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SAOR1AJ I CONTENS

UVOD I INTRODUCTORY NOTE (Aieksandra Todorovic-SuceviC)

VODAIWATER

UVODNE RECI I INTRODUCTORY WORDS (Dragoljub Kos) 4

PRIPREMA TEHNOLOSKEVODE (HPV) I CHEMICAL WATER TREATMENT (CWT) DEMI VODE (RNP) I DEMI WATER (ORP) 6 MODRI(A 8 GORENJE (DEMI) 10 ALUMIL 12 FABRIKA SLADOLEDA /ICE-CREAM FACTORY 14 FIAT KATAK I, II, Ill 14-19 ~WM W

PRIPREMA PIJACEVODE I DRINKING WATER TREATMENT STANARI 22 TUZLA 22 ~M~ U PRECISCAVANJE SANITARNO-FEKALNE VODE I SANITARY SEWER WATER TREATMENT BRUS 24 BLACE 26 ~~o m KRAUEVO 28 SABAC 30 PRECISCAVANJETEHNOLOSKEVODE I INDUSTRIAL WATER TREATMENT GORENJE PPOV 32

RAZVOJ HIDROMASINSKE OPREME U FUNKCIJI POSTROJENJA I DEVELOPMENT OF HYDRO-MECHANICAL EQUIPMENT IN THE FUNCTION OF A PLANT TPS SEPARATOR /TPS LAMELLA SETTLER 34 KOALESCENTNI SEPARATOR!/ COALESCENT SEPARATORS 36 UGUS(IVA( MUUA I SLUDGE THICKENER 36 REZERVOAR ZA PRIHVAT UUA I RESERVOIR FOR OIL RECEIVING

RASHLADNI SISTEMI VECIH KAPACITETA I COOLING SYSTEMS OF HIGHER CAPACITIES ASU BOR U.S.STEEL SERBIA

OTPRASIVANJE I DEDUSTING HENKEL, KRUSEVAC HOLCIM TNG RNP I LPG-OIL REFINERY PANCEVO TERMOELEKTRANA I POWER PLANT NIKOLA TESLA ZELEZARA SMEDEREVO I SMEDEREVO IRONWORKS ZENICA I ZEN I CA-STEEL MILL

36

38 40

44 46 48 48 50 52

ZENICA-ELEKTRO DEO I ZENICA-ELECTRICAL PROJECT 54 ANDRITZ 2013 54

rBI\6 YEAR 6 I SPECIAl EDITION 2013

UVOD Ovaj broj News-a posvetili smo temi zastita zivotne sredine. Priblizicemo vam sve ono sto smo radili 23 godine na polju pripreme, preciscavanja otpadnih voda: komunalnih, tehnoloskih i pripreme pijace vode.

Otprasivanje je drugo poglavlje ovog broja i pokazuje nasa iskustva u toj oblasti.lskustvo smo sticali saradnjom sa stranim firmama, koje su nam svojim rigoroznim zahtevima pomogle da postanemo eksperti. Firme sa kojima smo saradivali su Holcim, Fiat, Henkel, Rafinerija nafte Pancevo (GaspromnjeftL U.S.Steel, Messer i mnoge drug e.

Aleksandra

INTRODUCTORY NOTE

This issue of News we devoted to the environmental protection. We would like to introduce you with everything we have been doing over 23 years in the field of preparation, purification of technological and municipal (used) wastewater and drinking water preparation.

Dedusting is the second chapter of this issue and shows our experience in this field. We have gained experience by cooperation with foreign companies that helped us with their rigorous requirements to become experts. We have cooperated with Holcim, Fiat Henkel, Oil Refinery in Pancevo (Gazprom Neft) U.S.Steel, Messer and many others.

Sincerely, Aleksandra

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UVOONE RECI Direktor sektora za zastitu zivotne sredine Dragoljub Kos, dip/. ing. mas.

Zastita covekove okoline i unapredenje zivotne sredine je u danasnje vreme jedan od najvaznijih zahteva koji se postavljaju pred drzave, narode, privredne subjekte i svakog pojedinca.

Shvatajuci vaznost zastite zivotne sredine, kompanija Delta lnzenjering je formirala poseban sektor u svojim redovima, cije je programsko opredeljenje zastita covekove okoline i unapredenje zivotne sredine. Multidisciplinarni tim Delta lnzenjeringa programski i celovito resava sve probleme vezane za zastitu vazduha, vode i zemljista. Veliki je broj industrijskih postrojenja koja doprinose znacajnom zagadenju atmosfere emitujuci mnogobrojna jedinjenja-gasove i tecne iii cvrste cestice. Antropogeni izvori zagadenja atmosfere, pored razlicitih industrijskih procesa, svakako su i pogoni za sagorevanje fosilnih goriva (ugalj, nafta) i drveta, transport i sagorevanje otpada. Delta lnzenjering je u velikom broju ovakvih slucajeva uspesno resio zastitu vazduha filtriranjem (fabrika deterdzenata Henkel u Krusevcu i fabrika praskastih gradevinskih adheziva Henkel u lndiji). Postavljanjem elektrostatickih filtera na liniji proizvodnje sumporne kiseline u Rafineriji nafte Pancevo i na kotlovskim postrojenjima u TE Nikola Tesla u Obrenovcu, Delta lnzenjering je doprineo da vazduh iznad Panceva i Obrenovca bude cistiji. Specificna inzenjerska resenja je Delta lnzenjering realizovao na sistemima za otprasivanje u industriji cementa Holcim u Popovcu na linijama transporta klinkera, cementa, otprasivanju rotacione peci, kao i na sistemu otprasivanja na mlinu uglja. Kao poseban uspeh u zastiti vazduha u oblasti erne metalurgije, Delta lnzenjering istice svoj doprinos u resavanju problema otprasivanja konvertora u Zelezari Smederevo i otprasivanje visokih peCi u Zelezari Zenica. Ne smeju se zanemariti ni resenja otprasivanja ugljene prasine na transportnim sistemima u okviru REIK-a Kolubara, Vreoci, Obreno­vac, koje je Delta lnzenjering uspesno realizovao iii kroz projekte iii kroz inzenjering aktivnosti. Posebna paznja multidisciplinarnog tima Delta lnzenjeringa je usmere­na ka resavanju problema vezanih za vodu. Voda se u industriji pojavlju­je kao sirovina, kao nosilac energije, kao transportno sredstvo, kao rastvarac, kao meduproizvod, ali skoro uvek kao sistem za eliminisanje otpadnih materija. Ta njena poslednja uloga, kao otpadnih voda, jeste veoma mocan faktor uticaja coveka na zagadenje zivotne sredine (hidrosfere). Sektor voda, potpomognut svim ostalim organizacionim celinama Delta lnzenjeringa (projektovanje, inzenjering, elektro-sek­tor), programski celovito i uspesno resava probleme u oblasti vodosnabdevanja, navodnjavanja, preciscavanja otpadnih voda, reciklaze i ustede vode u industriji i komunalnoj delatnosti. Projektovanje, istrazivanje, razvoj i konsalting, kao delovi pomenutog programskog opredeljenja Delta lnzenjeringa, doprinose zastiti zivotne sredine, gde se voda pojavljuje kao znacajan zagadivac u raznovrsnim

ljudskim aktivnostima. Gradovi Lopare, Tuzla, Obrenovac svoje probleme vodosnabdevanja pijacom vodom uspesno su resili aktivnim ucescem Delta lnzenjeringa. ResavajuCi problem otvorenih rashladnih sistema kompresorske stanice i konvertorskih duvnica u Zelezari Smederevo i prevodeCi ih u zatvorene, recirkulacione rashladne sisteme, Delta lnzenjering je znacajno doprineo ustedi vode, kao i zastiti prirodnog vodotoka od uticaja otpadne toplote. Rezultati u oblasti preciscavanja industrijskih otpadnih voda koje je Delta lnzenjering ostvario u proteklom periodu respektivni su i znacajni. Rekonstrukcija postrojenja za preciscavanje zauljenih otpadnih voda u rafinerijama nafte Pancevo i Beograd, sa ugradnjom koalescentnih separatora sopstevenog razvoja i proizvodnje, doprinela je u velikoj meri sprecavanju zagadenja reke Dunav kao medunarodnog vodotoka. lzgradnjom dva postrojenja za preciscavanje otpadnih voda u Fabrici cementa Holcim u Popovcu, zasticeni su od zagadivanja cisti i relativno mali vodotokovi Toplik i Crnica. Na ovim postrojenjima je Delta lnzenje­ring uspesno primenio moderne ultrafiltracione metode preciscavanja u ovoj industrijskoj grani. Fabrika automobila Fiat automobili Srbija u Kragujevcu prvi put od svog postojanja uspesno preciscava svoje otpadne vode na postrojenju Katak, koje je Delta lnzenjering, po sistemu,Jijuc u ruke", realizovao u tri faze u periodu od 2009. do 2012. godine. lzrada projektne dokumentacije za centralna gradska postrojenja za preciscavanje komunalnih otpadnih voda za gradove Subotica, Kraljevo, Brus, Blace samo je potvrda aktivnog ucesca Delta lnzenjeringa u komunalnoj delatnosti i njegovog doprinosa zastiti prirodnih vodotoko­va od zagadenja koja poticu od ovako velikih urbanih sredina. Na kraju bih napomenuo da je Delta lnzenjering, kao odgovorna kompanija, kroz svoj sistem menadzmenta definisao i sistem zastite zivotne sredine. Delta lnzenjering poseduje Sertifikat ISO 14001 (pored ISO 9001 i ISO 18001 ), koji kroz svoju organizacionu strukturu obuhvata aktivnosti planiranja, odgovornosti, kvalitetne realizacije radnih procesa, razvoj, uvodenje novih tehnologija i politiku zastite zivotne sredine, kao delove ukupnog sistema menadzmenta. lskustva stecena u Delta lnzenjeringu upucuju na zakljucak da je upravljanje zastitom neposredne radne okoline neodvojivo od kvalitet­ne zastite i unapredenja zivotne sredine. I u narednom periodu Delta lnzenjering ce odgovorno i maksimalno nastojati da znacajno doprinese zdravoj zivotnoj sredini, kako bi doprineo zadovoljavajucem kvalitetu zivota ljudi.

INTRODUCTORY WORDS

Department of Water Treatment and Manager of Environmental protection department Dragoljub Kos, Dipl.lng.Mech.

Environmental protection and improvement of the environment is nowadays one of the most important demands to be placed before the governments, nations, companies and every individual.

Recognizing the importance of environmental protection, Delta lnzenjering has formed a separate group in its ranks which program­principle is environmental protection and improvement of the environ­ment. A multidisciplinary team of Delta lnzenjering comprehensively solves all problems related to the protection of air, water and land. There are a large number of industrial plants that contribute to significant pollution of the atmosphere by emitting numerous compounds-gases, liquid or solid particles. Anthropogenic sources of atmospheric pollution, in addition to various industrial processes, are also the plants for burning of fossil fuels (coal, oil) and wood products, transport and waste combustion. Delta lnzenjering has successfully solved the protection of air by filtration in a large number of such cases (Detergent Factory Henkel in Krusevac, Plant for Powdered Industry Adhesives Henkel in lndjija). With installation of electrostatic filter at the producing line of sulfuric acid in Pancevo Oil Refinery and Boiler Plants in TPP Nikola Tesla in Obrenovac, Delta lnzenjering has contributed that the air above Pancevo and Obrenovac get cleaner. Delta lnzenjering has implemented specific engineering solutions on dedusting systems in the Cement Industry Holcim in Popovac on the clinker and cement transport lines, rotary furnace dedusting and dust collection system on the coal mill. As a significant success in air protection in the field offerrous metallurgy Delta lnzenjering highlights its contribution in solving the problem of converter dedusting in Smederevo Steel Plant and blast furnace dedust­ing in Zenica Steel Plant. One must not forget the solutions of coal dust dedusting on transportation systems within Mining Energy Industrial Complex Kolubara, Vreoci, Obrenovac, which Delta lnzenjering has successfully finished either through designing or engineering activities. Special attention of a multidisciplinary team in Delta lnzenjeringis focused on solving problems related to water treatment. Water appears in the industry as a raw material, as a carrier of energy, as a mean of transportation, as a solvent, as an intermediate productand almost always as a system for eliminating of waste materials. That last role is a very powerful factor of human influence on environmental pollution (hydrosphere). The group for water treatment, supported by all other organizational units ofDelta lnzenjering (design, engineering, electrical group), comprehensively and successfully solves problems of water supply, irrigation, wastewater treatment, recycling and water saving in industry and municipal services. Designing, researching, development, consulting are all parts of the mentioned program orientation of Delta lnzenjering, to contribute the environment protection where water is emerging as a significant pollutant in a variety of human activities.

Cities of Lopare, Tuzla, Obrenovac are some of the cities which had their problems of drinking water supply effectively resolved by active participation of Delta lnzenjering. Solving the problem of open circuit cooling systems for compressor station and the converter oxygen lances in Steel Production Plant Smederevo and transforming them into closed circuit cooling systems, Delta lnzenjering has significantly contributed to water saving and protected the natural water ftowfrom the impact of waste heat. Results in industrial wastewater treatment, which Delta lnzenjering achieved in the past, are respective and significant. Reconstruction of Oily Wastewater Treatment Plant in the Oil Refinery Pancevo and Belgrade, with the installation of coalescent separators with its own development and production, has greatly contributed to the prevention of the Danube River pollution as an international waterways. With construction of two Waste Water Treatment plants in the Cement Factory Holcim in Popovac, clean and relatively small water ways of Toplik and Crnica were protected from pollution. In these plants Delta lnzenjering has successfully applied modern ultra-filtration methods of treatment in the industry. For the first time since its existence Fiat Automobiles Serbia, a Car Factory in Kragujevac, successfully purifies its wastewater at Katak Plant, which was designed by Delta lnzenjering on a "turnkey" base in three phases during the period 2009-2012. Preparation of project documentation for the Central City Facilities for Municipal Wastewater Treatment for the Cities of Subotica, Kraljevo, Brus, Blace is a confirmation of the active participation of Delta lnzenjering in communal activity and its contribution to natural watercourseprotection from pollution emanating from such large urban areas. Finally, I would note that Delta lnzenjering, as a responsible company, through its management system has defined an environment manage­ment system. Delta lnzenjering possesses ISO 14001 certification (in addition to ISO 9001 and ISO 18001), which as parts of the overall management system, includes through its organizational structure planning activities, responsibilities, quality of work processes implementation, development, introduction of new technologies and environmental protection policy. The experiences gained in Delta lnzenjering point to the conclusion that the management of environment protection in the immediate working area is inseparable from the environment protection and improvement. In the future Delta lnzenjering will responsibly and maximally strive to significantly contribute the healthy environment in order to improve the overall quality of life.

6

PRIPREMA TEHNOLOSKE VODE [HPV1

OBEZBEDENJE OEM I VODE I NEUTRALIZACIJA OTPADNIH VODA IZ HPV-A RAFINERIJE NAFTE PANCEVO

U sklopu realizacije novih postrojenja (MHC -DHT, HGU, SARU) na kojima se obavlja proizvodnja derivata evropskog kvaliteta, Delta lnzenjering je isprojektovao, izgradio i pustio u rad novi sistem za obezbedenje demineralizovane, tj. demi vode i neutralizaciju kiselo-baznih otpadnih voda, koje nastaju regeneracijom katjonske i anjonske linije za proizvodnju demi vode, sa izgradnjom novih rezervoara u kojima se odvija proces neutralizacije otpadnih voda. Demineralizovana voda se proizvodi u postrojenju za hemijsku pripremu postupkom jonske izmene i filtracijom na filterima sa mesanom ispunom. Osim rekonstrukcije i izgradnje nove linije cevovoda, projektom je predvideno da se skladisna zapremina za demi vodu prosiri za 500m3 kako bi se obezbedilo kontinualno i pouzdano snadbevanje novih potrosaca. Ovo prosirenje je ostvareno izgradnjom dva nova celicna rezervoara FB-9331 i FB-9332, pri cemu je svaki rezervoar zapremine 250m3

• Rezervo­ari su opremljeni svim potrebnim procesnim prikljuccima, kao i prikljuccima za predvidene instrumente.

Novi reakcioni prostor je predviden u vidu dva celicna rezervoara, svaki zapremine 800m3 (FB-9403 i FB-9404). U njemu se obavlja proces neutalizacije kiselo-baznih otpadnih voda, koje se generi­su regeneracijom jonskih smola u jonskim kolonama u HPV-u. Rezervoari su opremljeni svim potrebnim procesnim prikljuccima, kao i prikljuccima za predvidene instrumente. Sredstva za neutralizaciju otpadnih voda su sumporna kiselina (H

2S0

4) i natrijum hidroksid (NaOH).

Doziranje sumporne kiseline se obavlja preko novih dozirnih pumpi (radna i rezervna) iz postojeceg rezervoara FB-9251. Predvideno je da potisni cevovod dozirnih pumpi bude recirkula­cioni. On se racva u dva odvojena voda ito prema novim neutrali­zatorima. Na ovim vodovima se nalaze regulacioni ventili iza kojih se dovodni cevovod dalje racva prema svakom neutralizato­ru tako da se sumporna kiselina uvodi u najmanje cetiri tacke. Ovo je uradeno zbog pravilne raspodele dozirne kolicine sumpor­ne kiseline po celoj reakcionoj zapremini neutralizatora. Doziranje natrijum hidroksida se obavlja preko novih dozirnih pumpi (radna i rezervna) iz postojeceg rezervoara FB-9252. Potisni cevovod dozirnih pumpi je takode recirkulacioni i prema neutralizatorima se racva u dva odvojena voda na kojima su postavljeni regulacioni ventili. lza ventila cevovod se racva i u neutralizatore kako bi se natrijum hidroksid uvodio u najmanje cetiri tacke. Ovo je uradeno zbog pravilne raspodele dozirne kolicine natrijum hidroksida po celoj reakcionoj zapremini neutra­lizatora. Pracenje i upravljanje postrojenjem za demineralizaciju vode i neutralizaciju otpadnih voda se vrsi preko postojeceg DCS-a (Distributed Control System), tj. njegovim prosirenjem koje je obavljeno u saradnji sa lnvensys Foxboro. Ovo je postojeci nadzor­ni sistem u HPV-u koji se, izradom odgovarajuceg softvera i ugradnjom odgovarajuce opreme, koristiti za pracenje i nadzor rada novog postrojenja za demineralizaciju vode i neutralizaciju kiselo-baznih otpadnih voda koje se generisu iz HPV-a. Vrednost ovog ugovora iznosi 1,3 miliona eura.

CHEMICAL WATER TREATMENT lCWT1 OEM I WATER SUPPLY FOR NEUTRALIZATION

OF WASTEWATER FROM CWT IN OIL REFINERY PANCEVO

Within the implementation of new plants (MHC-DHT, HGU, SARU), which are used for manufacturing of European quality derivatives, Delta lnzenjering has designed, engineered and commissioned a new system for supply of demineralized water and neutralization of acid and alkali wastewater that originates from regeneration of cation and anion production lines of demi water with the construction of new reaction tanks for the Wastewater Neutralization Process. Demineralized water is produced within the Water Preparation Plant by I on Exchange Process and filtrations on mixed beg filters. Besides the reconstruction and installation of a new pipe line, project foresees the expansion of storage for demi water by 500m3 to ensure continuous and reliable supply of the new plants. This expansion is achieved by building of two new steel tanks FB-9331 and FB-9332. Each tank has a capacity of 250m3•

The tanks are equipped with all necessary process connections as well as connections for belonging instruments. The new reaction tanks for neutralization of wastewater are made of steel- each has a capacity of 800 m3 (FB-9403 and FB-9404). Inside those is carried out the neutralization process of acid and alkali wastewater generated by regeneration of ion resins in ion exchangers in CWT. The tanks are equipped with all necessary process connections as well as connections for belonging instruments. For Wastewater Neutralization Process are used sulfuric acid (H

2S0

4) and sodium hydroxide (NaOH).

The dosage of sulfuric acid is carried out through new dosing pumps (active and spare) from the existing tank FB-9251.

It is planned for the discharge pipe line of dosing pumps to be recirculating. It splits into two separate lines toward new neutral­izers. In these lines are valves beyond which the supply pipeline branches to each neutralizer so that sulfuric acid is introduced into at least four points. This was done because the proper division of the dosing amount of sulfuric acid throughout the reaction volume neutralizer. The dosage of sodium hydroxide is carried out through new dosing pumps (active and spare) from the existing tank FB-9252. The discharge pipeline of dosing pumps is also recirculating and also toward neutralizers it splits into two separate lines on which are the control valves. From the valves pipeline splits into neutralizers in order to sodium hydroxide be introduced in at least four points. This was done due to the proper division of sodium hydroxide dosing volume for neutral­ization throughout the all reaction volume of the neutralizer. Monitoring and management of Plant for Water Demineraliza­tion and Wastewater Neutralization is carried over through the existing DCS (Distributed Control System), ie. its expansion, which took place in conjunction with lnvensys Foxboro. This is existing monitoring system in CWT, which is used to monitor and control operation for Water Demineralization Plant and Acid and Alkali Wastewater Neutralization Plant, which is generated from CWT by developing the appropriate software and appropriate equipment. The value of the Contract amounts is € 1.3 million.

_______________________________________________________________________ ]

8

REKONSTRUKCIJA POSTROJENJA ZA HEMIJSKU PRIPREMU VODE U RAFINERIJI ULJA MOD RICA

Korozija i talozenje tesko rastvornih soli (karbonata, silikata, gipsa) osnovni su problemi koji se javljaju u eksploataciji parnih kotlova. Da bi se omogucio njihov nesmetan rad, neophodno je obezbediti vodu visokog stepena cistoce.

Hemijska priprema vade (HPV) za parne kotlove visokog pritiska i dopunu rashladnog sistema u Rafineriji ulja Modrica realizuje se u postrojenju koje je izgradeno 1980. godine i ne ispunjava savremene ekonomsko-ekoloske zahteve. Delta lnzenjering obradio je predlog unapredenja u okviru glavnog tehnolosko-masinskog projekta rekonstrukcije HPV-a. Postojeci proces demineralizacije vade odvija se na principu jonske izmene i realizovan je na dve proizvodne linije, kapaciteta po 50m3/h. Kao osnovni uzroci smanjene efikasnosti procesa identifikovani su istosmerna regeneracija i mesanje slabo bazne i jako bazne jonske mase unutar anjonskih kalona. Kada se proces regeneracije odvija u smeru koji je isti kao i tok vade u radnom rezimu (ad vrha prema dnu), joni koji su zadrzani u gornjem sloju jonoizmenjivacke mase moraju proci kroz celu kolonu. Sloj smole na dnu kolone poslednji biva osloboden nepozeljnih jona, i potrebno je propustati veliku kolicinu regene­racionog sredstva da bi se specila kontaminacija tretirane vade pri ponovnom prelasku u radni rezim. Ukoliko se regeneracija odvija u smeru od dna prema vrhu, sloj smole na dnu kolone je u kontaktu sa najcistijom vodom i svezim regeneracionim sredstvom. OCuvanje integriteta tog polirajuceg sloja doprinosi smanjenoj potrosnji sredstva za regeneraciju i omogucava efikasniji povratak u radni rezim. Radi ostvarivanja maksimalnih performansi suprotnostrujne regeneracije, predlozeno je tehnicko resenje koje obuhvata rekonstrukciju cevovoda sa pripadajucim ventilima, rekonstuk­ciju katjonskih jonoizmenjivackih kalona u pogledu smanjenja slobodne zapremine (trenutno iznosi cca 50%) i ugradnju fizicke barijere - place sa dvostrano postavljenim difuzorima (sapnicama) za razdvajanje dva tipa jonskih masa u anjonskim izmenjivackim kolonama. Ocekivani rezultat rekonstrukcije je smanjenje specificne potrosnje sredstava za regeneraciju po metru kubnom proizvedene vade, povecanje kolicine tretirane vade izmedu dve uzastopne regeneracije i smanjenje kolicine otpadnih voda od rastresanja, regeneracije i ispiranja.

Exhaustion Regeneration

+ + + + +

~~~ ~ ~ ~~ Clean zone- almost no leakage + + + + +

Exhaustion Regeneration

Clean zone- almost no leakage + + + + +

~~ i ~~ + + + + + c=J Regenerated resin - Exhausted resin

RECONSTRUCTION OF CHEMICAL WATER

TREATMENT PLANT IN OIL REFINERY MODRICA

Corrosion and sedimentation of non soluble salts (carbonate, silicate, plaster) are the main problem that can occur during operation of steam boilers. In order to enable their smooth operation it is necessary to ensure high quality of water.

Chemical water treatment (CWT) for high-pressure steam boilers and supplementing the cooling system in Oil Refinery Modrica is performed in a facility that was built in 1980 and does not fulfill modern economic and ecological requirements. Delta lnzenjering elaborated an improvement proposal within the Main Process and Mechanical Design for the reconstruction of CWT plant. The current Water Demineralization Process is carried out on the principle of ion exchange and is implemented on two production lines with capacity of 50m3/h each. The main causes of reduced process efficiency are: regeneration in parallel flow and mixing of weak base and strong base ion mass within the anion columns. When the Regeneration Process takes place in the parallel flow (same flow direction like in operating mode- from top to bottom), ions that are retained to the upper layer of ion exchange mass must pass through the entire column. Resin layer on the bottom of column is last freed of undesirable ions, and it is necessary to use large amount of regeneration agents to prevent contamination of treated water in the return to operating mode. If the regeneration takes place in counter flow direction -from the bottom to the top, resin layer on the bottom of a column is in contact with the purest water and fresh regenerative agent. Preserving the integrity ofthis polishing layer contributes to reduced consumption of regenera­tion agents and allows more efficient switch to operating mode. In order to achieve maximum performances from counter flow regeneration, technical solution is proposed that involves the reconstruction of pipeline with associated valves, reconstruction of cationic ion exchange columns for the reduction of free volume (currently is about 50%) and installation of physical barrier - a panel with double mounted diffusers for separation of two types of ion masses in the anion exchange columns. The expected result of the reconstruction is reducing of the specific consumption of regeneration agents per cubic meter of produced water, increasing of treated water amount between two successive regenerations and reducing wastewater amount from backwash, regeneration and rinsing.

POSTROJENJE ZA PRIPREMU DEMINERALIZOVANE VODE GORENJE. VALJEVO

Za potrebe Fabrike rashladne tehnike Gorenje izvedeno je postrojenje za pripremu demineralizovane (demi) vode za liniju predobrade u okviru Lakirnice. Postrojenje kao ulaz moze da koristi i gradsku i bunarsku vodu. Kapacitet postrojenja je 3m3 /h ulazne vode.

Proces pripreme demi vode pocinje filtriranjem na mehanickom samoispirnom filteru finoce 90~m. Samoispirni filter je progra­mabilan i moze se podesiti vreme izmedu dva ispiranja. Nakon grubog filtera, voda ide na omeksavanje. Omeksavanje vode vrsi se na jonoizmenjivackim kolonama koje rade u dupleks sistemu. Dok se jedna kalona regenerise, druga je u radu, cime se obezbeduje kontinualno snabdevanje vodom. Regeneracija jonoizmenjivackih kalona vrsi se automatski pomocu rastvora natrijum-hlorida (NaCI). Omeksana voda se dodatno filtrira na filter sa aktivnim ugljem. Osnovna uloga ovog filtera je uklanjanje hlora, prevashodno iz gradske vode. Filter sa aktivnim ugljem se povratno ispira periodicno. Period izmedu dva povratna ispiranja moze se podesavati. Tokom povratnog ispiranja nema prolaska vode dalje u sistem. Voda pripremljena prethodno opisanim postupcima dolazi na uredaj za reverznu osmozu. Na ulazu u RO uredaj nalazi se mikrofilter finoce 5 ~m u slucaju da neka cestica jonoizmenjivacke

smole iii aktivnog uglja ude u sistem. RO uredaj se sastoji od pet modula i obezbeduje oko 2Am3/h permeata izlazne provodnosti ispod 50 ~S/cm2• Efikasnost RO uredaja, odnosno odnos izmedu kolicine permeata i ulazne (sirove) vode se krece izmedu 0)5 i 0,83. Ukoliko opadne ispod 0) bilo bi pozeljno da se uradi CIP (Cleaning in Place) ciscenje. U toku rada RO uredaja dozira se antiskalant, koji sprecava formiranje naslaga na membranama. Demineralizovana voda se skladisti u rezervoaru za permeat zapremine V= 1Om3

•

lz rezervoara za permeat deo vode se uzima za drugi stepen reverzne osmoze, kapaciteta 401/h, koja treba da obezbedi vodu provodnosti ispod 10 ~S/cm2• Permeat visokog kvaliteta se skladisti u rezervoaru za perm eat zapremine V=SOI. Demi voda se do potrosaca transportuje pomocu dve pumpe koje rade u rezimu radna/rezervna, ali mogu da rade i obe para Ieino. Potrosnja vode prema predobradi moze se pratiti preko meraca protoka ugradenog na potisni cevovod pumpi.

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DEMINERALIZED WATER TREATMENT PLANT GORENJE. VALJEVO

For the purpose of the Factory for Refrigerating Household Appliances Gorenje has been constructed a Demineralized Water Treatment Plant for a preprocessing line within Paint Shop. DWT plant inlet water may be from Municipal Waterworks or from local wells. The plant capacity is 3m3/h of inlet water.

A Demi Water Treatment Process begins with filtering at mechanical self-rinsing filter with fineness of 90 ~m. The self-rinsing filter is programmable and the time between two washing can be adjusted. After the coarse filter, water goes to the softening. Water softening is performed on ion exchange columns that operating in duplex system, ie. while one column regenerates, the other is in operation. This ensures continuous supply of water. Regeneration of ion exchange columns is performed automatically using sodium chloride (NaCI). Softened water is then filtered through an active carbon filter. The main role of this filter is to remove chlorine, primarily from the waterworks water. The filter with active carbon is back fiushed periodically. The period between two back fiushes can be adjusted. During the back fiush water doesn't pass in the system. Water prepared with previously described procedures comes to the unit for reverse osmosis. On the entrance to RO unit is a micro filter with fineness of 5 ~m in the case that some particle of ion exchange resin or active carbon enter the system. RO unit consists of five modules and provides about 2.4 m3/h of permeate and output conductivity under 50 ~S/cm2 • The efficiency of RO unit or the ratio between the amounts of permeates and input (raw) water varies between 0.75 and 0.83. If it drops below 0.7, it would be desirable to do CIP (Cleaning in Place). During operation of RO unit antiscalant is dosed to prevent the formation of scales on the membranes. Demineralized water is stored in a tank for permeate with volume of 1Om3

•

From tank with permeate the water is taken for the second stage of reverse osmosis with capacity of 401/h, which should provide water with conductivity below 10 ~S/cm2• High quality permeate is stored in a tank for permeate with volume of 501. Demi water is transported to the consumers by two pumps that run in a working I reserve mode, but can both operate in parallel. Water consumption toward preprocessing can be traced through the fiow meter installed on the pumps discharge pipeline.

FABRIKA ZA OBRADU ALUMINIJUMSKIH PRO FILA ALUMIL COATING SRB U NOVOJ PAZOVI

Fabrika za obradu aluminijumskih profila Alumil Coating Srb u Novoj Pazovi ima pogon za njihovu galvansku zastitu. To je linija za hromatizaciju al-profila, gde je hromna presvlaka dobra podloga za finalnu plastifikaciju.

Postrojenje za tretman otpadnih voda ove fabrike, koje je realizo­vano tokom 2003/4. godine i od tada je u radu, preciscava tehnoloske otpadne vade iz pogona galvanizacije. Kapacitet postrojenja je 4 m3/h hromatnih i 13 m3/h ispirnih otpadnih voda. Kvalitet otpadnih voda je takav da su pretezno zagadene rastvorenim hemijskim supstancama, suspendovanim materi­jama, teskim metalima i da su kiselo-baznog karaktera, neugodnog mirisa i neprijatnog izgleda i boje.

Na postrojenju su predvideni sledeCi tehnoloski procesi precisca­vanja otpadnih voda:

~ obrada hromatnih otpadnih voda (otpadnih eulataL ~ obrada zbirnih otpadnih voda sa jedinstvenom

neutralizacijom svih otpadnih tokova i konacnom obradom zbirnih otpadnih voda,

~ preciscavanje, dejonizacija i recirkulacija ispirnih voda.

Svi su integrisani u jedinstven tehnoloski proces. U daljem definisanju navedenih tehnoloskih procesa na postroje­nju dolazi se do osnovnih postupaka abrade kojima se preciscavaju tehnoloske otpadne vade. Kombinovani fizicko-hemijski postupci:

~ proces ftokulacije, ~ proces aeracije, ~ proces filtriranja i apsorpcije na aktivnom uglju.

Fizicki tretman otpadnih voda sastoji se iz sledeCih usvojenih postupaka:

~ proces dekantacije, istalozavanja i sedimentacije u statickom talozniku,

~ proces filtriranja na pescanim filterima.

Obrada mulja takode se sastoji iz kombinacije nekoliko postupaka: ~ ftokulacija mulja, ~ dehidratacija mulja procesom, ~ filtriranje pod pritiskom na komornoj filter presi, ~ konacno odlaganje, ~ dispozicija muljnih pogaca posle sprovedenih postupaka

karakterizacije i kategorizacije te vrste cvrstog otpada na komornoj filter presi,

~ konacno odlaganje i dispozicija muljnih pogaca posle sprovedenih postupaka karakterizacije i kategorizacije te vrste cvrstog otpada.

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ALUMIL COATING SRB FACTORY FOR MANUFACTURE

OF ALUMINIUM PROFILES IN NOVA PAZOVA

Alumil Coating Srb- Factory for Manufacture of Aluminium Profiles in Nova Pazova has a plant for their protection by galvanization.lt is a chrome-plating line for Al-profiles, where chrome coating is a good foundation for the final plastic coating.

The Watewater Treatment Plant of this factory treats technological wastewater from the Galavization Plant. It was completed during the course of 2003/04 and it has been in operation since that time. The capacity of the plant is 4 m3/h of chrome-containing wastewater and 13 m3/h of rinsing wastewater. The quality of wastewater is such that it is of acid-base character, unpleasant smell, appearance and colour.

It has been planned that the below stated technological processes of wastewater treatment will be applied in the plant:

~ Technological treatment of chrome-containing waters (waste eulates),

~ Technological treatment of collective wastewater with uniformed neutralization of all waste flows and final treatment of collective wastewater,

~ Technological purification, deionization and recirculation of rinsing water.

They are all integrated into one technological process. Further definitions of the above mentioned technological processes at the plant provide the essential treatment processes used to treat technological wastewater. Combined physical-chemical procedures:

~ Flocculation process, ~ Aeration process, ~ Active coal filtration and absorption process.

Physical wastewater treatment consists of the following adopted procedures:

~ Decanting, settling and sedimentation process in the static settling unit

~ Filtration process in sand filters.

Mud treatment also consists of combination of several procedures, such as: ~ Mud flocculation, ~ Mud de-hydration by pressure filtration

in the chamber filter press, ~ Final removal and disposal of mud cakes after the properties

and categories of this type of solid waste had been determined.

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FABRIKA SLADOLEDA DELYUG (DANAS NESTLE] U STAROJ PAZOVI

Postrojenje za preciscavanje otpadnih voda fabrike sladoleda izgradeno je tokom 2001/02. godine i od tada je u eksploataciji.

Na postrojenju se preciscavaju tehnoloske i sanitarno-fekalne otpadne vade. Kapacitet postrojenja je 350m3 preciscenih otpad­nih voda dnevno.

Predvidene su sledece faze tehnoloskog procesa preciscavanja otpadnih voda:

~ egalizacija, tj. usrednjavanje otpadnih voda po protoku i kvalitetu odvija se unosenjem vazduha u vodu u egalizacionom bazenu,

~ koagulacija uz doziranje polialuminijum-hlorida, ~ ftotacija pomocu rastvorenog vazduha, ~ istalozavanje otpadnih voda u poduznom talozniku

sa translatornim zgrtacem mulja,

REKONSTRUKCIJA POSTROJENJA ZA PRECISCAVANJE OTPADNIH VODA

~ dvostepena bioloska obrada koja se odvija u bioaeracionim bazenima uz recirkulaciju aktivnog mulja, koji se istalozava u statickim taloznicima sa radijalnim zgrtacima mulja.

Vazduh za bioaeraciju se obezbeduje pomocu kompresora-du­valjki, dok se neposredan unos vazduha u vodu obavlja pomocu pecurkastih difuzora.

Zavrsna obrada izbistrenih otpadnih voda odvija se na sporom filteru sa ispunom od kvarcnog peska. Recipijent preciscenih otpadnih voda jeste obliznji melioracioni kanal, cije vade nisu menjale svoj kvalitet nakon prihvatanja eftuenta sa postrojenja.

U FABRIC I AUTOMOBILA FIAT AUTOMOBILI SRBIJA

U rekordnom roku od pet i po meseci, Delta lnzenjering je zavrsio rekonstrukciju postrojenja za preciscavanje otpadnih voda iz nekoliko pogona fabrike, uz uvodenje savremene opreme u funkciji preciscavanja.

Postojece postrojenje za preciscavanje otpadnih voda je izgrade­no pocetkom devedesetih godina proslog veka i nikad nije pusteno urad, s obzirom nato da nisu izgradene pumpne stan ice i potisni cevovodi kojima bi se otpadne vade transportovale do postrojenja. Pri postavljanju novog koncepta preciscavanja otpadnih voda, vodilo se racuna o maksimalnom iskoriscenju postojece tehnolo­loske opreme, odnosno postojecih rezervoarskih zapremina. Takode, izvrsena je sanacija objekta Katak, u kame je postrojenje smesteno, kao i sanacija sekundarnog cevnog mosta. U odnosu na prvobitnu koncepciju preciscavanja, postavljenu pre vise od 20 godina, doslo je i do odredenih izmena u tehnoloskom pogledu, taka da je proces preciscavanja zasnovan na usrednjava­nju kvaliteta sa medusobnom korekcijom pH broja.

Ovako koncipiranim resenjem se postize ujednacavanje kvaliteta izlaznog eftuenta, koji ce zadovoljiti MDK (maksimalno dozvolje­ne koncentracije) date Pravilnikom o ispustanju otpadnih voda u gradsku kanalizaciju Kragujevca.

Pored linije vade, novoprojektovano postrojenje obuhvata i liniju mulja, odnosno hidro-masinsku opremu koja je u funkciji dehidratacije natalozenog mulja. Ugradena oprema na postrojenju za preciscavanje otpadnih voda je najsavremenija, svetskih renomiranih proizvodaca opreme, dok su specificni delovi opreme i konstrukcija, odnosno uredaji poput paketnog taloznika i koalescentnog separatora, proizvod Delta lnzenjeringa.

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Technological and sanitary wastewaters are treated at this plant. The capacity of the plant amounts to 350m3 of treated wastewa­ter daily.

It has been planned that the below mentioned phases of waste­water technological treatment shall be performed at the plant

~ Equalization, ie. bringing wastewater to medium properti­es in respect of flow and quality by introducing a it into water in the equalization pool,

~ Coagulation by feeding in poly-aluminium-chloride, ~ Floatation by means of dissolved air, ~ Settling of wastewater in Longitudinal Settling Unit by

means of translator mud shovel,

DELYUG ICE-CREAM FACTORY IN STARA PAZOVA

The Wastewater Treatmnent Plant for the Ice-Cream Factory was constructed during the period 2001/02 and it has been in operation since.

~ Double-stage biological treatment in bio-aeration pools including recirculation of active mud, which has settled in the Static Settling Units by means of radial mud shovel.

Air required for bio-aeration is provided by means of compressors blowers, while direct introduction of air into water is carried out by means of mushroom-like Diffusing Units, Final treatment of settled wastewater is carried out by means of slow filter having quartz sand filling. The nearby melioration canal receives the treated wastewater, which water did not change the quality after receiving effluent from the plant.

RECONSTRUCTION OF WASTEWATER TREATMENT PLANT AT CAR FACTORY FIAT AUTOMOBILES SERBIA

The existing Wastewater Treatment Plant was built in early 1990s but never put into operation, because the pump stations and pressure pipelines were not constructed to transport wastewater to the plant. In setting up a new concept of watewater treatment was taken care that the existing technological equipment be utilized to maximum, ie. the existing tank capacities. In addition, Katak Facility, in which the plant is located, has been completly reconstructed, as well as the secondary pipeline bridge. Compared to the original conception of treatment set up some 20 years ago, there are some changes in technological terms, so

In a record time of five and a half months Delta lnzenjering completed reconstruction of the Wastewater Treatment Plant for process water coming from several factory plants, with introduction of modern equipment in a treatment function.

that the treatment process is based on the averaging of output efluent quality, which will satisfy MPC (Maximum Permissible Concentration) as stipulated by the Regulations on Wastewater Discharge into the municipal sewage of Kargujevac. In addition to the water Line, a new designed plant covers also the mud Line, in other words, hydro-mechanical equipment in the function of dehydration of the Mud Settler Unit. Equipment installed in the Wastewater Treatment Plant features the latest design, supplied by renowned world producers, while the specific parts of equipment and structure such as Pack Unit and Coalescent Separator are products of Delta lnzenjering.

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POSTROJENJA ZA PRECISCAVANJE OTPADNIH VODA IZ POGONA LAKIRNICE I POGONA FARBANJA BRANIKA-KAlAK II, FAZA REKONSTRUKCIJE

Bilo je neophodno da postojece postrojenje za preciscavanje otpadnih voda bude dodatno rekonstruisano u pogledu kolicine i kvaliteta tehnoloskih otpadnih voda, odnosno prilagoefeno novim zahtevima buduce lakirnice, kao i buduceg pogona za farbanje branika.

II faza rekanstrukcije pastrojenja (PPOV Katak II faza) je amagucila preciscavanje dva advajena taka tehnalaske atpadne vade, kaa i abradu mulja. Kancept preciscavanja tehnalaskih atpadnih vada za II fazu je zasnavan na razdvajanju takava atpadnih vada. Predvidena je pasebna linija za tretman kantinualnih i pasebna linija za tretman diskantinualnih atpadnih vada. Linija za abradu mulja je zajednicka za abe linije vade, kaa i hemijska stanica adakle se abavlja daziranje patrebnih hemikalija. Za prihvat kantinualnih atpadnih vada je iskariscen pastajeci prihvatni rezervaarski prostar, pazicianiran u akviru abjekta Katak, kaji je vee rekanstruisan u taku I faze. Patpuna navu fazu u preciscavanju diskantinualnih, adnasna periadicnih atpadnih vada, predstavlja bialaska abrada, a prihvatni rezervaar i bialaski uredaj su izgradjeni sa druge strane pruge u adnasu na pastajeci abjekat Katak. lmajuci u vidu pavecanje kapaciteta pastrojenja, rezervaari i aprema za abradu mulja su navi i smesteni su u akviru pastaje­ceg abjekta Katak.

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RECONSTRUCTION OF WASTEWATER TREATMENT FROM COATING AND BUMPER FINISHING PLANT-

KAlAK II

It was necessary thet the existing Wastewater Tretment Plant is further reconstructed in terms of quantity and quality of process wastewater and adjusted to the new demands of future Coating Plant, as well as future Bumper Finishing Plant.

The second phase of reconstruction (WWTP Katak Phase II) should enable treatment of two separate flows of industrial wastewater and a slugde treatment. The concept of industrial wastewater treatment for Phase II is based on the separation of wastewater flows.

The concept anticipates a separate line for tretament of continous and also a separet line for treatment of discontinous wastewater. The sludge line will be common for both water lines, same as the Chemical Station used for dozing of chemicals.

For acceptance of continous wastewater will be used the existing recipient tank area, located within Katak Facility, which has already been reconstructed during Phase I.

A completely new phase in treatment of discontinous, ie. periodi­cal wastewater, is the biological treatment whereby the recipient tank and biological device will be built on the other side of the railway in relation to the existing Katak Facility.

Considering the increased plant capacity, sludge treatment tanks and equipment will be new and located within the existing Katak Facility.

PROJEKAT REKONSTRUKCIJE IIZGRADNJE POSTROJENJA ZA TRETMAN TEHNOLOSKIH OTPADNIH VODA Ill FAZA

Tokom 2012. godine u fabrici automobila u Kragujevcu (FAS) okoncana je izgradnja Ill faze postrojenja za tretman otpadnih voda.

Na postojece rekonstruisano postrojenje za premcavanje tehnoloskih otpadnih voda iz pogona lakirnice i pogona farbanja branika (Katak II, radovi izvrseni 2011-12), izvedeno je postro­jenje za preciscavanje tehnoloskih otpadnih voda poteklih od pranja automobila, rashladnih kula, pogona presa i pogona montaze.

Predvideni prosecni casovni protok je 42 m3/h, dok maksimalni casovni kapacitet moze biti 60m3/h.

Koncept preciscavanja tehnoloskih otpadnih voda je zasnovan na fizicko-hemijskom tretmanu tehnoloske otpadne vode, uz postupak uklanjanja ulja i masnoca. Kompletan tehnoloski postupak vrsi se postupno, u procesu koji obuhvata:

~ Egalizaciju tehnoloskih otpadnih voda; ~ Hemijski tretman (koagulacija, bazifikacija, ftokulacija); ~ Bistrenje i evakuacija mulja; ~ Prihvatanje tretirane vode u cilju distribucije na dalju

preradu, odnosno recirkulaciju.

lzgradnja postrojenja obuhvatila je novu hemijsku stanicu (skladistenje, priprema i doziranje rastvora sumporne kiseline, ferihlorida, natrijum hidroksida, nutrijenta, benton ita i anjonskog polielektrolita), betonski objekat (spoljna jedinica gabaritnih dimenzija 16 x 9 x 5) m), sacinjen od dva procesna rezervoara za prihvat i egalizaciju otpadne vode i cevni most (duzine 25 m, visine 4,8 m), odnosno montazu nove procesne opreme unutar postojeceg objekta. U tom cilju je izvrsena gradevinska rekonstrukcija objekta Katak od gradevinske ose 8x- 11x, sto je

podrazumevalo rusenje dela meduspratne konstrukcije, razbija­nje postojece ploce i izlivanje nove podne ploce, kao i rekonstruk­ciju elektro, vodovodnih, hidrantskih i instalacija za toplovodno grejanje.

Proverom rada postrojenja, ustanovljena je izuzetna efikasnost primenjenog postupka preciscavanja, s obzirom nato da je stepen redukcije nezeljenih parametara u sirovoj vodi koji odstupaju od maksimalno dozvoljenih koncentracija (mineralna ulja, nikl i cink) cak 98%.

Upravljacki sistem je baziran na programibilnim logickim kontrolerima (PLC -ovima). lzvedena je vizuelizacija rada postrojenja, akvizicija podataka, generisanje izvestaja bitnih za analize rada, kao i pouzdano komandovanje svim delovima postrojenja. Za centralnu vizuelizaciju, akviziciju i arhiviranje podataka predviden je SCADA sistem, postavljen u komandnoj sobi. Na SCADA sistemu je graficki prikazan kompletan tehno­loski proces i radno stanje svih segmenata postrojenja.

lntegrisano postrojenje (Katak II i Katak Ill) tretira tehnolosku otpadnu vodu iz cele fabrike do nivoa kvaliteta eftuenta potreb­nog za dalji tretman na buducem postrojenju za recirkulaciju (Katak IV).

lzgradnja ovog sistema predstavljala je izazov iz aspekta tehno­logije i gradjevine. Uspesno su prevazideni svi problemi, losi vremenski uslovi (pocetak gradevinskih radova je bio u toku zimeL visoki nivoi podzemnih voda i sagradjeno je jed no od najsavremenijih postrojenja u Srbiji i ovom delu Evrope.

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DESIGN FOR RECONSTRUCTION AND CONSTRUCTION OF INDUSTRIAL WASTEWATER TREATMENT PLANT,

During 2012 was completed construction of Wastewater Treatment Plant- Phase Ill.

On the existing reconstructed plant for treatment of industrial wastewater from the Paint Shop and the Bumper Paint Shop (Katak II, works executed 2011-12), was constructed a plant for treatment of industrial wastewater stemming from several production plants: car wash, cooling towers, press shop and mounting.

Estimated average hourly flow rate is 42 m3/h, while the maximum hourly capacity can be 60m3/h.

The concept of industrial wastewater treatment is based on the physical-chemical treatment of industrial wastewater, with the removal of oil and grease procedure. The complete technological process was gradually carried out in a process that includes:

~ Equalization of industrial wastewater; ~ Chemical treatment (coagulation, basification, fiocculation); ~ Clarification and sludge evacuation; ~ Acceptance of treated water to the distribution for further

processing or for recirculation.

Construction of the new plant included a new chemical station (storage, preparation and dosing of sulfuric acid solution, ferichloride, sodium hydroxide, nutrient, bentonite and anionic polyelectrolyte), concrete building (outdoor unit with dimensions of 16 x 9 x 5.2 m) is composed of two process tanks for receiving and equalization of wastewater and pipe bridge (length 25 m, height 4.8 m), ie. an installation of a new process equipment within the existing building. For this purpose was carried out construction of the Katak Facility from construction axis 8x -11x, which included demolition of a part of structure between fioors, breaking of the existing plate and pouring of a new fioor plate, as well as the reconstruction of electrical, plumbing, hydrant and installations for central heating.

Checking of the plant operation was established remarkable efficiency of the applied treatment, given that the degree of reduction of unwanted parameters in raw water, which deviate from the maximum permissible concentration (mineral oil, nickel and zinc) as much as 98%.

The control system is based on programmable logic controllers (PLCs).lt was made visualization of plant operation, data acquisi-

PHASE Ill

tion, generation of reports relevant to the work analyses and reliable control to all parts of the plant. For central visualization, data acquisition and data archiving was designed a SCADA system, installed in the control room. On the SCADA system is graphically displayed complete technological process and the working condition of all plant segments.

Integrated plant (Katak II and Katak Ill) treats industrial wastewa­ter from the entire plant to the level of effluent quality required for further treatment in the future plant for recirculation (Katak IV).

The construction of this system has been a challenge in terms oftechnology and construction. All problems have been success­fully overcome, bad weather conditions (start of construction works was in the winter), high groundwater levels. One of the most modern plants in Serbia and this part of Europe has been built.

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HOLCIM PRECISCAVANJE OTPADNIH VODA

Uklopivsi se u ovu globalnu koncepciju tretmana voda, Delta lnzenjering je izradio projektnu dokumentaciju za objekte vodosnabdevanja i za preciscavanje upotrebljenih voda, a nakon toga je zapoceta realizacija. Prioritet pri realizaciji imali su objekti preciscavanja zagadenih voda, pa je do sada realizovano:

~ Postrojenje za preciscavanje otpadnih voda sa del a fabrike Polysius, sa ispustom preciscenog efiuenta u potok Toplik,

~ Postrojenje za preciscavanje otpadnih voda sa del a fabrike FLS, sa ispustom preciscenog efluenta u reku Crnicu.

Prvo postrojenje je u eksploataciji dve godine, dok je drugo pusteno u rad u novembru 2008. godine. Kapacitet postrojenja Toplik je 4 1/s, dok je kapacitet postrojenja Crnica 20 1/s. Na oba postrojenja preciscavaju se zbirne otpadne vode (zagadene atmosferske i sanitarno-fekalne otpadne vode). Nakon odvojenih predtretmana, zbirne otpadne vode se precisca­vaju na postrojenjima na kojima su primenjeni kombinovani,

U Fabrici cementa Holcim u Novom Popovcu jedinstveno je resavano vodosnabdevanje i preciscavanje otpadnih voda u okviru programa zastite zivotne sredine koji fabrika sprovodi od vremena zavrsene vlasnicke transformacije.

klasicni i savremeni nacini preciscavanja. Pored predfiltracije i fizicko-hemijskih metoda preciscavanja (koagulacije, fiokulacije i talozenja), primenjeni sui savremeni metodi vakuumske ultrafil­tracije.

Rezultat ovako integrisanog tehnoloskog procesa preciscavanja otpadnih voda jeste visok kvalitet izlaznih voda, radi zastite potoka Toplik i reke Crnice.

Fizicko-hemijske i bakterioloske analize preciscenih otpadnih voda i sprovedene analize njihovog uticaja na recipijente, koje je radio lnstitut za nuklearne nauke Vinca, dokazale su visoku efikasnost postrojenja, a time i ispravnost primenjenih tehnologi­ja na postrojenjima koje su u direktnoj funkciji zastite ekosistema vodotokova, pa stoga i zivotne sredine u sirem smislu. Pored ovih postrojenja realizovan je i rashladni sistem fabrike sa pumpnom stanicom za recirkulaciju rashladne vode, rashladnim kulama i distributivnim cevovodom.

20 -----------------------------------------------------------------------

HOLCIM WASTEWATER TREATMENT

A Cement Factory in Popovac has the uniform solution of water supply and water treatment system within the Environment Protection Program, which the factory has been implementing since the time of the completion of the property transformation.

Having respected this global concept of water treatment, Delta lnzenjering has prepared the project documentation for both Water Supply Units and for the Utilized Water Treatment Units and then started the construction of these units. The priority has been given to the Polluted Water Treatment Units and after that was started the implementation:

~ The plant for the treatment of waste water coming from the part of Polysius Factory, with the discharge of the resulting effluent into the Toplik Stream,

~ The plant for the treatment of waste water coming from the part of FLS Factory, with the discharge of the resulting effluent into the Crnica River.

The first plant has been in operation for two years, while the second plant was constructed in the course of 2008, ie. it was put into operation in November 2008. The capacity of the Toplik Plant is 41h while the capacity of the Crnica Plant is 20 1/s. Collective wastewater is treated at both plants (polluted atmospheric and sanitary­discharge water). After the separate pre-treatment, collective wastewater is treated at the plants combining the classic and the modern treatment methods. In addition to pre-filtration and physical-chemical treatment methods (coagulation, fiocculation and settlement), the modern methods of vacuum ultra-filtration are also applied. The result of such an integrated technological process of wastewater treatment is the high quality of outlet water, all this with the aim to protect the Toplik Stream and the Crnica River. Physical-chemical and bacteriological analyses of the treated waste­water and the performed analyses of their effect on the recipients, which had been made by the Vinca Nuclear Scientific Institute, have proved the high efficiency of the plant, and thus the adequacy of the applied technologies in the plants in the direct function of the protection of the ecological system of water fiows and in the function of the protection of the environment in the wider sense as well. In addition to those plants, the cooling system of the factory has also been implemented, with a Pumping Station for re-circulation of cooling water, Cooling Towers and distribution pipeline.

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..-

PRIPREMA PIJACE VOOE POSTROJENJE ZA PRIPREMU VODE ZA PICE I VODOSNABDEVANJE, RUDNIK I TERMOELEKTRANA STANARI

Rudnik i termoelektrana Stanari, deo EFT grupe, 18. maja ove godine zapoceli su izgradnju potpuno nove termoelektrane, instalisane snage 300 MW, u Stanarima- Republika Srpska. Angazovanje Delta lnzenjeringa ogledalo se u izradi glavnog projekta za vodosnabdevenje i pripremu pijace vode za gradiliste termoelektrane, ukupnog kapaciteta od 80 m3/h, i postrojenja za pripremu pijace vode za upravnu zgradu i rudnik, kapaciteta 2 1/s, po sistemu ,Jijuc u ruke". Radi primene bunarske vode kao napojne, tretman vode se ogledao u redukciji gvozda, mangana i amonijaka ciji je sadrzaj u vodi visestruko veci od MDK vrednosti: za gvozde 3,27 mg/1 (MDK=0,3 mg/1) i mangan 0,3 mg/1 (MDK=O,OS mg/1).

Tehnicke karakteristike:

0,00-;- 3,27 0,00 -;- 0,30

0,01 -;- 0,195 6,23 -;- 7,42

VODOSNABDEVANJEGRADATUZLE PIJACOM VODOM

Pumpna stanica sirove vode u krugu TETuzla sa automatskim ..,.

Tehnoloski postupci tretmana vode su: ~ Prethodna oksidacija sa rastvorom natrijum hipohlorita (NaOCI), ~ Filtracija kroz posebno pripremljenu ispunu od zelenog

peska (green sand) sa kontinualnom regeneracijom, ~ Zavrsna dezinfekcija rastvorom natrijum hipohlorita (NaOCI), ~ Zavrsno regulisanje pH vrednosti vode.

Otpadna voda od ispiranja filterskih kalona se odvodi drenaznim kanalom u saht, gde se obavlja talozenje, odnosno razdvajanje bistre faze i mulja, koji se evakuise povremenim ispumpavanjem muljnim pumpama.

Vrednost ugovora iznosi 650.000 eura.

~ 0,1 6,8-;- 8,5

samoispirnim filterima, Federacija BiH ,.. ~=================="'--..::;;

UF postrojenje (vakuumska ultrafiltracija) sa duvaljkama za ..,. povratno pranje membrana vazduhom i UF moduli uronjeni u vodu ,.. ~!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!1!!!!!!~!!!!!!!!~;J.J;;;,;;;,;~~~;.....:_:~~~.!

22 ----------------------------------------------------------------------

ORIN KING WATER TREATMENT

DRINKING WATER TREATMENT AND WATER SUPPLY PLANT COAL MINE AND POWER PLANT STANARI

On May 181h of this year, Stanari Coal Mine and Power Plant part of the EFT Group, laid the foundation stone for the construction of a brand new power plant installed capacity of 300 MW, in the city of Stanari - Republika Srpska. Engaging of Delta lnzenjering was reflected in development of the main design for water supply and preparation of drinking water for the power plant construction site, with a total capacity of 80m3 /hand a plant with a capacity of 21 Is for the preparation of drinking water for the administration building and the coal mine on a 'turnkey' base. In order to use well water as inlet water, water treatment is reflected in the reduction of iron, manganese and ammonium, which content in water is several times higher than Maximal Allowed Concentrations Values: for iron 3.27 mg/1 (MAC= 0.3 mg/1) and manganese 0.3 mg/1 (MAC= 0.05 mg/1).

Technical characteristics:

0,00-;- 3,27 0,00 -;- 0,30 0,01-:- 0,195 6,23-;- 7,42

The technological processes of water treatment are: ~ Previous oxidation with a solution of sodium hypochlorite

(NaOCIL ~ Filtration through a specially prepared filling of green

sand with continuous regeneration, ~ Final disinfection with solution of sodium hypochlorite

(NaOCIL ~ Final adjustment of water pH.

Wastewater from the rinsing of filter columnsis drained with the drainage channel in the manhole, where is carried out sedimen­tation or separation of clear phase and sludge, which is evacuated by occasional pumping out with the sludge pumps.

The value of the Contract is E 650,000.

::;; 0,1 6,8 -;-8,5

DRINKING WATER SUPPLY FOR THE CITY OF TUZLA

_.... Raw Water Pump Station within TPPTuzla with automatic self-rinse ~ filters, the Federation of Bosnia and Herzegovina

_.... VU plant (vacuum ultrafiltration) with a blower for backwashing of ~ membranes with air and VU modules are immersed in water

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PRIPREMA PIJACE VODE LOP ARE Postrojenje za preradu sirove recne vade

i dobijanje vade za pice u gradu Lopare- ~ Republika Srpska

Paketni taloznik sa slozenim paketnim ..,_ elementima i paketni elementi ,.

PRECISCAVANJE SANITARNO-FEKALNE VOOE

POSTROJENJE ZA PRECISCAVANJE SANITARNO-FEKALNIH OTPADNIH VODA BRUS PPOV BRU

Akumulacija Celije nastala je pregradivanjem reke Rasine i svrstana je u kategoriju izvoriSta prvog ranga za meduregionalno i regional no vodosnabdevanje.

Pijacom vodom iz ovog izvorista snabdeva se preko 87% stanovnika Krusevca i okolnih naselja. U sklopu aktivnosti koje za cilj imaju produzetak veka akumulacije, predvidena je izgradnja postrojenja za preciscavanje komunalnih otpadnih voda opstine Brus. Projektantski tim Delta lnzenjeringa angazovan je na poslovima izrade projektne dokumentacije za buduce postrojenje. Obradeni su idejni tehnolosko-masinski projekat, idejni elektro-projekat i idejni gradevinski projekat, te se u potpunosti maze sagledati obim i novcana vrednost radova za kompletnu izgradnju postrojenja. Populacija i produkcija otpadnih voda iz industrije u opstini Brus za projektni period do 2037. godine procenjeni su na 10.500 ekvivalentnih stanovnika. Kao projektni parametri usvojeni su: dnevna kolicina otpadnih voda od 1.732m3/dan i vrsni casovni protok od 144,4 m3 /h. Koncept preciscavanja postavljen je taka da odgovori na najstroze

zahteve u pogledu kvaliteta efluenta. Pored mehanickog tretma­na za uklanjanje grubih necistoca, predvidena je sekundarna i tercijarna obrada otpadnih voda u postupku sa aktivnim muljem. Odabran je process sa sekvencijalnim sarznim reaktorima (SBR) koji karakterise velika fleksibilnost u pogledu variranja kolicine otpadnih voda koje se tretiraju. Procesi bioloske oksidacije organskih materija, nitrifikacije, denitrifikacije i kombinovanog biolosko-hemijskog uklanjanja fosfora, kao i talozenje i dekanta­cija, odvijaju se u istoj reakcionoj zapremini u postrojenjima ovog tipa. Vodenje procesa je vremenski zadato i realizovano preko PLC i SCADA sistema. Predvideno je da se aerobna stabilizacija viska mulja odvija u odvojenom rezervoaru. Dehidratacija stabilisanog mulja obavlja se na centrifuga uredaju, uz dodatak sredstava za kondicioniranje mulja. Muljni kolac se odlaze u kontejnere i maze se odvoziti na deponiju iii koristiti za dubrenje poljoprivrednih povrsina.

24 ____________________________________________________________________ ___

PREPARATION OF DRINKING WATER Plant for processing of raw river water and

~ obtain of drinking water in Lopare­Republika Srpska

LOPARE

~ Settling tank with complex packet "111111111 elements and packet elements

CENTRAL MUNICIPAL WASTEWATER TREATMENT PLANT

BRUS

The Celije reservoir is formed by damming ofthe River Rasina and is classified in the category of first-rank wellsprings for inter-regional and regional water supply.

From this wellspring with drinking water is supplied over 87% of Krusevac and surrounding villages. Within the activities aimed at the extension of the accumulation lifetime is planned the construction of a Central Municipal Wastewater Treatment Plant for the city of Brus. The Design Team of Delta lnzenjeringis involved in the preparation of project documentation for a future plant. Preliminary Process Design, Electrical Conceptual Design and Preliminary Construe­tion Design were processed so that the scope and monetary value of the works for complete construction of the plant can be fully considered. Population and production of industrial wastewater from the municipality of Brus for design period up to 2037 have been estimated at about 10,500 population equivalent and asdesign parameters were accepted: daily wastewater amount of 1,732 m3/day and maximal hourly flow of 144.4 m3/h. The concept of treatment is set to respond to the most stringent

requirements in terms of effluentquality. In addition to the mechanical treatment for removing of coarse particles is planned the secondary and tertiary wastewater treatment in the activated sludge process. A process with sequential batch reactor (SBR) is selected, which is characterized by high flexibility in terms of varying amounts of wastewater to be treated. Processes of biological oxidation of organic materials, nitrification, de-nitrification and combined biological and chemical phospho­rus removal as well as sedimentation and decantation, take place in the same reaction volume in the plants of this type. Managing the process is time-tasked and realized by PLC and SCADA systems. It is anticipated that the aerobic stabilization of excess sludge takes place in a separate tank. Dehydration of stabilized sludge is carried out on centrifuge with the aid of sludge conditioning. Sludge cake is disposed in containers and can be transported to the landfill or used for farmlands fertilization.

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POSTROJENJE ZA PRECISCAVANJE SANITARND-FEKALNIH DTPADNIH VODA BLACE

U opstini Blace u proslosti je izgradeno postojenje za precisca­vanje komunalnih otpadnih voda koje danas nije u funkciji. Na istoj lokaciji predvidena je izgradnja potpuno novog postrojenja koje bi odgovorilo savremenim zahtevima u pogledu zastite zivotne sredine. Srednji protok otpadne vade iznosi 20,11/s (q24), dok je maksi­malni casovni protok (q12) 144,4 m3/h, odnosno iznosi 40,21/s. Organsko opterecenje za 10 SOOES (sto odgovara kraju projektnog perioda) procenjeno je kao 630kg BPKS/dan. U okviru idejnog tehnolosko-masinskog projekta, projektanti Delta lnzenjeringa postavili su koncept preciscavanja koji odgova­ra zastiti vodoprijemnika osetljivog na eutrofikaciju i ponudili su moderna tehnicka resenja. Za primarni tretman otpadne vade (uklanjanje krupnih necistoca, cestica peska, te masti i ulja) predvidena je kompaktna predtretmanska jedinica. Sekundarno preciscavanje i uklanjanje nutrijenata (azota i fosfora) realizovano je u sekvencijalnim sarznim reaktorima (SBR). Ciklus svakog SBR podrazumeva smenu nekoliko faza: punjenje sa reakcijom, reakciona faza, talozenje mulja i odlivanje efluenta. Promenom radnog rezima reaktora u reakcionoj fazi (mesanje bez uduvava­nja vazduha/aeracija reakcione smese) obezbeduje se smena

PDSTRDJENJE ZA PRECISCAVANJE

anoksicnih, anaerobnih i aerobnih uslova i obezbeduje odvijanje procesa nitrifikacije, denitrifikacije i bioloskog uklanjanja fosfora. lstovremeno, sam SBR ima i ulogu primarnog i sekundarnog taloznika. Prateca hidro-mehanicka oprema odabrana je taka da omoguCi uspesno odvijanje procesa dekantacije, izvlacenja viska mulja i njegovog dopremanja na proces aerobne stabilzacije. Pri dimenzionisanju SBR reakcionih bazena i za proracun duzine trajanja pojedinih faza ciklusa, projektanti Delta lnzenjeringa rukovodili su se preporukama Nemackog udruzenja za vodopri­vredu, otpadne vade i otpad (Standard ATV-DVWK-A 131E i Uputstvo DWA-M 210).

SANITARNO-FEKALNIH OTPADNIH VODA- SUBOTICA

Delta lnzenjering je 2009. godine uradio glavni masinski projekat central nag postrojenja za tretman otpadnih voda grada Subotice (140.000ES).

Mehanicki tretman vade obuhvata filtraciju kroz grube i fine resetke, uklanjanje peska i masti kao prima rna talozenje. Biolosko preciscavanje ce se vrsiti koriscenjem sistema sa aktivnim muljem sa nitrifikacijom i denitrifikacijom. Za uklanjanje fosfora usvojen je hibridni prostupak- kombinacija uklanjanja fosfora biolos­kim i hemijskim putem, tj. talozenja doze trovalentne soli gvozda u bioloskom bazenu. Anaerobna stabilizacija uguscenog primarnog i sekundarnog mulja odvijace se u digestoru, a mehanicka dehidratacija na trakastoj filter presi. Biogas koji se generise u procesu anaerobne stabilizacije mulja koristice se za proizvodnju elektricne energije i top late za postrojenje.

A Municipal Wastewater Treatment Plant in the municipality of Blace has been built but it is not functional. At the same location the construction of a brand new plant is planned. The plant would respond to modern demands in terms of environmental protec­tion. Average flow of wastewater is 20.11/s (q24) while the maximum hourly flow is (q12) 144.4 m3/h, ie. 40.21/s. The organic load for 10 SOOPE (corresponding to the end of the design period) is estimated as 630 kg BPKS/day. In the Preliminary Process Design, Project Engineers of Delta lnzenjering set up the concept of treatment corresponding to protection of water recipient that is sensitive to eutrophication and offer modern technical solutions. For the primary waste­water treatment (removal of large debris, sand particles, grease and oil) is planned a Compact Pretreatment Unit. The secondary treatment and nutrient removal (nitrogen and phosphorus)

CENTRAL MUNICIPAL WASTEWATER TREATMENT PLANT

BLACE

were implemented in a Sequential Batch Reactor (SBR). A cycle of each SBR involves replacement in several phases: filling with the reaction, the reaction phase, precipitation of sludge and effluent drain. Changing of the reactor operating mode in the reaction phase (mixing without air blowing/aeration of the reaction mixture) provided changing of anoxic, anaerobic and aerobic conditions and provides a process of nitrification, denitrification and phosphorus biological removal. At the same time, SBR has a role of the primary and secondary sedimentation tank. Supporting hydro-mechanical equipment was chosen to enable the successful development of the decantation process, extraction of excess sludge and its delivering to the aerobic stabilization process. When sizing SBR reaction pools and calculating the length of individual phase, Project Engineers of Delta lnzenjering are guided by recommendations of the German Association for Water Management, Wastewater and Waste (Standard A TV-A 131 E DVWK and Instruction DWA-M 210).

CENTRAL MUNICIPAL WASTEWATER TREATMENT PLANT

SUBOTICA

Delta lnienjering developed a Main Mechanical Design Project of the Central Wastewater Treatment Facility of the City ofSubotica (140,000 ES) in 2009.

A mechanical treatment as a first phase includes filtration through coarse and fine grids, sand and grease removal, as well as the primary settling. A biological treatment will be carried out using the activated sludge system with nitrification and denitrification. For phosphorus removal was accepted so-called hybrid procedures, or a combina­tion of biological and chemical phosphorus removal by precipita­tion with trivalent iron salts dosage in biological pool. Anaerobic stabilization of thickened primary and secondary sludge will be carried out in the digester and mechanical dehydration on the band filter press. The biogas generated in Anaerobic Sludge Stabilization Process will be used to produce electricity and heat for the plant.

GENERALNI PROJEKAT POSTROJENJA ZA PRECISCAVANJE OTPADNIH VODA GRADA KRALJEVA (PPOV KRALJEVOJ

lzradu generalnog projekta sa prethodnom studijom opravdan­osti za kanalizacioni sistem, kao i za postrojenje za preciscavanje otpadnih voda grada Kraljeva, finansirala je Evropska unija kroz projekat podrske u pripremi projekata za IPA Ill komponentu (PPF4) na predlog Ministarstva energetike, razvoja i zastite zivotne sredine.

lnzenjeri Sektora voda Delta lnzenjeringa su, kao sastavni deo projektantskog tima PPF4 ispred Louis Berger-a, uradili kompletnu projektnu dokumentaciju koja, pored generalnog projekta kanalizacione mreze i postrojenja za grad Kraljevo, obuhvata i generalne i idejne projekte kanalizacione mreze i postrojenja za preciscavanje otpadnih voda za Brus i Blace.

lmajuCi u vidu da je izgradnja PPOV Kraljevo zapoceta 1980. godine i da je postrojenje delimicno izgradeno tokom devede­setih (ulazna pumpna stanica sa peskolovom), postavljen je koncept postrojenja koji je na nivou generalnog projekta obraden u dva varijantna resenja.

Projektovani kapacitet postrojenja za preciscavanje otpadnih voda (PPOV Kraljevo) zadovoljava ocekivani broj ekvivalent stanovnika za 2038. godinu koji iznosi 120.000 ES.

Konceptualnim resenjem se za oba varijantna resenja predvida vise nezavisnih linija koje omogucavaju faznost izgradnje. Takode, predvideno je i eventual no prosirenje kapaciteta za jos 40.000 ES u slucaju nag log porasta industrijskog opterecenja za sledeCih 10 do 20 god ina, sto bi na kraju dalo ukupan kapacitet postrojenja od 160.000 ES.

Generalnim projektom su obradene sledece dve opcije tretmana otpadnih voda i mulja:

~ Konvencionalno postrojenje sa aktivnim muljem i anaerob­nom stabilizacijom mulja,

~ SBR postrojenje sa aerobnom stabilizacijom mulja.

Konvencionalno postrojenje obuhvata fizicki predtretman otpad­nih voda, za kojim slede primarno talozenje, bioloski tretman sa uklanjanjem nutrijenata i sekundarno talozenje.

U okviru ove varijante je predviden anaerobni tretman aktivnog mulja sa proizvodnjom biogasa.

Projektom su predvidene tri linije za bioloski tretman, uz izgrad­nju jedinstvenog objekta za mehanicki predtretman otpadne vade koja dolazi na tretman, kao i zajednicki tretman mulja i produkcija biogasa.

Objekti za mehanicki predtretman, koji su vee izgradeni, bili bi rekonstruisani u skladu sa potrebama novoprojektovanog postrojenja.

SBR postrojenje, kao drugo varijantno resenje generalnog projekta, predvideno je kao sistem od sest SBR reaktora, bez prethodnog rezervoara i sa sarznim punjenjem, shodno uputstvu DWA-M 210, odnosno Standardu ATV-DVWK-A 131 E. SBR koncept uklanjanja BPK5, HPK, azota i fosfora zasnovan je na bioloskom tretmanu otpadne vade, koji se odvija u jed nom bazenu, sto znaci da se proces primarnog talozenja, bioaeracija sa recirkulacijom aktivnog mulja i sekundarno talozenje obavljaju u istoj reakcionoj zapremini (sarzni reaktor). Sam proces se odvija u sekvencama, odnosno u fazama ciklicnog karaktera. Naknadna stabilizacija mulja odvija se u bazenima za aerobnu stablizaciju.

28 ________________________________________________________________ __

GENERAL DESIGN FOR THE WASTEWATER TREATMENT

Development of the General Design with the Pre-Feasibility Study of the Sewage System and Wastewater Treatment Plant in the city of Kraljevo is funded by the European Union through the support project in the preparation of designs for IPA Component Ill (PPF4) on the proposal oft he Ministry of Energy, Development and Environmental Protection.

Engineers from the Group for Wastwater Treatment in Delta lnzenjering, as an integral part of the Design Team PPF4 of Louis Berger, have done a complete project documentation, which in addition to the General Design of the sewerage network and plants for the city ofKraljevo includes the General and Preliminary Designs of sewerage network and WWTP for Bruce and Blace.

Bearing in mind that the construction of WWTP Kraljevo isinitiated in 1980 and that the plant is partially built in the nineties (input pump station with a sand trap), a plant concept was set and at the level of General Design processed in two optional solutions.

The designed capacity of the Wastewater Treatment Plant (WWTP Kraljevo) satisfies the expected number of population equivalent for 2038 and amounts 120,000 PE.

With a conceptual solution are planned multiple independent lines, for both optional solutions, which enable the construction

SBR Plant, as well as other alternative solution for the General Project, is planned as a system of six SBR reactors, without previous tank and with batch filling, according to Instruction DWA-M 210 or Standard ATV-DVWK-A 131 E. SBR concept of removing BODS, COD, nitrogen and phosphorus is based on biological wastewater treatment that takes place in a

PLANT IN THE CITY OF KRALJEVO

in stages. It also foresees the possibility for expansion of the additional40,000 ES in case of a sudden rise in industrial load for the next 10 to 20 years, which would ultimately give the total plant capacity of 160,000 PE.

The General Design deals with the following two options of wastewater and sludge treatment:

~ The Conventional Plant with activ sludge and anaerobic sludge stabilization;

~ SBR plant with anaerobic sludge stabilization.

The Conventional Plant involves a physical wastewater pretreat­ment, which is followed by primary sedimentation, biological treatment with nutrient removal and secondary sedimentation.

In this versionis planned anaerobic treatment of active sludge with the production of biogas.

The design provides three lines for biological treatment with construction of an Unified Facility for Mechanical Pretreatment of wastewater that comes to treatment, as well as the common sludge treatment and biogas production.

The Mechanical Pretreatment Facilities, which are already constructed, would be reconstructed in order to meet needs of a newly-designed plant.

pool, which means that the process of primary sedimentation, bioaeration with recirculation of active sludge and secondary sedimentation is performed in the same reaction volume (batch reactor). The process is done in sequence or phases cyclic character. Subsequent stabilization of the sludge takes place in the pools for aerobic stabilization.

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TEHNICKA KONTROLA GLAVNOG PROJEKTA POSTROJENJA ZA PRECISCAVANJE OTPADNIH VODA PPOV SABAC

(

\

cilju zastite reke Save od zagadenja komunalnim otpadnim vodama poreklom iz gradskog podrucja Sa pea i gravitirajucih prigradskih naselja, krenulo se u realizaciju centralnog gradskog postrojenja za preciscavanje otpadnih voda (PPOV Sabac).

S obzirom na veliki znacaj izgradnje precistaca u nasoj zemlji, Delta lnzenjering (Sektor voda) je na zahtev JKP Vodovod-Sabac prihvatio da izvrsi tehnicku kontrolu glavnih projekata postroje­nja, kao ida pruzi sve potrebne konsultantske usluge koje se ticu pocetka izgradnje samog postrojenja.

Predvideno je da se na ovom postrojenju preciscavaju prikupljene sanitarne otpadne vode kao i industrijske otpadne vode, koje su odgovarajucim predtretmanima dovedene do kvaliteta definisa­nog Uredbom o granicnim vrednostima emisije zagadujucih materija u vodi i rokovima za njihova dostizanje (Siuzbeni glasnik RS, br. 67/11, 48/12).

Po kapacitetu, postrojenje za preciscavanje otpadnih voda je projektovano u dve faze. Faznost je definisana na osnovu biolos­kog opterecenja u odnosu 2/3+ 1/3. Kapacitet PPOV za fazu lA iznosi 84000 ES, dok je za kraj projek­tnog perioda, odnosno za fazu IB, predvideno prosirenje na konacnih 126.000 ES.

Osnovno hidraulicko i organsko opterecenje za PPOV Sabac dato je kroz sledecu tabelu:

1/s 1/s 1/s 1/s

233 473 324 877

84.000

325 650 460

1.200 126.000

Glavne projekte postrojenja- PPOV Sabac je uradio IWA Consalt d.o.o, odnosno HochtiefSolutions AG iz Nemacke, na vrlo visokom tehnickom nivou, posebno u procesnom (tehnolosko-masinskom) delu.

30 ---------------------------------------------------------------------

TECHNICAL CONTROL OF THE MAIN DESIGN FOR THE WASTEWATER TREATMENT PLANT

SABAC

In order to protect the River Sava from the pollution with municipal wastewater originating from the city of Sabac and belonging suburbs, the implementation of central Wastewater Treatment Plant for the city of Sabac has started.

Given the great importance of building a Wastewater Treatment Plant in our country, Delta lnzenjering (Group for Water Treatment) at the request of Public Utility Company for Water Supply of Sabac agreed to carry out technical inspection of the Detail Design and to provide all necessary consulting services relating to construction of the plant.

It is planned thatthis facility treats the collected hosehold sewage water and industrial wastewater, which is brought to the quality

defined by Regulation on emission limit values in waters and deadlines for their achievement (Official Gazette of RS, No. 67/11, 48/12) by the appropriate pre-treatment.

According to a capacity, Wastewater Treatment PI antis designed in two phases. Phasing is defined by a biological load in relation 2/3 + 1/3. The capacity ofWastwater Treatment Plant for Phase lA is PE 84,000, and at the end of the project period, ie. Phase IB planned an extension to the final PE126,000.

The basic hydraulic and organic load for Wastewater Treatment Plant Sabac is given by the following table:

1/s 1/s 1/s 1/s

233 473 324 877

84,000

The Detail Design ofSabacWWTP was done by IWA Consalt and HochtiefSolutions AG- Germany, on very high technical level, especially in the process (technical-mechanical) design part.

325 650 460

1,200 126,000

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PRECISCAVANJE TEHNOlOSKE VOOE

POSTROJENJE ZA PRECISCAVANJE OTPADNIH VODA IZ LAKIRNICE- GORENJE. VALJEVO

Za potrebe Fabrike rashadnih uredaja Gorenje u Valjevu projektovano je postrojenje za preciScavanje otpadnih voda koje nastaju u proizvodnom procesu.

Otpadne vade mogu se podeliti na kontinualne i diskontinualne, odnosno ispirne i koncentrate respektivno. Koncentrati se ispustaju iz kada predobrade povremeno i skladiste u rezervoaru B01. Rezervoar B01 je podzemni, beton­ski, zapremine 25m3

• Prepumpavanje otpadne vade iz bazena koncentrata se vrsi pomocu dve klipno-membranske pumpe, od kojih je jedna radna, a jedna rezervna. Usvojene pumpe su proizvodaca Prominent, tipa Sigma S2BA, sledecih tehnickih karakteristika:

~ Nominalni protok: 0=2501/h, ~ Maksimalni protok: Qmax=3501/h, ~ Radni pritisak: p=4bar.

lspirne vade se sakupljaju sa komada koji se cede nakon pranja i betonskim kana lam transportuju do rezervoara spirnih voda B19. Rezervoar B19 je betonski, podzemni, zapremine 30m3

• Transport ispirnih otpadnih voda iz podzemnog rezervoara B19 vrsi se pomocu potopljenih centrifugal nih pumpi sledecih karakteristika:

~ Proizvodac: Grundfos, ~ Nominalni kapacitet: Q=3m3/h, ~ Maksimalni kapacitet: Qmax=5,6m3/h, ~ Visina dizanja: H=Sm.

Pumpe rade u rezimu radna i rezervna. Protok se mora drzati konstantnim kako bi doziranje hemikalija bilo odgovarajuce. Merenje pH vrednosti vrsi se automatski i kontinualno.

Proces preciscavanja otpadnih voda je koncipiran taka da dolazi do mesanja ispirnih voda i koncentrata koji su prosli predtre­tman radi uklanjanja masti. Zbirne otpadne vade prolaze

fizicko-hemijski tretman uz talozenje na lamelnom talozniku, odakle se preliv nakon finalne kontrole pH-vrednosti ispusta u kanalizacioni sistem fabrike, koji je dalje povezan na gradsku kanalizaciju grada Valjeva, a istalozeni materijal pomocu pneumatske pumpe transportuje na kondicioniranje. Nakon kondicioniranja i uguscivanja, mulj se pomocu zavojne pumpe transportuje na presovanje u komornu filter presu. Pumpa za mulj je frekventno regulisana preko davaca pritiska ugradenog na potisnom cevovodu pumpe.

Celim postrojenjem automatski upravlja procesor (PLC), smesten u elektro-komandni orman. Postrojenje se maze voditi kako u lokalnom (rucnom) taka i u automatskom rezimu.

32 -----------------------------------------------------------------------

INDUSTRIAL WATER TREATMENT

TREATMENT PLANT FOR WASTEWATER FROM PAINT SHOP- GORENJE, VALJEVO

A Wastewater Treatment Plant is designed for wastewater generated in the production process for the purpose of the Factory for Refrigerating Household Appliances Gorenje.

Wastewater can be divided into continuous and discontinuous or flush and concentrates respectively. Concentrates are released from tubs of pre-treatment periodically and stored in a tank B01. The tank B01 is underground and is made from concrete, with volume of 25m3

• Pumping of wastewa­ter from the concentrates basin is done by using two diaphragm pumps of which one is active and one is spare. The installed pumps are from the manufacturer Prominent, type Sigma S2BA, with the following technical characteristics:

~ Nominal flow: 0=2501/h ~ Maximal flow: Qmax=3501/h ~ Operating pressure: p=4bar

Rinsing water is collected from the pieces that are draining after washing and by a concrete channel transported to a rinsing water tank B19. The tank B19 is underground and is made from concrete, with a volume of 30m3

• Transport of rinsing wastewater from the underground tank B19 is performed using submerged centrifugal pumps with following characteristics:

~ Manufacturer: Grundfos ~ Nominal capacity: Q=3m3/h ~ Maximal capacity: Qmax=5,6m3/h ~ Lift height: H=5m

The pumps are operating as work/spare. The flow rate must be kept constant in order to keep chemical dosing appropriate. Measurement of pH-value is carried out automatically and continuously. The process of wastewater treatment is designed so there is mixing of flush water and concentrate which have undergone previous treatment for the removal of grease. Cumulative wastewater undergoes physical-chemical treatment with sedimentation on a lamella sedimentation tank, from where­overflow is discharged after the final control of pH to the sewer system ofthe factory, which is connected to the sewage system the City of Valjevo and sediment material using pneumatic pump transported to the conditioning. After conditioning and thickening, sludge is transported by a progressive cavity pump to dewatering in a chamber filter press. The sludge pump has frequency regulating drive controlled by a pressure transmitter installed in the discharge pipe line of the pump. Whole plant is automatically run by PLC processor located in the electrical-control cabinet. The plant can be run in the local (manual) and automatic mode.

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RAZVOJ HIDROMASINSKE OPREME U fUNKCIJI POSTROJENJA RAZVOJ I PRIMENA LAME LA TPS SEPARATORA

U skladu sa zahtevima trzista za kvalitetnim, a u isto vreme i sto povoljnijim resenjima, Delta lnzenjering je poslednjih god ina razvio sopstvenu konstrukciju TPS separatora - uredaja za separaciju bistre faze i mulja u tehnologiji obrade voda.

Princip rada TPS separatora

The Working Principle ofTPS Separator

Karakteristike TPS-a koje je ugradio Delta lnienjering

TPS (Trapezni Plocasti Separator) je uredaj koji, koristeci vecu masu flokulisanih cestica u vodi (a samim tim i vecu inerciju), vrsi razdva­janje bistre faze.

Ovaj taloznik omogucava pored grubih cvrstih cestica i dekantaciju finih cestica peska i zrnastog materijala, suspendovanog materijala, kao i flokula metal nih hidroksida iii baznih soli.

Proces talozenja spada u grupu sedimentacionih procesa, odnosno razdvajanja cvrste od tecne faze usled dejstva sile zemljine teze (gravitacione sile). Ova sila deluje na svako zrno, cesticu iii flokulu, usled koje one dobijaju odredenu brzinu padanja i ako je ta brzina veca od usponske brzine vode u talozniku, talozenje ce se uspesno odvijati.

TPS se sastoji od rezervoara I tanka za smestaj potrebnog broja kompleta lamela. Napravljen je uglavnom od ugljenicnog celika, mada moze biti izraden i od drugih materijala.

Na dnu tanka je po celoj duzini lateralnog zida postavljen uredaj za separaciju i odvajanje mulja. Na najnizem delu ovog uredaja se po potrebi nalazi puzni transporter za efikasniju evakuaciju mulja. Lamele separatora se montiraju kroz gornji otvor tanka i mogu se po potrebi bez problema izvaditi radi ciscenja iii zamene. Lamele su po pravilu izradene od GRP-a (Glass Reinforced Polyester). Celicna konstrukcija GRP lamela je opremljena podesivom prelivnom trakom sa Tomsonovim prelivom.

9- 15 m3/h 9- 15 m3/h

3 m3/h

2x0.6 m3

2x0.6 m3

0.20 m3

2

34 ______________________________________________________________________ _

DEVELOPMENT OF HYDRO-MECHANICAL EQUIPMENT IN THE FUNCTION OF A PLANT

Characteristics ofTPS Separators installed by Delta lnienjering

DEVELOPMENT AND APPLICATION OF lTPSJ LAMELLA SETTLER

In accordance with market demands for high quality and at the same time most favorable solutions, Delta lnzenjering has in the last few years developed its own construction ofTPS (Trapezoid Plate Separator)­separator, a device for separation of clear phase and sludge in the Water Treatment Technology.

TPS is a device which makes clear phase separation using the mass offiocculate particles in the water (and therefore higher inertia).

This separator allows decantation of fine particles of sand and granular materials, suspended materia land metal hydroxide fioccule or base salts in addition to the rough solid particles.

Settling process is one ofthe sedimentation process, ie. separation of solid from liquid phase due to the force of gravity (gravitational force). The force acting on each grain, particle or fioccule, due to which they get a certain settling speed and if the speed exceeds the rise speed of water in the settling speed tank, sedimentation will be successfully carried out.

TPS Lamella separator consists of a reservoir/tank to accommodate the required number of sets of lamellas. It is made mostly of carbon steel, but can also be made from other materials.

At the bottom of the tank, along the length of the lateral wallis installed the device for sludge separation. At the lowest end of the device, if necessary, is a screw conveyor for efficient sludge evacua­tion. The separator lamellas are mounted through the tank top opening and, if necessary, can be removed for cleaning or replace­ment without problems. The lamellas are typically made ofGRP (Glass Reinforced Polyester). Steel construction of GRP lamellas is equipped with an adjustable overfiow weir (Thompson's overfiow weir).

9-15 m3/h 9-15 m3/h

3 m3/h

2x0.6 m3

2x0.6 m3

0.20 m3

2 2

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RAZVOJ KOALESCENYNIH SEPARAYORA

U okviru projekta postrojenja za preciscavanje otpadnih voda za Fabriku rashladnih uredaja Gorenje- Valjevo, Delta lnzenjering je konstruisao i isporucio koalescentni separator za odvajanje faza u dvokomponentnom jednofaznom sistemu tecnost-tecnost za deemulgovana ulja.

Posto proces deemulgacije zahteva veoma kiselu sredinu (niske pH vrednosti 2-2,5), separator je u potpunosti izraden od polipropilena. Zbog karakteristika procesa kao medijum za koalescenciju koriscena je paketna ispuina LIQUI-NOMIX, americkog proizvodaca KIMRE. lspuna se sastoji od 10 slojeva specijalno umrezenih polipropilenskih vlakana, ukupnih dimenzija 500x300x224 mm. Kapacitet separatora je 1m3/h. Samostalna struktura LIQUI-NOMIX® ispune pokazala se kao dobra zbog velikog broja vlakana koja su upravna na tok, vel ike povrsine svetlog otvora, razlicitih monofilamentnih via kana kao i razlicitih materijala za izradu via kana koji su dostupni.

UGUSCIVAC MULJA PPOV KAYAK II

Za potrebe preciscavanja otpadne vode iz Lakirnice u fabrici Fiat Automobili Srbija, Delta lnzenjering je konstruisao i montirao nas do sada najveci celicni ugusCivac mulja.

U pitanju je standardni radijalni uguscivac mulja sa levkastim dnom, sledecih dimenzija:

Preenik 5000 m ~==================~

Visina dlindrienog dela 3300 m ~==================~

Nagibdna 9° Ukupna vlsina (ukljueujud nosele stope} 4500 m

Uguscivac mulja je izveden sa obodnim prelivnim kanalom i prirubnickim vezama/spojevima za ulaz-izlaz vode i mulja. Uguscivac je takode opremljen zgrtacem mulja sa centralnim pogonom.

Uobicajeno je da se koriste vlakna precnika 0.2-0.9 mm i povrsi­na svetlog otvora od 94-97%. Moguca je kombinacija razlicitih stilova pletenja vlakana unutar jednog paketa kako bi se postiglo­uklanjanje iii filtracija odredenih cestica iii fino poliranje.

Kompozitnost LIQUI-NOMIX® materijala omogucuje dugorocnu eksploataciju, male troskove odrzavanja i mogucnost ponovnog koriscenja. Mulj i cvrste cestice se lako uklanjaju sa ispune pranjem pomocu deterdzenata iii mlazom vode pod visokim pritiskom.

Prelivne trake i pregrade su izradene od nerdajuceg celika, dok su ostali delovi izradeni od ugljenicnog celika. U cilju zastite od korozije, svi uronjeni delovi ugusCivaca su zasticeni sa epoksi-bitumenskim premazom, dok su suvi delovi premazani neorganskom osnovnom bojom na bazi cinka i zavrsnim premazom na bazi poliuretana.

REZERVOAR ZA PRIHVAY ULJA [PPOV KAYAK Ill]

Ovaj rezervoar je projektovan i izraden za potrebe prihvata povrsinskih masti i ulja iz tehnoloskih otpadnih voda iz fabrike Fiat Automobili Srbija koji se uz pomoc cevastog skidaca uklanjaju sa povrsine vode u prihvatnom egalizacionom bazenu. Specificnost ovog rezervoara je ta da je on u potpunosti pocinkovan, a zbog lokacije za instalaciju morao je biti takode u

potpunosti izolovan sa elektrogrejnim kablovima u cilju zastite od zamrzavanja u zimskim mesecima. Rezervoar je vertikalni, cilindricnog oblika, zapremine 2,4 m3

, sa meracem nivoa cija je uloga da pumpu, kojom se prikupljeni sadrzaj transportuje u kamion-cisternu, zastiti od rada"na suvo'~

Within the project for the Wastewater Treatment Plant for Refrig­erating Houshold Appliances Gorenje Valjevo, Delta lnzenjering has designed and engineered a coalescent separator for separa­tion in two-component, one-phase, liquid-liquid system, with goal to separate deemulgated oil from wastewater. Process of oil deemulgation requires very acid environment (pH values 2 to 2,5) so the separator had to be made entirely from polypropylene. Due to process requirements, LIQUI-NOMIX coalescent pad, made by US manifacturer KIMRE, was used as coalescence media. Coalescent pad is made out of 10 layers of

DEVELOPMENT OF COALESCENT SEPARATORS

specialy placed polypropylene fibers, outside dimensions 500x300x224 mm. Capacity of the device is 1m3/h. The self-supporting LIQUI-NOMIX® structure works well in both clean and dirty services because of the large number of fibers perpendicular to the flow, the high void space and the variety of monofilament diameters and materials of constructions available. The styles of material most commonly used in this service range in diameter from 0.2 - 0.9 mm and 94-97% void space. Combinations of styles can be used together in single stages to achieve particulate removal/filtration and fine polishing. The composite feature of the LIQUI-NOMIX® material allows long term operation, low maintenance, and reusability. Sludge and solids are easily cleaned from the material with cleaning solutions or high-pressure washes.

SLUDGE THICKENER (WWTP KAlAK Ill For the treatment of wastewater from the Paint Shop in the factory Fiat Automobiles Serbia, Delta lnzenjering has designed and installed so far our largest steel sludge thickener.

This is a standard radial sludge thickener with the funnel bottom and with the following dimensions:

5000m 3300 m go

4500m

The sludge thickener is designed with the perimeter overflow channel and flange connections/fittings for entrance and exit of water and mud.

It is also equipped with a sludge scraper, with the central drive. Overflow weirs and dividers are made of stainless steel, while other parts are made of carbon steel. In order to protect against corrosion, all submerged parts of the sludge thickener are protected with epoxy- bituminous coating, while the dry parts coated with inorganic primer colour, zinc based and a final coating of polyurethane.

RESERVOIR FOR OIL RECEIVING (WWTP KAlAK Ill)

This tank is designed and developed for the acceptance of surface grease and oil from industrial wastewater from the Factory Fiat Automobiles Serbia which are removed by tubular remover from the surface of the water in the reception equalization pool. The specificity of this tank is that it is completely galvanized, and for installation location also had to be completely isolated with electric heating cables for protection against freezing in winter months. The tank is vertical, cylindrical shape, with a volume of 2.4 m3.ln the tank is installed a level meter which role is to protect the pump, by which the collected content is transported in a tanker, from dry running.

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RASH LAO N I SISTEM I ~

VECIH KAPACITETA

RASHLADNI SISTEM POSTROJENJA ZA RAZLAGANJE VAZDUHA MESSER. DOH

U akviru projekta pastrojenja za razlaganje vazduha - ASU Bar, kaji za patrebe Messer-Tehnagasa projektuje Delta lnzenjering, Sektar za vade bia je angazavan za projektavanje rashladnag sistema. U pitanju je zatvareni recirkulaciani rashladni sistem kapaciteta 650m3 /h rashladne vade.

Osnavni delavi avag rash lad nag sistema su: 1. Pumpna stanica za rashladnu vadu: U pumpnaj stanici smestena je sva aprema patrebna za pravilna funkcianisanje rashladnag sistema. Srce celag sistema cine pumpe za rashladnu vadu. Projektam su predvidene dve radne i jedna rezervna horizantalna centrifugalna pumpa, proizvadaca Allweiler, sledeCih tehnickih karakteristika:

~ Protak: 0=325 m3/h; ~ Napar: H=42 m; ~ Broj abrtaja: n=1450 min-1; ~ Snaga na vratilu: P1 =45,6 kW; ~ Snaga matara: P=55 kW.

Osim pumpi, u abjektu se nalazi filter za rashladnu vadu kapaciteta 50 m3/h, patpuna autamatizavana dazirna stanica sa svam pripa­dajucam apremam i setam za merenje karozije u cevavadu, kaa i filter za vadu za dapunu rashladnag sistema kapaciteta 50m3/h.

2. Rashladne kule sa bazenam za rashladnu vadu: Projektam je predvidena ugradnja dve rashladne kule dimenzi­ja 4840x4840x5540mm, proizvadaca SPX, na betanskam rezervaaru, sa prinudnam promajam, suprotnasmernim takam sa lamelnam ispunam, sledecih tehnickih karakteristika:

~ Protak: 0=325 m3/h; ~ Ulazna temperatura: tin=39 oc; ~ lzlazna temperatura: taut=29 °(; ~ Kapacitet hladenja: Oh=7,53 MW; ~ Precnik ventilatara: D=3530 mm ~ Broj abrtaja: n=311 min-1; ~ Snaga ventilatara: Pv= 14) kW.

3. Bazen za vadu za dapunu rash lad nag sistema: Bazen je apremljen patapljenim centrifugalnim pumpama kapaciteta 50m3/h. Projektam je predvidena jedna radna i jedna rezervna pumpa. Sastavni dea bazena je i suvi saht u kame je smestena sva patrebna cevavadna armatura.

38 -----------------------------------------------------------------------

COOLING SYSTEMS OF

Within the project for the new Air Separation Plant - ASU Bar, which is designed by Delta lnzenjering for Messer Tehnogas, Group for Water Treatment inside Delta lnzenjering has been involved in designing of the cooling system. It's a closed recirculating cooling system with a capacity of 650m3/h of cooling water.

The main parts ofthe cooling system are: 1. Pumping station for cooling water: Inside pump station is located all the equipment needed for proper functioning of the cooling system. The heart of the whole system are the cooling water pumps. The design foresees two operational and one spare horizontal centrifugal pump, manufac­tured by Allweiler, with the following technical characteristics:

~ Flow: 0=325 m3/h; ~ Head: H=42 m; ~ RPM: n=1450 min-1; ~ Power on shaft: P1 =45,6 kW; ~ Engine power: P=55 kW.

Except the pumps inside the building is a filter for cooling water with a capacity of 50m3 /h, a fully automated dosing station with

HIGHER CAPACITIES COOLING SYSTEM

OF AIR SEPARATION PLANT MESSER. BOR

all accompanying equiment and equiment for measurement of corosion inside the pipe, as well as a water filter for make-up water with capacity of 50m3 /h.

2. Cooling towers with a pool of cooling water: The design foresees installation of two cooling towers with the dimensions 4840x4840x5540 mm, manufacturer SPX, on a concrete tank, with forced draft, counter current flow of air and water, lamella film fill, with the following technical characteristics:

~ Flow: 0=325 m3/h; ~ Inlet temperature: tin=39 oc; ~ Outlet temperature: tout=29 oc; ~ Cooling capacity: Oh=7,53 MW; ~ Fan diameter: D=3530 mm ~ RPM: n=311 min-1; ~ Fan power: Pv=14) kW;

3. Make-up water tank: The tank is equipped with two submersible centrifugal pumps, with a capacity of 50m3/h. The design foresees one operational and one spare pump. An integral part of the pool is dry manhole which houses all necessary pipe line fittings.

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U.S. STEEL SERBIA

Sistem kiseonickih kopalja, odnosno konvertorskih duvnica u pogonu celicane, omogucava dotok potrebne kolicine kiseonika za predvidene tehnoloske procese u Konvertorskom odeljenju Zelezare u Smederevu.

U drugoj polovini 2011. godine Delta lnzenjering je zavrsio izvodenje zatvorenog rashladnog sistema, koji je u funkciji hladenja kiseonickih kopalja.

Projekat spada u red teze rangiranih, u pogledu tehnickih uslova na samoj lokaciji i veoma kratkog roka koji je bio predvi­den za izgradnju rashladnog sistema. Vazno je napomenuti da su sistemi hladenja konvertorskih duvnica u pogonima svetskih zelezara, obicno otvorenog, odnosno protocnog tipa, sa stalnom potrosnjom vode.

U tom smislu uspesno ,zatvaranje" rashladnog sistema, odnosno uspostavljanje recirkulacionog sistema, poboljsalo je ekoloski aspekt Zelezare Smederevo i automatski smanjilo troskove za utrosenu vodu, sa 450 m3/h na 25m3/h.

Paralelno sa izvodenjem radova na Zatvorenom rashladnom sistemu konvertorskih duvnica, Delta lnzenjering je uspesno izvodio radove na drugom rashladnom postrojenju, unutar pogona Zelezare u Smederevu.

U pitanju je zatvoreni rashladni sistem u funkciji Kompresorske stan ice. S obzirom na veoma teske us love koji su bili pri izvode­nju rashladnog postrojenja, posebno u pogledu rada Kompre­sorske stanice koja nije smela da stane u radu, izveden je svojevrstan podvig, narocito u pogledu prevezivanja procesnog cevovoda velikog precnika, kao i u pogledu parcijalnog pustanja rashladnog sistema u rad. Rashladni sistem Kompresorske stan ice pravi ustedu zelazari u vodi (novcu) od 1200 do 1800 m3 /h.

40 -----------------------------------------------------------------------

U.S. STEEL SERBIA

System of oxygen lances or converter blowers in the Steel Mill provides supply of required amount of oxygen for planned technological processes in the Converter Department of the Steel Mill in Smederevo.

In the second half of 2011 Delta lnzenjering has completed the Closed Cooling System, which cools the Oxygen Lance System. The project is among the difficult ones in terms of technical require­ments on the location and the very short term that was planned for the construction of the cooling system.

Converter Blower Cooling Systems in the world Steel Mill Plants are usually open, flow type, with constant water consumption. Establishing a recirculation system improved the ecological side of the factory in Smederevo and thus reduced the cost of consumed water from 450m3 /h to 25 m3 /h ..

Delta lnzenjering has successfully made the Closed Cooling System of converter blowers, which was put into operation automatically. In parallel with the construction of the Closed Cooling System of converter blowers, Delta lnzenjering has successfully carried out works on the second Cooling Plant in the Steel Mill Smederevo. This is a Closed Cooling System inside the compressor stations.

Given the very difficult conditions during operations in the Cooling Plant especially during the continuous running of the compressor station, we performed the accomplishment of connecting process pipelines with large diameter and partial commissioning of the cooling system in operation.

For several months, Compressor Station Cooling System in the stable, recirculation mode and saves water of the Steel Mill from 1200 to 1800 m3 /h.

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I

T

SISTEM OTPRASIVANJA TORNJA ZA SUSENJE POLUPROIZVODA HENKEL MERIMAI KRUSEVAC

U fabrici Henkel Merima u Krusevcu 2009. godine pusten je u pogon top filter, najsavremeniji ekoloski sistem zastite. Ugradnja top filtera je realizacija dugorocno planirane investicije kompanije Henkel u iznosu od million eura.

Top filter, koji se ugraduje na fabricki toranj, potpuno zadrzava sve vrste cestica i mikrocestica koje ostaju u vazduhu nakon procesa proizvodnje, taka da je vazduh koji se ispusta potpuno cist. Osim skoro stoprocentno prociscenog vazduha koji se ispusta u atmosferu, top filter obezbeduje i potpunu ustedu vade i smanjuje utrosak elektricne energije koja je do sada trosena na ekoloske sisteme zastite, cime se sjedinjuju svi aspekti zastite zivotne okoline i odrzivog razvoja.

Kljucno mesto u tehnoloskom postupku proizvodnje deterdzenata zauzima Toranj AT 7101 (konvektivna susara) u kame se obavlja proces susenja poluproizvoda na principu rasprsivanja tecne faze pod visokim pritiskom.

Dimenzije tornja su: ~ D=8 m- precnik tornja ~ H'··-40 m- visina tornja

Energent za susenje je topao vazduh ulazne temperature tu=270 ooc koja usled procesa susenja i povecanja relativne vlaznosti izlaznog vazduha opada i dostize neku izlaznu temperaturu od oko tiz= 140 ooc. Toranj za susenje je koncipi­ran taka da je u njemu moguce obavljati susenje pri istosmer­nom i suprotnosmernom toku energetskog fiuida, tj. vazduha i sirovine. Postojeci sistem preciscavanja izlaznog gasa iz tornja bio je koncipiran na vlaznom preciscavanju.

Delta lnzenjering je radi povecanja efikasnosti sistema preciscavanja izlaznih gasova u procesu susenja u tornju izvrsio adaptaciju kompletnog sistema preciscavanja i prelazak na sistem suvog filtriranja izlaznog vazduha iz tornja. Ugraden je filter na vrhu tornja koji preciscava sav izlazni vazduh iz tornja za susenje poluproizvoda. Filter je vrecasti, MikroPul -Tip HP 926 10 THR BM, sa impulsnim otresanjem komprimovanim vazduhom. Dimenzije filtera su 06500 i visina oko 7,8 m. Kompenzacija termickih dilatacija tornja i filtera resena je postavljanjem kompenzatora 06500 mm na prelazu izmedu njih.

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DEDUSTING TOWER FOR DRYING SEMI-MANUFATURED GOODS SYSTEM

In 2009 was put into operation top filter, the latest environmental protection system in the Factory Henkel Merima in Krusevac. Installation of the top filter is the realization of the planned long-term investment of Henkel in the amount of one million euros.

Top filter, which is installed at the factory tower, fully retains all kinds of particles and micro-particles that remain in the air after the production process, so that the air is discharged completely clean. In addition to nearly one hundred percent purified air is discharged into the atmosphere, the top filter provides complete water savings and reduced power consumption that has been spent on environmental protection systems, which unites all aspects of environmental protection and sustainable develop­ment.

Key role in the Technological Process of Detergents Production has Tower AT 7101 (convective drying) that is used for the drying process of semi-manufactured goods on the principle of liquid phase spraying under high pressure.

HENKEL MERIMA KRUSEVAC

Dimensions of the tower are: ~ D = 8 m -diameter of the tower ~ H ~ 40 m - height of the tower

Energy source for drying is the hot air with inlet temperature = 270 ooc that due to the drying process and the relative humidity increasing of outlet air decreases and reaches an outlet temperature of about tiz = 140 ooc. The drying tower is designed so that it can dry same and reverse flow of the energetic fluid, ie. air and raw materials. The existing purification of outlet gas from the tower system was designed to wet purification.

To increase the efficiency of the purification of outlet gas from the tower system, Delta lnzenjering did renovate complete system of purification and transition to the dry filtering system of outlet air from the tower. The filter was built-in on the top of the tower, which cleans all outlet air from the tower for drying of semi-manufactured goods. It is a bag filter, Mikropul -Type HP 926 10 THR BM, with pulse shaking of compressed air. The filter dimensions are 06500 and height of approximately 7.8 m. Compensation of thermal dilatation of the tower and the filter is solved by placing the compensator 06500 mm at the transition between them.

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CEMENTNA INDUSTRIJA U 2004. GODIN I HOLCIM

Nakon preuzimanja cementare Novi Popovac u aprilu 2002. godine, Holcim je obavio snimanje ekoloske situacije. U skladu s tim, Holcim je 2004. godine potpisao ugovor vredan oko cetiri miliona eura sa italijanskom firmom Redecam, o nabavci vrecastih filtera koji ce znacajno smanjiti emisiju prasine u atmosferu.

Uraaeni su projekti novog filterskog postrojenja za uklanjanje prasine u postojecem sistemu rotacione peci/mlina sirovina, filtera mlina cementa br.3 i filtera mlina cementa br.4 cementare Holcim N. Popovac. Delta lnzenjering je angazovana kao projektantaska kuca s obzirom nato da je u pitanju objekat od znacaja za Republiku.

lzvrsene su sledece modifikacije i izvedene nove instalacije: ~ rekonstrukcija postojeceg rashladnog tornja i transporta prasine,

~ vrecasti filter sa mlaznim impulsom, transport prasine i noseca konstrukcija,

~ ventilator za vazduh u sistemu iza filtera, ~ dimnjak nakon ventilatora za vazduh, ~ cevovod izmeau postojecih instalacija (rashladnog tornja,

mlina sirovina) i novog filtera/ventilatora za vazduh/dimnjaka, ukljucujuci i svu nosecu konstrukciju.

U periodu jul-avgust 2004. godine Delta lnzenjeringa je izradio projekat Sistem otprasivanja linije za pakovanje sa vrecastim filterom za Holcim. lzvrsena je montaza vrecastog filtera proizvoaaca Scheuch- Austrija, sa radijalnim ventilatorom. Cementna prasina, koja se izdvoji na filterskim vrecama, otresa se komprimovanim vazduhom i sakuplja u konusnom dnu filtera,

puznim transporterima i kanalima odvodi se u elevator i preko njega vraca u proces pakovanja cementa u vrece. Vrecasti filter i ventilator su oprema nove generacije, sa vrlo visokim stepenom preciscavanja zaprasenog vazduha. Koncentracija prasine u vazduhu koji se ispusta u atmosferu nakon filtriranja je 20 mg/m3

, sto je u skladu sa evropskim standardima. Novi aspiracioni sistem za liniju pakovanja sa vrecastim filterom je omogucio najbolje moguce uslove radne i zivotne sredine, s obzirom na to da se radilo o vazduhu veoma ugrozenom cementnom prasinom.

Uspesno obavljeni poslovi na projektovanju u oblasti otprasivanja u cementnoj industriji u 2004. godini otvorili su vrata Delta lnzenjeringu za nove projekte otprasivanja, kao sto su:

~ Rekostrukcija i dogradnja zgrade pakovanja sa dve linije pakovanja cementa u vrece i sistemom otprasivanja cementare Holcim - N.Popovac,

~ Otprasivanje u fabrici deterdzenata Henkel u Krusevcu, ~ Otprasivanje konvektorskog i mikserskog odelenja celicane

U.S.Steel u Smederevu, ~ Otprasivanje visoke peci u zelezari Arcelor Mittal u Zenici.

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CEMENT INDUSTRY IN 2004 HOLCIM

After takeover of the Cement Plant in Novi Popovac in April 2002, Holcim has done examination of the environmental situation. In 2004 Holcim signed a contract, worth about 4 million euros, with the Italian company Redecam, on the purchase of bag filters, which will significantly reduce the emission of dust in the atmosphere.

Delta lnzenjering was engaged as design company since it is an object of importance for the Republic of Serbia. The designs were prepared for a new filter plant for dust removal in the existing system of rotary furnace/raw mill and cement mill filters No.3 and No.4 in Cement Plant Holcim in N. Popovac.

The following modifications and new installations were provided: ~ reconstruction of the existing cooling tower and dust

transport, ~ bag filter with jet impulse, dust transport and support

structure, ~ fan for air in the system behind the filter, ~ chimney behind fan for air, ~ pipeline between existing installations (cooling tower,

raw mill) and a new filter/fan for air/chimney, including all supporting structure.

In July-August 2004, Delta lnzenjering designed dedusting system of packaging line with a bag filter for Holcim. The bag filter with a radial fan manufactured by Scheuch from Austria was mounted. Cement dust which is extracted on the filter bags, is shaken off by compressed air and is collected in the filter cone bottom, with screw conveyors and channels drains away in elevator and through it back in the packaging process of cement in the bags. The bag filter and fan are the new generation equipment with a very high level of purification of dust air. Dust concentration in the outlet air is 20 mg/m3, according to the European standards for allowable emission of air that is released into the atmosphere. The new aspiration system for packaging lines with a bag filter provides the best possible conditions and working environment, given that it is the highly degraded air by cement dust.

Well done works on the design in the field of cement industry in 2004 opened the door for Delta lnzenjering for the new projects, such as:

~ Reconstruction and upgrading of package building with two lines of cement packaging in bags and with dedusting system ofHolcim Cement Factory inN. Popovac,

~ Dedusting system in Henkel Detergent Plant in Krusevac, ~ Dedusting of convector and mixer facility in U.S.Steel

Ironworks in Smederevo, ~ Dedusting of Blast Furnace No.4 in Arcelor Mittallronworks

in Zenica.

REKONSTRUKCIJA FILTERA TERMOELEKTRANA NIKOLA TESLA

Odlukom Evropske komisije iz 2010. godine dodeljena je Srbiji (EPS u Termoelektrani Obrenovac) donacija za rekonstrukciju elektro-filtera na TENT-u B2. Na konkursu za nosioca posla izabrana je zapadnoevropska firma Hamon. Delta inzenjering je ucestvovao na realizaciji projekta kao isporucilac nosece konstrukcije filtera i kucista filtera. Poslovi su obuhvatali poboljsanje sistema elektro-filtera koji smanjuje emisiju cestica iz bloka B1 ispod granica emisije cestica koje su predvidene Direktivama o velikim postrojenjima za sagorevanje za odrziv vremenski period koji je u skladu sa Zakonima o ocuvanju zivotne sredine, kao sto je zahtevano Ugovorom o Energetskoj zajednici. Obim projektantskih i ugovorenih radova obuhvatao je izradu projekta izvedenog stanja na osnovu funkcionalne specifikacije, isporuku materijala i opreme, gradevinskih, masinskih i elektro-radova, kao i

RAFINERIJA NAFTE PANCEVO

U okviru projekta adaptacije pretakalista TNG-a (tecni naftni gas) realizovace se modernizacija vanprocesnih postrojenja uvodenjem nove tehnologije merenja pri dopremi i otpremi na auto i zeleznic­kom pretakalistu TNG-a, s obzirom na to da postojece auto i zeleznicko pretakaliste ne pruza potrebnu efikasnost, tacnost i sigurnost u skladu sa vazecim zakonima, tehnickim propisima i propisima za zastitu zivotne sredine. Cilj i svrha ovog projekta je integrisano, moderno, pouzdano, ekoloski prihvatljivo, precizno i centralizovano upravljanje i nadzor nad instalacijama na pretakalistu TNG-a u NIS-RNP, uz primenu metroloskih uslova i propisa Republike Srbije za obracunsko merenje. lzvodenje radova povereno je iskljucivo clanicama Delta grupe.

uklanjanje azbestne izolacije, pustanje u rad, vracanje jedinice urad i testiranje po zavrsetku radova. Cilj investicionog projekta je da se znacajno smanji emisija prasine iz 620 MW Bloka B1 ispod granica koje postavljaju Direktive o zastiti zivotne sredine Evropske unije. Direktive Evropske zajednice zahtevale su da blokovi A6 i B2 Termoelektrane Nikola Tesla budu u skladu sa najnovijim evropskim i srpskim zakonima o spremnosti za ispunjavanje Direktiva EU o velikim postrojenjima za sagorevanje, koje su stupile na snagu 1. januara 2008. godine. Ovo zahteva da elektro-filteri mogu da ispunjavaju ogranicenje emisije od 50 mg/Nm3 redovno i pouzdano. Evropska zajednica zeli da unapredi postrojenje elektro-filtera tako da se nivoi emisije podudaraju sa Direktivama EU o velikim postrojenjima i sa zakonima Republike Srbije, preko opsega opterecenja za preostali period rada stanica.

Maksimalne dozvoljene vrednosti (MDV) granicnih vrednosti emisije cestica prema Direktivama o velikim postrojenjima za sagorevanje su sledece:

OIL REFINERY PANCEVO

The modernization of Nonprocedural Plant in the project of LPG (Liquefied Petroleum Gas) Adaptation, will be carried out by introducing a new measurement technology at delivery and dispatch at the car and railway decanting of LPG, given that the existing car and railway decanting does not provide the required efficiency, accuracy and security in accordance with applicable laws, technical regulations and rules for the environment protection. The aim and purpose of this project is an integrated, modern, reliable, environmentally friendly, accurate and centralized management and control of installations at the decanting of LPG in NIS-ORP, with the application of metrological conditions and regulations in the Republic of Serbia for accounting measurement. Execution of works has been entrusted exclusively to the members of Delta Group.

RECONSTRUCTION OF ELECTROSTATIC PRECIPITATORS POWER PLANT NIKOLA TESLA

The maximum allowable values (MAY} of particulate emission limit values according to the Large Combustion Plants Directive are the following:

Serbia was awarded (Electric Power Industry of Serbia in Power Plant Obrenovac) with donation for the reconstruction of electrostatic precipitators at TENT B2 by a decision of the European Commission from 2010. At the open competition for the contractor was selected Western European Company Hamon. Delta lnzenjering has participated in the project realisation as a supplier of the filter supporting structure (steel structure) and casing. The works comprised the upgrade of the Electrostatic Precipitator System, which reduces the particulate emissions from Unit B1 below LCPD particulate emission limits for a sustained period of time that is consistent with the Environmental Acquits, as required under the Energy Community Treaty. The scope of designand contract works hasincludeddevelopment of the Detailed Design on the basis of the functional specification, delivery of materials and equipment, civil, mechanical and electrical works, as well as removal of asbestos-bearing insula-

tion, commissioning, return of the Unit in operation and testing on works completion. The objective ofthe investment project was to significantly reduce the dust emission from 620 MW Unit B1 below the limits set by the relevant EU Environmental Directive. DECrequires that Nikola Tesla A6 and B2 Units compile with the most recent European and Serbian legislation in readiness for the European Union Large Combustion Plant Directive (LCPD)l, which came into force on January P1 2008. This requests that the Electrostatic Precipitators (ESPs) be able to regularly and reliably­meet emission limit of 50 mg/Nm3

•

~ DEC, Directive ofEuropian community

~ LCPD, Large Combustion Plant Directive

~ EC, Europian Community EC wanted to enhance the precipitator plant, so that emission levels will comply with LCPD and with legislations of Republic of Serbia, over a load range for the remaining life of the stations.

'Directive 2001 /80/ec ofthe European parliament and of the Council from 23" October 2001

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SEKUNDARNO OTPRASIVANJE KONVERTORSKOG ODELJENJA ZELEZARA SMEDEREVO

U objektu celicana u okviru Zelezare Smederevo odvijaju se tehnoloski procesi prilikom kojih je dolazilo do vel ike emisije prasine i grafita.

lzmerene vrednosti ovih emisija su prelazile zakonom propisane vrednosti, pa je pokrenut investicioni projekat ciji je cilj smanjenje emisije u mikserskom i konvertorskom odeljenju celicane.

Americka firma Hatch napravila je studiju postojeceg stanja i resenje za smanjenje emisije prasine u atmosferu. Nihovo resenje je optimizovani sistem, koji maze da zadrzi vise od 95% struje dimnih gasova koji se oslobadaju tokom procesa proizvodnje celika. Studija postojeceg stanja i novo resenje uradeni su na osnovu modelovanja svih procesa pri kojima dolazi do emisije dimnih gasova.

U miksersko odeljenje dopremaju se lonci sa tecnim gvozdem, proizvedenim u visokim pecima. Pre ulivanja tecnog gvozda u mikser, svi lonci moraju da produ kroz postupak skidanja troske. U toku skidanja troske dolazilo je do velike emisije prasine i grafita. Procesi ulivanja i izlivanja tecnog gvozda u/iz miksera su takode bili izvori emisije prasine i grafita. Ovi procesi su bili pokriveni sistemom za otprasivanje koji nije bio u funkciji. U mikserskom odeljenju je zamenjen postojeci sistem za hvatanje struje dimnih gasova novim, koji je povezan na novi vrecasti filter.

Ponekad, kada uslovi proizvodnje to zahtevaju, nije moguce upotrebiti mikser za ulivanje tecnog gvozda u ulivni lonac, vee se obavlja tzv. prelivanje, odnosno direktan transfer tecnog gvozda iz visokopecnog lonca u ulivni lonac pomocu jednog od mikserskih kranova. Ovaj proces nije bio pokriven sistemom za otprasivanje,

iako se prilikom ovog procesa javljala velika emisija prasine i grafita. Novi sistem optprasivanja je obuhvatio i ovaj proces, odnosno izvor prasine.

U konvertorskom odeljenju izvori emisije su sami konvertori u kojima se vrsi proizvodnja celika iz tecnog gvozda, celicnog lama i raznih drugih legirajucih metalnih i nemetalnih dodataka. Na svakom od tri konvertora je ugraden i u upotrebi samo primarni sistem otprasivanja. Primarni sistem otprasivanja je najefikasniji tokom duvanja kiseonika u konvertor, kada se oslobadaju i najvece kolicine konvertorskih gasova. Medutim, u procesu ubacivanja gvozdenog i celicnog lama i ulivanja tecnog gvozda u konvertor, kao i pri izlivanja celika i troske iz konvertora, dolazilo je do emisije koja vecim delom nije mogla biti skupljena primarnim sistemom i koja se oslobadala u hali konvertorskog odeljenja i dalje kroz krov u atmosferu, te taka utica Ia na ukupnu emisiju cele zelezare.

Novi sistem za sekundarno otprasivanje se sastoji od novih hauba za hvatanje struja dimnih gasova, pripadajucih cevovoda, bloka vrecastih filtera sa pneumatskim otresanjem, odgovarajucih ventilatora i dimnjaka. Sistem je dokazao svoju efikasnost kroz ogromnu kolicinu sakupljene prasine i grafita koji se, umesto da budu ispusteni u atmosferu, vracaju u proces proizvodnje.

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SECONDARY DEDUSTING OF CONVERTER FACILITY SMEDEREVO IRONWORKS

In the Steel Mill Facility in Smederevo Ironworks are taking place technological processes which led to very high very high emission of dust and graphite.

The measured values of these emissions exceeded the legally prescribed values and therefore investment project was initiated, which aim is to reduce emission in the Mixer and Converter Facility of the Steel Mill.

Hatch, a North American firm, has made a study of the current situation and solution to reduce dust emissions in the atmosphere. Their solution is an optimized system that can hold more than 95% of the flue gases that are released during the production of steel. A study of the current situation and a new solution was made based on the modeling of all processes which lead to the emission of fiue gases.

In the Mixer Facility are delivered pots with liquid iron produced in a blast furnace. Before pouring liquid iron into the mixer all the pots have to go through the process of slag removing. In the course of slag removing has been plagued by high emissions of dust and graphite. The processes of casting and pouring of liquid iron to/from the mixer were also sources of dust and graphite. These processes were covered by dedusting system, which was not operational. In the Mixer Facility has been replaced the existing systems for capturing the fiue gases with new one, which is connected to a new bag filter. Sometimes, when the production conditions requires it, it is not possible to use the mixer for liquid iron infiowing in the pouring pot but to perform so-called overfiow, ie. direct transfer of liquid iron from the blast furnace pot into pouring pot using one

of the mixer crane. This process was not covered by dedusting system although during this process occurred large dust and graphite emission. The new dedusting system has covered this process, ie. source of dust.

In the Converter Facility sources of emission are converters themselves, which are used for production of steel from liquid iron, steel fracture and various other alloying metal and nonmetal elements. On each of three converters is installed and in use only the primary dedusting system. The primary dedusting system is most effective during oxygen blowing in the converter, when is released the largest amounts of the converter gases. However, in the process of iron and steel fracture inserting and liquid iron pouring in the converter, as well as during the outfiow of steel and slag from the converters there was an emission, which for the most part could not be collected by the primary system and which is released in the Converter Facility Hall and through the roof in the atmosphere and thus is affected the total emission of the whole Steel Mill.

A new secondary dedusting system consists of the new hoods for capturing of flue gases fiows, associated piping, the bag filters block with pneumatic shaking, appropriate fans and chimneys. The system has proved its effectiveness through an enormous amount of accumulated dust and graphite, which returns into the production process instead of being released into the atmosphere.

OTPRASIVANJE VISOKE PECI BR.4 ARCELOR MITIAL.ZENICA

Turska kompanija CVS izradila je CFD (Computational Fluid Dynamics) studiju i resenje za novi sistem za otrasivanje livne platforme u zgradi visoke peci br. 4 u kompaniji Arcelor Mittal u Zenici. Cilj ave studije je smanjenje emisije prasine u atmosferu. Njihova resenje je optimizovani sistem koji maze da zadrzi vise ad 95% struje dimnih gasova koji se oslobadaju tokom procesa izlivanja tecnog siravog gvozaa iz vi sake peci. Na osnovu navede­ne studije, proracunskih podataka i graficke dokumentacije koju je dobio ad kompanije CVS, Delta lnzenjering je uradio glavni projekt i usaglasio ga sa lokalnim propisima. Svrha ovog prajekta je postavljanje hauba ilili prekrivki na mestima presipa. Neke haube su pokretne zbog potreba odrzava­nja. Haube su povezane glavnim cevovodom sa novim filterskim postrajenjem.

Osnovni elementi ovog sistema za otprasivanje su: ~ Dve haube na izlivnim otvorima, po jedna za svako

izlivno mesto, ~ Dve haube iznad gibajucih rina, ~ Dve haube iznad skimera, ~ Postavljanje novog filtera, ukljucujuci i sistem lancastih

transportera za odvoaenje prasine i silos za prikupljanje prasine.

Novi sistem za otrasivanje bice opremljen opremom za automat­sko upravljanje da bi se kontinualno kontrolisale sve faze procesa.

CVS je predlozio instaliranje novog sistema za otprasivanje koji se sastoji ad:

~ Dve haube skimera sa kruznom odvodnom cevi kapaciteta po 80.000m3 /h

~ Dve haube na izlivnim otvorima. Ove haube se postavljaju da izvuku dim koji se stvara prilikom otvaranja izlivnog otvora sa kapacitetom po 250.000m3 /h

~ Dve haube se postavljaju iznad gibajucih rina taka da odvuku dim i prasinu koja se stvara prilikom presipanja sirovog gvozaa sa gibajuce rine u lonac, sa kapacitetom po 250.000m3 /h

~ Set kana Ia promera 01 OOOmm, 01800 mm i 02700 mm koji su rasporeaeni po rubu hale gde se nalazi livna platforma

~ Glavni cevovod promera 02700 mm za prikupljanje i odvodjenje dima i prasine do novog filterskog postrojenja, ukupnog kapaciteta 580.000 m3/h

~ Filtersko postrojenje sa ukupnom povrsinom filterske tkanine 6.500 m2

~ Sistem lancastih transportera za odvoaenje prasine koji se postavlja ispod konusa filtera i hvataca varnica i silos za skladistenje prasine zapremine 60m3

~ Dimnjak pramera 03.300 mm ~ Ova ventilatora sa asinhronim motorima snage po

1.500 kW.

Siravo gvozae i traska se izlivaju iz visoke peci i idu kana lima kraz gibajuce rine do lonca, odnosno bazena za granulaciju troske. Siravo gvozae i troska se razdvajaju pomocu ski mer bloka. Siravo gvozae ide do prenosnog lonca kraz gibajucu rinu, a troska u komoru za granulaciju troske.

Tokom izlivanja/livenja, teen a gvozae dolazi u kontakt sa atmos­ferskim kiseonikom (0) prilikom kretanja duz rine. Zbog visoke temperature (1300-1500°(), gvozae reaguje sa kiseonikom i form ira okside gvozaa (npr. Fe

203' takozvani bra on plamen).

Troska ne reaguje sa atmosferskim kiseonikom jer su njene komponente uglavnom vee oksidirane. lpak, alkalni oksidi (npr. Na

20 i K

20) mogu dais pare iz traske uz emisiju cestica.

U cilju zastite okoline na livnoj platformi i smanjenja emisije prasine u okolinu, otpadni gasovi puni prasine treba da se prikupljaju i ciste. Kolicine prasine u dimu su nepravilne, zavisno ad faze procesa, radnih uslova na izlivnim otvorima, ponasanja visoke peci tokom pracesa i pozicija ventila. Otpadni vazduh bice ociscen pomocu vrecastog filtera. lzdvojena prasina ce biti skupljena u konuse filtera. Dva ventilatora (jedan uvek u radu) izvlace vazduh koji u sebi ima veliku koncetraciju prasine. U filteru se odvaja prasinu iz vazduha, zatim kroz dimnjak u atmosferu izbacuje preciscen vazduh.

CVS Tehnologies, a Turkish company, has developed a CFD (Computational Fluid Dynamics) study and solution for a new dedusting system for the casting platform in Blast Furnace Building No.4 of Arcelor Mittal Zenica. The aim of this study is to reduce dust emission to the atmosphere. Their solution is an optimized system that can hold more than 95% of the flue gases that are released during the outflow of liquid pig iron from the blast furnace. Based on this study, budget data and graphical documentation received from the company CVS Tehnologies, Delta lnzenjering has developed a main design and coordinated it with the local regulations. The purpose of this project is to install the hoods and I or coverings in outpouring places. Some hoods are movible in case of maintenance need. The hoods are connected with a main pipeline to a new filter plant.

The basic elements of this dedusting system are: ~ Two hoods on outpouring openings, one for each outpouring

location, ~ Two hoods above tilt runner, ~ Two hoods above the skimmer, ~ A new filter, including the chain conveyors system for removal

of dust and dust collection silo, A new dedusting system will be equipped with an automatic management equipment in order to continuously control all phases of the process.

DEDUSTING OF THE BLAST FURNACE N0.4 ARCELOR MITTAL. ZENICA

CVS is proposed to install a new dedusting system consisting of: ~ Two skimmers hoods with circular drain pipe, with a

capacity of 80,000 m3/h ~ Two hoods on outpouring openings. These hoods are set

to get out the smoke that is created during the opening of outpouring openings, with a capacity 250,000 m3/h

~ Two hoods are placed above tilt runner to get out the smoke and dust that is created during the outpouring of pig iron from tilt runner into the pot, with a capacityof 250,000 m3 /h

~ Set of channels with diameter 01000 mm, 01800 mm and 02700 mm that are arranged at the edge of the hall where the casting platform is placed

~ The main pipeline with diameter 02700 mm for collection and removal of smoke and dust to a new filter plant, with a total capacity of 580.000 m3/h

~ Filter plant with a filter fabric, total surface of 6.500 m2

~ The system of chain conveyors for dust removal, which is placed under the filter cone, spark arrester and silo for dust

storage, with volume 60m3

~ Chimney, with diameter 03.300 mm ~ Two fans with asynchronous motors, with power

of 1.500 kW each.

Pig iron and slag are discharged from the blast furnace and went through the channels of tilt runner to the pot, ie. pool for slag granulation. Pig iron and slag are separated using skimmer block. Pig iron went to the transmission pot through tilt runner and slag in the slag granulation chamber.

During pouring/casting, liquid iron coming into contact with atmospheric oxygen (0

2) when moving along the tilt runner.

As a result of high temperature (1300-1500°Ct iron reacts with oxygen and forms iron oxides (eg Fep), so-called brown flame. Slag does not react with atmospheric oxygen, since its components are generally already oxidized. However, alkali oxides (e.g. Na

20 i

Kp) can evaporate from slag with particle emission.

In order to protect the environment on the casting platform and reducing of dust emission into the environment, waste gases full of dust should be collected and cleaned. The amount of dust in the smoke is irregular depending on the process stage, working conditions at the outlet openings, blast furnace conduct during the process and the valve position. Exhaust air will be cleaned using the bag filter. Separated dust will be collected in the filter cones. Two fans (one always in operation) extract air, which has a high concen­tration of dust. In the filter dust is separated from air and then purified air is ejected through the chimney into the atmosphere.

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ELEKTRO-PROJEKAT ARCELOR MITTAL ZENICA

TR . POZICIJA: D ..

ZAD. POZICIJA: 0 ..

TEMPERATLRA: D "C

~~ ZAD.VR~RAD

Postrojenje za otprasivanje visoke peci br. 4 u elektro smislu predstavlja koncept potpuno integrisanog automatizovanog tehnoloskog sistema.

Automatska stanica: PLC- Siemens 57 CPU 315-2 PNIDP HMI stan ice: broj stanica 2 I Siemens ET200M + KTP1000 basic color 10,4"TFT display Operatorska stanica: SCADA PC racunar I lnvensys In Touch 10.1 Glavni izazov ovog projekta bila je frekventna regulacija motora dva ventilatora sledecih karakterisitika: Un=690V, P=1,5 MW, brzina: (0 -1000) oblmin, struje (0-750) A

EKSPERTSKA KONFERENCIJA 0 CISCENJU DIMNOG GASA 2013. AND RITZ KONTROLA ZAGADIVANJA VAZDUHA

Predstavnici Delta inzenjeringa prisustvovali su ekspertskoj konferenciji u Gracu. Ovaj skup organizovala je firma And ritz, koja se, izme<iu ostalog, preko 30 godina bavi inovativnim tehnologi­jama u kontroli zaga<iivanja vazduha. Konferenciji je prisustvovalo preko 250 ucesnika iz evropskih zemalja, Juzne i Severne Amerike i Azije. Na sedamnaest predavanja ucesnici su mogli da saznaju mnogo novih podataka, detalja i cinjenica iz polja rada sa postrojenjima za proizvodnju elektricne energije i neophodnih (uz njih) postro-

jenja za preciscavanje dimnih gasova. Za ucesnike iz Srbije najinteresantnije predavanje je svakako bilo ono koje je odrzao Gernot Kaefer (preduzece Anritz) o najvecem postrojenju za desulfurizaciju dimnih gasova u Turceniju (Rumunija), koje uspesno radi preko 16.000 sati. U slikovitom Gracu, u divnoj sali u okviru manastira franjevackog reda Male brace, uz izvanrednu organizaciju i srdacno gostoprim­stvo domacina, skup je zavrsen pozdravnim govorom koji je odrzao dr Reissner, uz zelju da se ovakvi skupovi nastave.

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ZENICA DEDUSTING- ELECTRICAL PROJECT ARCELOR MITTAL, ZENICA

Dedusting Plant for the Blast Furnace No.4 in the electrical sense is the concept of a fully integrated automated technological system.

Automatic Station: PLC- Siemens 57 CPU 315-2 PNIDP HMI Stations: Number of stations 2 I Siemens ET200M + KTP1 000 basic color 10,4"TFT display Operator Station: SCADA PC computer I lnvensys In Touch 10.1 The main challenge of this project was the frequency motor regulation of two fans with following characteristics: Un=690V, P=1,5 MW, speed: (0 -1000) olmin, current (0-750) A

EXPERT CONFERENCE ON CLEANING OF FLUE GAS IN 2013

AND RITZ CONTROL OF AIR POLLUTION

The representatives of Delta lnzenjering attended the Expert Conference in Graz. This event was organized by the company Andritz. Over 30 years this company, among the other things, deals with innovative technologies for control of air pollution. The conference was attended by over 250 participants from European countries, North and South America and Asia.

At seventeen lectures, the participants were able to learn a lot of new information, details and facts from the fields of the electricity productionplantsand necessary (with them)ftue gas purification plants. For participants from Serbia the most interesting lecture was certainly one that was presented by Gernot Kaefer (company Anritz) about the largest Flue Gas Desulfurization Plant in Turceni (Romania), which successfully works over 16,000 hours. In the picturesque Graz, in the beautiful hall of the monastery of the Franciscan Order of Friars Minor, with excellent organization and warm hospitality, the meeting was ended with a speech of Dr. Reissner and with a desire thatsuch meetings be as many as possible.

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IMPRESUM lzdavac: DELTA INZENJERING

Privredno drustvo za konsalting, projektovanje i inzenjering Adresa: Milutina Milankovica 7G, 11 070 Novi Beograd

Telefoni: 011 7856 901, 7856 902 Fax: 011 3122 025

e-mail: office@deltainzenjering.rs www.deltainzenjering.rs

Urednik: Aleksandra Todorovic-Sucevic, PR Manager Dizajn: Agencija Citlik

Prevod: Ivana ACimovic Strucni saradnici:

Dragoljub Kos, Zoran Lekic, Predrag Nijemcevic, Dana Markovic, Nebojsa Ljutic, Slobodan Milojevic, Nebojsa Dutina,

Sveta Petrie, Milan Narandzic, Dragan Radicevic, Milos Debeljkovic Stampa: DMD stamparija

Tiraz: 500 primeraka

I delta inzenjering

L Privredno dru~tvo za konsalting, projektovanje i inZenjering

IMPRESSUM Publisher: DELTA INZENJERING Privredno drustvo za konsalting, projektovanje i inzenjering Address: Milutina Milankovica 7G, 11 070 Novi Beograd Phone: +38111 7856 901,7856 902 Fax: +38111 3122 025 e-mail: office@deltainzenjering.rs www.deltainzenjering.rs

Editor: Aleksandra Todorovic-Sucevic, PR Manager Design: Citlik Agency Translated by: Ivana ACimovic Expert Associates: Dragoljub Kos, Zoran Lekic, Predrag Nijemcevic, Dana Markovic, Nebojsa Ljutic, Slobodan Milojevic, Nebojsa Dutina, Sveta Petri(, Milan Narandzic, Dragan RadiceviC, Milos Debeljkovic Printed by: DMD printerhouse Number of copies: 500 printed copies