficiency in the process for obtaining greater volume of water that can be reused as a significant contribution towards conservation of fresh water.

The solution

WABAG was entrusted with the design, engineering, procurement, construction, installation, and start-up and test operation of an environmental friendly and cost efficient water management system for IOCL Paradip.

The effluent treatment and recycling plant, which is the largest industrial recycling plant in India, ensures this by recycling around 54,000 m3 of treated water every day for the refinery. Enabling water reuse of such a huge quantum by WABAG’s processes is outstanding in nature and sets a precedent for similar sustainable water management infrastructure in upcoming refineries. By ensuring maximum reuse of the generated effluent for application as process water in the refinery, dependence on freshwater is reduced by over 17,000 ML every year, helping prioritize fresh water for irrigation & domestic purposes, the priority sectors in India.

Technologies

The effluent is a cocktail of Oily water, stripped sour water, spent caustic, cooling tower blow down, sanitary wastewater & DM Plant regeneration waste which could severely impact the environment if discharged untreated.

This complex effluent is treated in a number of stages comprising free oil removal through API and TPI separator, emulsified oil removal through DAF (Dissolved Air Flotation), biological treatment using bio-tower and activated sludge process, treatment for spent caustic and treatment for landfill leachate. Subsequently, the treated effluent is subjected to further treatment (Ultra Filtration & High Efficiency Reverse Osmosis achieving a consistent recovery rate of around 85%) to enable reuse in the refinery. The concept is rounded off by final sludge treatment with thickening and dewatering in centrifuges.

The project highlights a comprehensive treatment model for a complex effluent where WABAG’s vision for eco-friendly solutions is reflected in the treatment of VOC (Volatile Organic Compounds) and passing of RO reject water through a hard COD management unit before discharge into the sea. This ensures the environment around the refinery is not polluted with harmful contaminants.

Global Recognition

ASSOCHAM honoured WABAG with Water Management Excellence Awards 2018 for “Outstanding Contribution in Water Efficiency & Conservation” for its comprehensive water management system for IOCL, Paradip at the National Conference-cum-Expo & Awards in Water Management, New Delhi.

Conclusion

Oil & Gas is the one of the major growth drivers of India’s economy. With a no. of mega refineries and petrochemical complexes planned in the next 3 years, the demand for water for process applications in such complexes is expected to grow manifold. In view of India’s water scenario, where the per capita availability is reducing, there is a need to provide feasible and sustainable water solutions. This will benefit in three ways. First, ensuring water security for industries, thus averting shutdowns, enhancing productivity. Second, water reduction in burden on limited freshwater sources available. The limited freshwater can be prioritized for domestic and agricultural consumption. Third, eco-friendly discharge of harmful and complex effluents is ensured in line with global environmental norms.

Ujams industrial project: Low footprint and high-efficiency water reclamation plant

Initial Situation – every drop counts

Windhoek lies in the middle of Namibia, the driest nation south of the Sahara. The city has always struggled with water shortages and – as an answer – since the 1960s, has been employing Water Reclamation facilities to enhance water security.

The Ujams Industrial Water Reclamation Plant is located in the city’s northern industrial area and treats around 1.5 million m3 industrial effluents per year. The existing WWTP had to be replaced with a new treatment plant to meet the new discharge regulations into sensitive freshwater sources.

Requirements

The aim of the new advanced industrial wastewater treatment plant was to purify the effluent and reclaim the water for further reuse in augmentation of the Klein-Windhoek River and other applications such as dust control during road construction. The plant treats a cocktail of effluents: an abattoir, a brewery and a tannery are the main sources of the wastewater. The major challenge was to cope with extreme variations in terms of influent load and characteristics – high and fluctuating COD (peaks > 10,000 mg/L) and nitrogen (peaks > 300 mg/L) concentration.

The solution – showing an extremely compact and flexible process design.

Within the framework of an international tender the City of Windhoek chose WABAG as an innovative and reliable partner to realize the water reclamation plant on BOOT model.

WABAG designed a compact, highly-efficient and flexible process including its new fine sieving technology MICROPUR® as advanced pre-treatment. This innovative fine sieving system significantly improves removal efficiency for organic contaminants & fibres as well as oils and fats, resulting in enhanced operational safety and reducing the load on downstream treatment steps. This ensures optimization of the complete wastewater treatment plant in terms of efficiency as well as a reduction in operating costs.

MICROPUR-MBR® – WABAG employed a combination of advanced fine sieving technology MICROPUR® with the well-known membrane bioreactor technology MARAPUR® This complete low footprint technology is characterised by high biomass concentrations in the activated sludge tanks, enhanced phosphorus and nitrogen removal and reduced activated sludge tank volumes.

The entire process scheme comprises fine screen, grit separation, dry weather buffer tank including pH-correction, microsieving of raw wastewater, biological process of denitrification and nitrification, membrane filtration with hollow fiber membranes, UV-Disinfection, clear water tank incl. utilities and firefighting, sludge treatment and odour treatment.

Prior to full-scale installation, the proposed patented, low footprint process design was verified by setting up a pilot plant and diligently testing for 7 months.

Public-private partnership – BOOT project

WABAG not only financed the project through a long-term loan from the German DEG, but also provided innovative, in-house developed technologies for sustainable water recycling. Moreover, the WABAG JV is responsible for professional plant management for a period of 21 years.

Know-how transfer right from the start

WABAG has been committed to continuous development of local expertise for effective plant management through training modules of international standards, starting with the operation procedure of the pilot plant. The project presents an exemplary cooperation in Windhoek, Namibia. It is the first BOOT project in the water sector for the city of Windhoek, the capital of Namibia.

Sustainable solutions. For a better life.

The WABAG Group head quartered in Chennai with its global presence in 4 Continents and more than 20 countries has a work-force of more than 2,000. With a history dating back more than ninety years, the group has emerged as a leading pure play water technology player across the globe with focus on emerging markets.

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