With increasing environmental concerns and legislations, waste water treatment is a mandate to continually improve the discharge standards and lower environmental hazards; IROCK offers sustainable solutions for treatment of all types of waste water.
We provide complete solutions for effluent treatment, common effluent treatment and sewage treatment which comprises physical, chemical & biological treatment based on advanced technologies. With over hundred successfully operating installations, our designs offer highly economic plant installation & operation, lowest footprint area, minimal waste generation and treats water to the specified standards.
* Biological Treatment
We offer various solutions for biological reactors which are based on suspended and attached growth. Under the suspended growth category, we offer one of the largest ranges of reactors with nutrient removal systems. While under attached growth category, we provide both moving and fixed bed systems.
* Bio Filter
As leader in waste water and sewage treatment, we offer Bio-Filter mechanism of sizes 60M and above to meet varying process requirement with high density non metallic media or any other conventional media to achieve high level of BOD removal at low operating costs. The key to high performance of Bio-Filter, besides media is the Rotary Distributor which is installed at the centre of the circular Bio-Filter tank. Our filters are designed to deliver consistent performance by uniformly distributing waste water over the media across the tank's diameter. The Rotary Distributor is provided with two or four arms, each fitted with spreader nozzles to spread and distribute waste water on the media.
* Sequential Batch Reactor (SBR)
The Sequential Batch Reactor (SBR) is an activated sludge process designed to operate under sequences of various phases of biological treatment where aeration and sludge settlement both occurring in the same tank. The SBR design is a fill and draw type activated sludge process where individual reactors are filled one by one to perform five discrete operations in sequence i.e. Anoxic or oxic fill, React, Settle, Decant and Idle/Waste sludge.
The SBR system is designed with an ability to treat a wide range of influent volumes. Hence, there is a degree of flexibility associated with work timings that can be achieved by altering the duration of treatment steps and number of cycles per day.
SBR aeration system generally consists of fine bubble air diffusers. In this process, the compressed air is sheared into small bubbles creating large specific surface area for higher mass transfer efficiency between air and waste water. SBR produces sludge that has good settling properties provided the influent waste water is added into the aeration filter in a controlled manner. An appropriately designed SBR process is a unique combination of equipment and software providing highest level of effluent quality on all parameters including BOD and Nutrient removal. Automated control minimizes the manual intervention and thus, there are fewer possibilities of operational errors.
* Moving Bed Bio Reactor (MBBR)
MBBR technology is a combination of attached and suspended growth technologies. Under this process, the media remains suspended in the reactor and offers additional surfaces for the microbes to grow. This in turn maximizes the growth of microbes in a given volume of aeration tank as compared to the conventional aeration without the media. The Bio-Film grows on the bio media surface and moves along with the water inside the reactor chamber creating the biomass. The efficiency of this biomass in reducing the organic load in waste water is a result of successful functioning of MBBR system.
Treatment plants are upgraded to increase BOD and nutrient removal capacity from the waste water by enhancing the uIrockization of existing reactor's capacity. Existing activated sludge plants can be upgraded to achieve nitrogen and phosphorus removal as well. The upgrade to IFAS or MBBR often consists of simply adding carriers and screens to existing basins that upgrades the current plants in a cost-effective and timely manner without major civil engineering and land requirements.
PLC based control system optimize IFAS/MBBR process performance by minimizing energy and chemical costs. By selecting innovative MBBR solutions, municipalities can cope with evolving regulation, aging infrastructure and growing population. Industrial plants can meet the strictest regulatory requirements for waste water discharge to the environment or to municipal collection systems, and address typical challenges such as variable inflow, seasonal peaks and high organic loads.
* Membrane Bio Reactor (MBR)
The Membrane Bio Reactor Technology is the most advanced development in the field of biological treatment of waste water that recycles in smaller footprint and under stringent discharge norms. The MBR technology combines the skills of the membrane specialists and the biological treatment engineers to deliver integrated treatment solutions with firm process guarantees such as BOD and TSS less than 5 mg/l and also removal of nutrients (nitrogen & phosphorous), coliforms.
Under this process, hollow fiber membranes are introduced to mixed liquor to separate treated effluent from mixed liquor. Membrane being the absolute physical barriers ensures complete removal of suspended impurities. MBR applications include retrofits of existing systems as well as installation of new systems, for both meeting the most stringent discharge norms and reuse. Treated waste water from MBR can be even reused for cooling tower make-up, to generate high purity water through Reverse Osmosis and other non-potable applications.
This process can help environment protection by treating waste water and making it suitable for variety of application and thus conserve precious drinking water. Biological system designed for MBR process operates at higher MLVSS concentration with higher sludge retention time and thus it produces a low quantum of biological sludge which inturn reduces the sludge dewatering cost.
Biological process fluid (mixed liquor) is pumped to the Membrane Operating System ("MOS"). The mixed liquor is introduced to membrane, along with air, evenly across the bottom of the tank through a unique two-phase jet system. This mixed liquor fills the membrane tank and flows upward through the membrane sub-modules, creating cross-flow dynamics across the membrane surface. This cross-flow continuously scours the membrane surface and prevents solid dehydration at the membrane surface. Applying a low-pressure vacuum to the inside of the membrane fiber pulls water through the membranes and pumps the filtered water to the next process step. Solids, including organics, bacteria, and most viruses, are rejected by the membrane system and are retained in the mixed liquor, which overflows the MOS back to the aeration tank.
The Membrane Operating System is an assembly with integral membrane modules arranged in rack assemblies, inserted into the membrane tank.
MOS Mixed Liquor Distribution & Recirculation Jets are designed to distribute the air scour and mixed liquor flow evenly across the membrane sub-modules.
This feature eliminates potential polarization (concentration) of suspended solids around the membrane fibers which could be main cause for the failure and damage of individual fibers thus sub-modules. Additionally, this feature provides even distribution of mixed liquor solids to each membrane unit, to ensure critically that all membranes see the same process conditions. The return recirculation of mixed liquor ensures influent comes in intimate contact with the concentrated biomass, offering better organism selection and added flexibility in the anoxic cycle for advanced nitrogen removal, when required. This same jet system also acts as an integral part of the membrane cleaning system, providing an efficient scouring of the membranes with chlorine cleaning solution. The integrated cleaning system allows the sub-modules to be quickly cleaned in place. Additionally, the clean and efficient procedure eliminates the need for membrane removal from process tanks that can damage membranes and present risks to plant operators.
Relaxation, Maintenance and in situ CIP are exclusive features of this MBR Process to ensure consistent water quality and complete membrane life. The entire operation is PLC controlled.
* Sludge Handling
Sludge handling is an important and crucial part of water & waste water treatment processes. Inadequate sludge handling system can pose serious environmental implications. The sludge can be organic or inorganic. Organic sludge may need further biological treatment before they can be disposed off after de-watering and drying. Inorganic sludge can also be taken for disposal only after adequate treatment for any hazardous chemicals which otherwise may pose environmental hazards.
* Anaerobic Digester
IROCK offers Anaerobic Digester with various options as desired for specific process application for treating organic sludge. The system can either be single stage or two stages, where in the latter option's second stage acts as the gas holder section. The digesters are provided with varying degree of off-take arrangement that withdraws digester and bio-gas for further processing.
* Digester Mixer
Gas Mixing System for mixing of Digester contents are provided by tapping bio-gas generated and recycled through adequately sized compressor, through gas mixing system of multiple gas lances perforated pipes, installed all over the tank area and extend deep into the tank from the Digester tank roof. In other option, the lances can be placed directly on the floor of digester tank and thus avoiding long lances. Both these options have their respective advantages and we can provide most optimum solution for specific requirement. The bio-gas system is equipped with fail safe devices to avert any accident in view of inflammable conditions around the Digester area.
IROCK also provide complete range of mechanical mixers for digesters that are mounted on top of the digester tank roof. These Mixers can be single or multiple on a single digestion tank depending upon the specific requirement.
* Belt Filter Press
IROCK Belt Filter Press (BFP) dewaters organic and inorganic sludge at least operating cost. BFP has the capacity to handle very lean sludge and for this an independent gravity drainage deck is provided to pre-thicken the sludge before it enters the main BFP sections. Sludge dewatering is achieved by bringing the sludge between the two moving belts which moves on the varying sizes of rollers keeping belts under tension through hydraulic /pneumatic cylinder system which results in squeezing out the liquid trapped between the solids and withdrawn separately through the filtrate trays. Adequate arrangement is provided for auto belt tracking which makes this system operator friendly.
The Belt Presses can be supplied in carbon steel or stainless steel construction depending upon the job requirement. These units can be supplied in different sizes upto 3M width.
* Gravity Belt Thickener
Gravity Belt Thickener (GBT) design is one of the most effective sludge pre-thickening units which can be applied for various organic and inorganic sludge to achieve desired results at least operating cost. The GBT can handle very lean sludge and is provided with an independent gravity drainage deck. Sludge pre-thickening in GBT is achieved by spreading the sludge uniformly across the width of the adequately sized belt, on top of which an independent gravity drainage deck is provided. The belt is carried on set of rollers keeping belt under tension through hydraulic cylinder system. Pre-thickened sludge is then discharged onto next process unit for further processing. Adequate arrangement is provided for auto belt tracking which makes the system operator friendly.
GBT units can be supplied in carbon steel or stainless steel construction depending upon the job requirement in different sizes upto 3m width.
* Combi Sludge Dewatering Unit
In order to multiply the individual benefits of Gravity Belt Thickener (GBT) and Belt Filter Press (BFP), Combi unit was innovated. This unit is an excellent dewatering system where lean sludge is first fed on to GBT for pre-thickening and then this pre-thickened sludge is carried on to BFP for final sludge dewatering.
Combi units can be supplied in carbon steel or stainless steel construction depending upon the job requirement in different sizes upto 3m width.
* Vacuum Drum Filter
Rotary Vacuum Drum Filter (RVDF) is one of the most prevalent practices in the industry to dewater all kinds of sludge at low capital cost. Even though these units consume higher power due to deployment of Vacuum Pump, these units are sIrockl preferred in given situations in view of their low cost maintenance. These units can be supplied in various sizes upto 80-90 sq. m. filtration area per unit. Depending upon the type of sludge, the dewatered solid discharge mechanism can have different configurations e.g. Belt Discharge, Knife Discharge, and String Discharge etc. These units can also be provided in carbon steel, rubber lined and stainless steel construction to meet specific application requirement. The RVDF is supplied with complete filtrate receiver, moisture trap and other accessories like Filtrate Pumps, Vacuum Pumps, and Blowers etc.
* Gravity Thickener
Gravity Thickener units are mechanically similar in feature to centre driven Clarifier described in the section. The only major difference is deployment of higher torque drive head in view of higher sludge load to be handled by the rake assembly. These units can be supplied in sizes upto 40m & above and made of carbon steel or stainless steel construction.
* Dissolved Air Flotation Thickener
IROCK offers Dissolved Air Flotation Thickener (DAFT) for sludge thickening especially prior to digester tank. This unit separates sludge by floating it through the Dissolved Air Flotation process and the inert grits settle down at the bottom removed separately thus preventing grits from entering the Digesters thereby reducing maintenance cost. The salient features of this unit are similar to DAF Separator which has been described in the separate section.
These units can also be deployed as the main process unit in certain Biological Treatment Systems where these can work as clarifier after the aeration tank. The typical application is low strength BOD waste water treatment using MBBR systems which generate low TSS after the aeration system.
* Bio Gas Handling
Bio-gas generated during anaerobic digestion is to be generally uIrockized by boilers, gas engines, incinerators or other devices requiring regular and consistent gas supply for which adequately sized bio-gas handling system is crucial between the gas producing units and the uIrockity point. We provide comprehensive range of equipment for the bio-gas handling system for this purpose.
* Gas Holder
IROCK provides Gas Holder with floating covers with options of vertical guided system or spiral guided system. The adequately sized structure is provided to ensure roller guidance above the gas holder tank area that in turn ensures structural rigidity even during maximum lifted conditions. The Gas Holder tanks are provided with upto 30-35m diameter & above.
Gas Holders are also available with engineered flexible membrane which is sealed tight either to the tank wall or tank floor.
* Gas Safety Equipment
IROCK’s comprehensive range of Gas Safety equipment for installation in bio-gas handling systems includes Pressure Relief Valve, Flame Trap, Flame Cell, Check Valve, Drip / Sediment Trap, Gas Burner etc.
* Oil Water Separation
IROCK offers wide range of treatment solutions for oil water preperation for efficient treatment & treatment to produce water.