Lime, ferric chloride, and sulphide precipitation for phosphorus, heavy metals, fluoride, and scaling ion removal. Non-advanced biological treatment in ISO containers.
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High-energy rapid mix (30–60 s) followed by tapered flocculation with variable-speed mixers for optimal floc growth.
Tube settlers and lamella clarifiers for high-rate solids separation with automated sludge removal systems.
Sand/dual-media filters followed by ion exchange for metals polishing and GAC for organics removal.
2-point pH control: alkaline precipitation (pH 9–11) followed by acid neutralisation (pH 6.5–8.5).
| Parameter | 10–25 m³/h | 25–50 m³/h | 50–100 m³/h | 100–200 m³/h |
|---|---|---|---|---|
| Precipitation Chemistry | Hydroxide (lime/caustic) + FeCl₃ | Hydroxide + sulphide (if needed) | High-rate hydroxide + sulphide | Multi-train with common sludge |
| Rapid Mix Tank | 0.5 m³, 60 s RT | 1.0 m³, 60 s RT | 2.0 m³, 60 s RT | 2× 2.0 m³, 60 s RT |
| Flocculation | 0.8 m³, 3-stage tapered | 1.5 m³, 3-stage tapered | 3.0 m³, 3-stage tapered | 2× 3.0 m³ tapered |
| Clarifier | Tube settler, 2 m² | Tube settler, 4 m² | Lamella, 8 m² | Lamella, 2× 8 m² |
| Phosphorus Removal | >95% to <0.5 mg/L | >95% | >95% | >95% |
| Heavy Metals | Cr, Cu, Zn, Ni, Pb >98% | >98% all metals | >98% all metals | >98% all metals |
| Fluoride Removal | >90% with lime | >95% with CaCl₂ + lime | >95% | >95% |
| Sludge Handling | Drum collection | Thickening hopper + PC pump | Thickening + dewatering | Dedicated sludge container |
| Power | 8–15 kW | 15–25 kW | 30–50 kW | 60–100 kW |
| SCADA | Tier 2: Standard | Tier 2–3: Advanced | Tier 3: Advanced | Tier 4: DCS |
Chromium, nickel, zinc, copper rinse waters and spent baths.
Heavy metals and active ingredient residuals from API production.
Fluoride, heavy metals, and silica from wafer fabrication.
Acidic waste streams with mixed metal content.
Acid mine drainage, process water with dissolved metals.
Lead, cadmium, and acid wastewaters from battery processing.
For emulsified oils and colloidal solids that complement precipitation.
IX polishing and GAC for residual metals and organics removal.
For TDS management and water recovery after precipitation.
Complete equipment inventory for Option I — Chemical Precipitation + Heavy Metals Removal. Process train: No | SCADA: Tier 2–4
Alkaline pH caustic handling, lime slurry dust control, sulphide toxicity
| Item Code | Description | Qty | Spec / Notes | Location |
|---|---|---|---|---|
| I-ME-01 | Inlet screen | 1 | 3–6 mm, manual or automatic | Inlet |
| I-ME-02 | Equalization tank (EQ) | 1 | 4–10 m³, PE or SS316L, mixing | EQ |
| I-ME-03 | Rapid mix tank (flash mixer) | 1 | SS316L, 0.5–2 m³, 30–60 s RT, high-shear mixer 1.5–3 kW | Rapid mix |
| I-ME-04 | Flocculation tank | 1 | SS316L or PE, 1–5 m³, 10–30 min RT, variable-speed mixer 0.5–1.5 kW | Flocculation |
| I-ME-05 | Tube settler / lamella clarifier | 1 | SS316L or FRP, 5–25 m², 60° plate angle | Clarifier |
| I-ME-06 | Sludge scraper / hopper | 1 | SS316L, automatic | Clarifier |
| I-ME-07 | Sand / dual-media filter | 1 | SS316L or FRP, 0.5–1.5 m³ | Filtration |
| I-ME-08 | Ion exchange vessel(s) (polishing) | 1–2 | SS316L or FRP-lined, 0.5–2 m³, downflow, resin: selective chelating or mixed-bed | Polishing |
| I-ME-09 | IX regeneration tank | 1 | PE, 1–3 m³, heating jacket optional | Polishing |
| I-ME-10 | pH correction tank (post-IX) | 1 | Rapid mix, 1–3 m³, PE or SS316L | Post-treatment |
| Item Code | Description | Qty | Spec | Driver |
|---|---|---|---|---|
| I-PU-01 | Inlet lift pump | 2 | 1 duty + 1 standby | VFD |
| I-PU-02 | EQ recirculation / transfer pump | 2 | 1 duty + 1 standby | Fixed |
| I-PU-03 | Rapid mix feed pump | 1 | Centrifugal, 1–3 bar | Fixed |
| I-PU-04 | Flocculation feed pump | 1 | Centrifugal, 0.5–2 bar | Fixed |
| I-PU-05 | Clarifier sludge pump | 1 | Progressive cavity, 1–5 m³/h | Fixed |
| I-PU-06 | Filtration feed pump | 1 | Centrifugal, 1–5 bar | Fixed |
| I-PU-07 | IX regeneration pump | 1 | Centrifugal, chemical-resistant | Fixed |
| I-PU-08 | Effluent discharge pump | 2 | 1 duty + 1 standby | Fixed/VFD |
| I-PU-09 | Lime slurry pump (if using lime) | 1 | Progressive cavity or peristaltic, abrasion-resistant | Fixed |
| I-PU-10 | Acid dosing pump | 1 | Diaphragm, 5–50 L/h | Fixed |
| I-PU-11 | Caustic dosing pump | 1 | Diaphragm, 5–200 L/h | Fixed |
| I-PU-12 | Ferric dosing pump | 1 | Diaphragm, 5–50 L/h | Fixed |
| I-PU-13 | Polymer dosing pump | 1 | Diaphragm, 1–20 L/h | Fixed |
| Item Code | Description | Qty | Range / Output | Tier |
|---|---|---|---|---|
| I-SI-01 | Inlet / outlet flow meter | 2 | Magnetic or ultrasonic | All |
| I-SI-02 | pH (EQ / rapid mix / floc / outlet) | 4 | 0–14 pH | All |
| I-SI-03 | Online metals analyser (Cr, Cu, Zn, Ni, Pb) | 1 | Colorimetric or ICP-OES (optional) | Tier 3 |
| I-SI-04 | Conductivity (outlet) | 1 | 0–50 mS/cm | Tier 2+ |
| I-SI-05 | Turbidity (outlet) | 1 | 0–100 NTU | Tier 2+ |
| I-SI-06 | TSS online (optional) | 1 | Optical or ultrasonic | Tier 3 |
| I-SI-07 | Level (all tanks) | 6–8 | Ultrasonic / hydrostatic | All |
| I-SI-08 | Differential pressure (filter) | 1 | 0–1 bar | Tier 2+ |
| Item Code | Description | Qty | Spec | Notes |
|---|---|---|---|---|
| I-DS-01 | Lime slurry (Ca(OH)₂) or caustic (NaOH) | 1 | Diaphragm or PC, 50–500 L/h, day tank 500–1000 L, dust collector if lime | |
| I-DS-02 | Ferric chloride (FeCl₃) | 1 | Diaphragm, 10–100 L/h, day tank 200–500 L | |
| I-DS-03 | Ferrous sulphate (FeSO2) | 1 | Diaphragm, 10–100 L/h, day tank 200–500 L | |
| I-DS-04 | Sodium sulphide (Na₂S) (if heavy metals) | 1 | Diaphragm, 5–50 L/h, sealed day tank, H₂S detection | |
| I-DS-05 | Acid (HCl or H₂SO2) neutralisation | 1 | Diaphragm, 10–200 L/h | |
| I-DS-06 | Polymer | 1 | Diaphragm, 1–20 L/h, make-down unit | |
| I-DS-07 | IX regenerant (HCl + NaOH or NaCl) | 1 | Diaphragm, 50–200 L/h | |
| I-DS-08 | Day tanks | 6–8 | 200–1000 L, PE, bunded, level alarm |
| Item Code | Description | Qty | Spec | Tier |
|---|---|---|---|---|
| I-SC-01 | PLC | 1 | S7-1200 or S7-1500 | Tier 2–4 |
| I-SC-02 | HMI | 1 | 10–15", IP65 | Tier 2–4 |
| I-SC-03 | pH cascade control (alkaline precipitation + neutralisation) | 1 | Two-point pH control | Tier 2+ |
| I-SC-04 | Metals analyser feedback (optional) | 1 | Auto-adjust coagulant dose | Tier 3 |
| I-SC-05 | Remote I/O | 2–3 | Distributed | Tier 3 |
| I-SC-06 | 4G / WiFi router | 1 | Industrial, VPN | Tier 3 |
| I-SC-07 | UPS | 1 | 1.5–2 kVA | Tier 3 |
| I-SC-08 | MCC / control room | 1 | SS304, IP55, air-conditioned, positive pressure | Tier 3–4 |
| Item Code | Description | Qty | Spec | |
|---|---|---|---|---|
| I-AU-01 | Rapid mix impeller | 1 | High-shear, 1.5–3 kW, SS316L | |
| I-AU-02 | Flocculation mixer (variable speed) | 1 | Low-shear, 0.5–1.5 kW, SS316L | |
| I-AU-03 | Ventilation | 2–3 | 200–500 m³/h | |
| I-AU-04 | LED lighting | 4–6 | 20W, IP65 | |
| I-AU-05 | HVAC (control room) | 1 | 3–6 kW | |
| I-AU-06 | Spill bund | 1 | 110% largest tank | |
| I-AU-07 | Pipework & valves (SS316L) | 1 set | DN25–DN150 |
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