RALEX® - WATER TREATMENT

Company General Presentation

Aquatech India

Tomas Dornik, MEGA a.s., Czech Republic

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Our mission

To be preferred supplier of electro-chemical membrane processes providing

superior solutions and services with maximum respect to the environment.

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Company profile

We are innovative and constantly growing private company with more than 25 years of experience in the production of ion-exchange membrane and supply of membrane technologies

Family owned company (Mr. Lubos Novak, Ph.D.) author or co-author of patents (>20), research reports (>100)

especially in the field of membrane processes, president of Czech Membrane Platform, founder of electro-membrane processes in CR

Core business is production of ion-exchange membranes, spacers, membrane stacks and supply of complex electro-membrane technologies on the basis of own know-how

Processes and products are certificated by ISO (EU standards) and GOST-R (Russian Standards)

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History

1995 2012

1975 – 1981: Central laboratories of uranium industry (CSUP)

1981 – 1990: Research and Development Institute of CSUP

since 1985: Industrial production of membranes RALEX®

1991 – 1992: MEGA - VVÚ s.p. – state company

• since April 1992: MEGA a.s.

• 2000: MEGA-TEC s.r.o.

• 2007: MEGA ProfiLine

• 2008: MemBrain

• 2012: MEGA Ukraine

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Production Plant in Straz pod Ralskem

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MEGA Group

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MemBrain s.r.o. R&D (research and development)

Subsidiary of MEGA a.s., Quick transfer of results of research works to industrial applications

Headquarters: Stráž pod Ralskem, Czech Republic

Founded: 2008

Employees: 56 Activities are mainly focusing into:

- the latest processing trends in the field of membrane processes

- electro-membrane processes

- hybrid membrane processes

- bipolar membranes

- gas separation

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Membrane Innovation Center (MIC) is a unique Center focusing on research and innovation in membrane processes, which provides:

new infrastructure for research and innovation activities

modern equipment of analytical, technological and mobile laboratory

net of industrial and academic organizations

more than ten years experience in R&D

support for education and popularization of the field

MemBrain s.r.o. Membrane Innovation Center (MIC)

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Our Offer in Membrane Processes

Products Heterogenous ion-exchange RALEX membranes® (

www.ralex.eu) Electrodialysis equipment (laboratory, pilot, industrial) Electrodeionization equipment Electrophoretic cells (flat, tubular)

Membrane technologies (turn-key delivery) Electrochemical (ED(R), EDI) Complex process lines (integrated membrane processes)

R&D and other services Consultancy, expertise, designing Laboratory and pilot scale trials Guarantee and post-guarantee service Staff training

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Main Products & Applications

Processes

ED, EDR, EDI, (RO)

Segment Water Food Special Apps Replacement E-coat

Product EWTU, HPWU, (RWTU)

EWDU ELPU RALEXEL, RALEX EFC

Application

Sludge lake water

treatment

Whey demineralization

L-carnitineDesalination

Membranes(GE-Ionics, Schekino)

Anode cell tubular

Ammonium nitrate

condensate

Mother liquor demineralizatio

n

Gama–butyrobetain desalination

Spacers(GE-Ionics)

Anode cellflat

TertiaryTreatment

UF permeate demineralizatio

n

Purification of organic solution

Electrodes(GE-Ionics)

Membrane tube

Brackish water

desalination

Lactulose syrup demineralizatio

n

Glycol purification ED Stacks(Eurodia)

Membrane roll

Waste waterRe-use

Skim-milkde-ashing

XyloseDesalination

Ultra-pure water

production

Re-use of rinse water from

galvanizing plant

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Strategic partners:

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Electrodialysis (ED) is an electrically-driven method of removing dissolved ionic compounds

- Dissolved solids may exist in a form of ions that are either positively or negatively charged (cations or anions)

- When an electrical potential is applied across the ion-selective membrane, cations migrate towards the negative electrode (cathode) and anions migrate towards positive electrode (anode)

- The driving force is DC electric field

Definition of Electrodialysis

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Ions are nothing more than atoms or molecules that have gained or lost an electron(s).- Generated by salts, acids or alkalies dissociation in water

- Both types – organic and inorganic

- Independent movement in solution

Definition and Characteristics of Ions

Cation is a positively charged (loosing of electron) ion- Cations migrate to the cathode

Anion is a negatively charged (gaining of electron) ion - Anions migrate to the anode

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Ion-exchange membranes present ion-selective barries

Cation-exchange membranes (CM)- Selective transport of cations

- Anionic transport blocked

- Permselectivity about 96 %

Anion-exchange membranes (AM)- Selective transport of anions

- Cationic transport blocked

- Permselectivity about 96 %

Ion-exchange Membranes

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Basic characteristics- Series of alternating ion-exchange membranes separated by

spacers

- One cation and one anion exchange membrane plus two spacers = cell pair

- Spacers are alternately connected to internal manifolds for proper liquids distribution

- Platinum-coated titanium electrodes

Electrodialyzer – Heart of the ED Process

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Electrodialyzer – Heart of the ED Process

1- Manifolds with built-in collectors

2 - Electrodes

3 - Ion exchange membranes

4 - Spacers

5 - Tie-rods, washers and nuts

6 - Assembly pins

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Membrane Stack ED/EDR-II

Membrane stack EDR-III

RALEX EDR stacks for industrial applications

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Small capacity EWT technology units

P-series - EWTU P10 and EWTU P20 are compact, fully autonomous processing

units for small size projects till 15 m3/hour (EWTU P10) and 20 m3/hour (EWTU P20); also suitable for piloting and/or testing

- Both single pass and batch process applicable

- Up to three stacks in series (for single pass mode)

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Medium-capacity EWT technology units

M-series - M45 and M90 are compact, fully autonomous processing units for

medium-capacity size projects till 45 m3/hour (EWTU M45) and till 90 m3/hour (EWTU M90);

- Operating in single-pass through mode- M45 - arrangement in one line ; up to three stacks in series- M90 - arrangement in two lines; up to three stacks in series a s

standard, can be designed with 2 concentration loops as four stages technology

RALEX® EWTU M45 RALEX® EWTU M90

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Large scale EWT technology units

TwinLine90 12L/3S (approx. 500 m3/hour of product)

TwinLine90- Inlet hydraulic skid with reversal valves, pneumatic actuated- Two EDR lines, 2, 3 or 4 stages- Outlet hydraulic skid- Pipe collectors

One TwinLine90

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MEGA industrial applications of ED/EDR in Water Reuse and Desalination

Water Reuse - of biologically pretreated waste waters to produce water for

agricultural or landscape irrigation- of discharged water from industry to reuse it back to a process

(as process water, make up water for cooling towers, RO brine recovery)

- treatment of waste condensates from fertilizer industry to reuse ED concentrate back in the production process and diluate in water management of the company

- …

Desalination- of tailing ponds (mining industry) - of gas well waters- of brackish waters to produce drinking water- …

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MEGA industrial applications of ED/EDR in Water Reuse and Desalination

0,1 $/m3

1 $/m3

10 $/m3

M

B C

IX/A

IX

1 g/L 10 g/L 100 g/L

BWRO

SWRO

EDI

ED

R

EDR

Reverse Osmosis

Evaporation

Ion Exchange

E-Separation

ROEDRIX

EDR Evap

TDS

Cost

Desalination cost of various technologies

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MEGA projects in Water Reuse: Project “Depurbaix” Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation

Client: BEFESA/ACSA

Project: Municipal waste water (tertiary) treatment to produce irrigation water

Locality: Barcelona, Spain

Commissioning: 2010

Feed specification: Municipal wastewater after biological and mechanical pre-treatment; 3200 microS/cm

Quality of Product: < 750 microS/cm

Capacity of product: 4x 12.000 m3/day (4x 500 m3/hour)

MEGA technology: RALEX EWTU TwinLine90 48L/2S (EDR-III/600)

Mode: Single pass, water recovery 86%

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MEGA projects in Water Reuse: Project “Depurbaix”Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation

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Process block scheme

Feed into wetland areasFeed into river Llobregat

Tailing pond K II

Filtration

ED

Secondary settler

WWTP Actiflo®

Coagulation, Injection,

Maturation, Lamella Clarifier

Discfilter

Disinfection

UV

Cartridgefiltration

Agricultural Irrigation

UF, RO, Ultraviolet

Injection into aquifer to prevent saline intrusion

Sand filtration

hypochlorite

MEGA projects in Water Reuse: Project “Depurbaix” Desalination of biologically pretreated municipal waste water to produce water for agricultural irrigation

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MEGA projects in Water Reuse: Project „A.R.P.C.“Desalination of biologically pretreated waste water to produce make up water for cooling towers

Client: GEMWATER/ ARAK PETROCHEMICAL CORPORATION

Project: Desalination of biologically pretreated waste water from petrochemical

plant to produce make up water for cooling towers

Locality: Arak, Iran

Commissioning: 2010

Feed specification: Wastewater after biological and mechanical pre-treatment, 1800 microS/cm

Quality of Product: 85% of desalination degree (approx. 200-250 microS/cm)

Capacity of product: 210 m3/hour

MEGA technology: RALEX EWTU 6L/3S (EDR-III/500)

Mode: Single pass, water recovery 85%

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Tailing pond K I

MEGA projects in Water Reuse: Project „A.R.P.C.“Desalination of biologically pretreated municipal waste water to produce make up water for cooling towers

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Process block scheme

MEGA projects in Water Reuse: Project „A.R.P.C.“Desalination of biologically pretreated municipal waste water to produce make up water for cooling towers

Waste water from Complex

Activated sludge

Sand filters + Carbon filters

Cooling tower make up

EDRDAF

Clarifier

Evaporation pond

Cartridge filters

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Client: DIAMO s.p., zavod GEAM

Project: Desalination of tailing ponds created by uranium mining

Locality: Dolni Rozinka, Czech Republic

Commissioning: 1986, extension 1995, extension 2007

Feed specification: Alkaline tailing pond waters from uranium mining with approx. 35 g/l TDS, containing, especially anions SO4

2- (20 g/l), NO3-, NO2-, cations NH4 , Na+, Ca2+, Mg 2+, other metals as Mo, organic matters, uranium U

Pretreatment: Addition of lime and soda ash to precipitation Ca2+ and Mg2+ , sand filtration sorption of heavy metals and uranium on ionexchange colon

filled by LEWATIT, sorption of organic solids on acivated carbon

Capacity, composition: ED (membrane stacks ED-II) in Feed&Bleed mode- Feed: 65 m3/h, TDS approx. 35 g/l- Diluate: 50 m3/h, TDS 12-15 g/l; Concentrate: 15 m3/h, TDS

min. 100g/l

RO- Feed: 50 m3/h, TDS 12 g/l- Permeate: 35 m3/h, TDS less than 0,5 g/l; Retentate: 15 m3/h,

TDS cca 40 g/l

Quality of Product: Desalinated stream is discharged after pH controlle to a river, concentrate is evaporated to the final commercial product of pure Na2SO4

MEGA technology: Combination of ED and RO; ED: RALEX EWTU 30xED-II/200

ED Mode: Feed&Bleed

MEGA projects in Desalination: Project „GEAM“Desalination of tailing ponds (mining industry)

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Tailing pond K I

Tailing pond K II

MEGA projects in Desalination: Project „GEAM“Desalination of tailing ponds (mining industry)

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Tailing pond K II

Tailing pond water

Sand filtration

GAC Filtration (sorption of

organic solids)

ED

Drainage water Ca and Mg

precipitation

Lime,Na2CO3

Sorption of heavy metals and U (on ion

exchange columns)

RORiver

Evaporation, Na2SO4

crystalization

Process block scheme

MEGA projects in Desalination: Project „GEAM“Desalination of tailing ponds (mining industry)

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TClient: ZSNP a.s.

Project: Desalination of tailing ponds created after production of aluminium oxide

Locality: Ziar nad Hronom, Slovakia

Commissioning: 2003

Feed specification: Very high alkalinity waters (pH 13-14) from red mud tailing pond (nearly 10g/l of free NaOH, containing anions OH-, CO3

2-, cations Na+, K+, metals as Al (1g/l), heavy metals Cr, As, Mo, V and some organic matters)

Pretreatment: Neutralisation with H2SO4 and precipitation using FeSO4 plus floccculant, sedimentation and filtration, additional acidification and double filtration before electrodialysis itself

Capacity, composition: Feed: 14,4 m3/hr at 37 g/l TDS ; Diluate: 11,8 m3/hr at 6 g/l TDS; Concentrate: 2,6 m3/hr at 180 g/l TDS

Quality of Product: Desalinated stream is discharged after pH controlle to a river, concentrate is evaporated to the final commercial product of pure Na2SO4

MEGA technology: ED: RALEX EWTU 12xED-II/200

Mode: Feed&Bleed

MEGA projects in Desalination: Project „ZSNP“Desalination of tailing ponds (mining industry)

DIV

ISO

N O

F M

EMBR

ANE

PRO

CESS

ES

MEGA projects in Desalination: Project „ZSNP“Desalination of tailing ponds (mining industry)

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Tailing pond water

Floculant

Sedimentation Sand and anthracite filtration I

Decarbonation

(by air)

ED

NaClO2 (disinfection)

RiverNeutralization,

As and Cr precipitation

H2SO4,

FeSO4

H2SO4,

NaClO2 (disinfection)

Sand and anthracite filtration II

Bag and Cartridge filtration

Evaporation, Na2SO4

crystalization

MEGA projects in Desalination: Project „ZSNP“Desalination of tailing ponds (mining industry)

Process block scheme

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TClient: GP RESOURCES

Project: Small capacity unit - treatment of gas well waters

Locality: Alberta-Calgary, Canada

Commissioning: 2008

Feed specification: Gas well water, TDS in range 10 000 – 18 000 mg/l

Quality of Product: Drinking water for hog barns, TDS under 500 mg/l

Capacity of product: approx. 40 m3/day

MEGA technology: RALEX EWTU P10 1xEDR-II/200-0.8;

Mode: Batch

MEGA projects in Desalination: Project „GRP“Desalination of gas well waters

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MEGA projects in Desalination: Project „GRP“Desalination of gas well waters

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MEGA projects in Desalination: Project „GRP“Desalination of gas well waters

Process block scheme

Gas well water

Bag

filtration 1 µm

GAC Filtration (sorption of

hydrogencarbons)

EDR

Drinking water

Feed tank 1

Feed tank 2

EDR

Brine tank

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TClient: Aigües del Ter-Llobregat (ATLL)

Project: Pilot unit - treatment of river water to produce drinking water

Locality: Abrera, Barcelona, Spain

Commissioning: 2008

Feed specification: River water, < 2 000 microS/cm, problem s with high level of Trihalomethanes

Quality of product: Potable water, 400-500 microS/cm

Capacity of product: 10-12 m3/hour

MEGA technology: RALEX EWTU P10 2xEDR-III/150-0.8

Mode: Single pass

MEGA projects in Desalination: Project „Llobregat-Abrera “Desalination of brackish waters to produce drinking water

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MEGA projects in Desalination: Project „Llobregat-Abrera “Desalination of brackish waters to produce drinking water

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MEGA projects in Desalination: Project „Llobregat-Abrera “Desalination of brackish waters to produce drinking water

Process block scheme

Llobregat

River

KMnO4 Coagulant Floculant

Sedimentation

ClO2

Sand filtration

GAC Filtration (dechlorination)

RemineralizationCO2 CO2

Cl2 Cl2

Drinking water

EDR

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MEGA projects in Chemical Industry: Project „JSC Minudobreniya “Treatment of waste waters from fertilizer industry

Client: JSC MINUDOBRENIYA – Rossosh,

Project: Treatment of waste waters from production of NPK in order to reuse ED concentrate back in the production process. Diluate stream is used in water management of the company.

Locality: Rossosh, Russia

Commissioning: 2012

Feed specification: 60 m3/hour of wastewater from ammonia nitrate production, 1,7 g/l (mainly NO3, NH4

+)

Requirement for product: ED concentrate approx.100 g/l (1 m3/h), diluate approx. 0,05 g/l (59 m3/h)

MEGA technology: Pretreatment - Sand filtration plus microfiltration

RALEX® EWTU М90 2L/4S EDR-III/600; RALEX® EWTU P15 2xED-II/250;

Mode: 1. part: Basic demineralization on RALEX® EWTU M90 2L/4S EDR-III/600 operating in one-pass mode

2. part: The concentration on the two units RALEX® EWTU P15 2xED- II/250 operating in batch mode

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MEGA projects in Chemical Industry: Project „JSC Minudobreniya “Treatment of waste waters from fertilizer industry

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MEGA projects in Water Reuse: Project „JSC Minudobreniya - Rossosh“Treatment of waste waters from fertilizer industry

Pretreatment

EWTU M90 2L/4S

EDR-III/600

Sand filtration

MF

2 x EWTU P15

ED-II/250

Electromembrane processes

Buffer tank

Product 1: Diluate

TDS = 0,05 g/lFeed water

TDS = 1,7 g/l

Product 2: Concentrate

(NH4NO3) TDS above 100 g/l

Process block scheme

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Unit A25

Nominal Parameters

feed 25 m3.h-1, TDS 3.0 g.l-1 (as NH4NO3), temp. 20 – 40°C

diluate TDS 0.10 – 0.25 g.l-1

concentrate TDS 100 – 200 g.l-1

energy consumption 3.5 kWh.m-3 (of upper defined feed)

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Unit A25

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Unit A25

Advantages in Comparison to the Conventional ED Concept

without intermediate tanks, pumps and instrumentation

compact footprint

optimized membrane area

the same spare parts for both types of membrane stacks

all main components doubled

possibility to have 1 line in operation and 1 line in repair or CIP

fast start to full production with constant products quality

no waste production even during CIP (reprocessing by A25)

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MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“Treatment of waste waters from fertilizer industry

Client: AO KUYBYSHEV AZOT

Project: Treatment of waste waters from production of NPK in order to reuse ED concentrate back in the production process. Diluate stream is used in water management of the company.

Locality: Togliatti, Russia

Commissioning: 2013

Feed specification: 60 m3/hour of wastewater from ammonia nitrate production, 2,9g/l

Requirement for product: ED concentrate approx.120 g/l, diluate approx. 0,04 g/l;

MEGA technology: RALEX® EWTU М90 2L/4S EDR-III/600; RALEX® EWTU 4xED-II/250; 2xRALEX® EWTU HPW P32 8xEDI-X

Mode: 1. part: Basic demineralization on RALEX® EWTU M90 2L/4S EDR-III/600 operating in one-pass mode

2. part: The concentration on the two units RALEX® EWTU 4xED-II/250 operating in batch mode

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MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“Treatment of waste waters from fertilizer industry

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MEGA projects in Chemical Industry: Project „Kuybyshev AZOT“Treatment of waste waters from fertilizer industry

Pretreatment

EWTU M90 2L/4S

EDR-III/600

MF

Electromembrane processes

Buffer tank

Product 1: Diluate TDS = 0,04 g/l

Feed water

TDS = 2,9 g/l

Product 2: Concentrate

(NH4NO3) TDS above 120 g/l

EWTU HPW P32 8xEDI-X

EWTU 4xED-II/250

Process block scheme

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Client: VWS Brasil Ltda

Project: Desalination pretreated industrial waste water after MBR to prepare water for further industrial usage in a petrochemical complex

Locality: Itaboraí – Rio de Janeiro, Brasil

Commissioning: supposed 2014

Feed specification: Industrial waste waters after MBR; TDS 1200mg/l

Quality of Product: TDS 210 mg/l

Capacity of product: 425 m3/hour

MEGA technology: RALEX EWTU TwinLine90 12L/3S (EDR-III/550)

Mode: Single pass, water recovery 85%

MEGA projects in Water Reuse: Project „Petrochemical Complex - Comperj “Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage

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MEGA projects in Water Reuse: Project „Petrochemical Complex - Comperj “Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage

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Process block scheme

MEGA projects in Water Reuse: Project „Petrochemical Complex - Comperj “Desalination of mechanically and biologically pretreated industrial waste water for further industrial usage

MBR

Waste water from Complex

Nut schell filter

Carbon filters

Mix Bed

Oil separator

RO

Boiler feed

EDRDAF

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MEGA projects in Water Reuse: Project „Achinsk“Desalination of mechanically and biologically pretreated industrial waste water to achieve the limits for discharge

Client: BIOTECHPROGRESS

Project: Desalination of mechanicaly and biologically pretreated industrial waste water to achieve the ecological limits for discharge to watercourse

Locality: Krasnoyarsk, Russia

Commissioning: supposed 2014-2015

Feed specification: Industrial waste waters after biological and mechanical pretreatment; TDS 1300mg/l

Quality of Product: TDS 500 mg/l

Capacity of product: 500 m3/hour

MEGA technology: RALEX EWTU TwinLine90 12L/2S (EDR-III/550) + 6L/2S

Mode: Single pass, water recovery 85%

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Process block scheme

MEGA projects in Water Reuse: Project „Achinsk“Desalination of mechanically and biologically pretreated industrial waste water to achieve the limits for discharge

Tailing pond K II

EDR

Organic removal

MBR

Bag filtration (TSS removal)

Feed water TDS = 1,3 g/l

RO

Diluate TDS = 0,37 g/l

Concentrate TDS = 7 g/l

Crystalization

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TClient: METITO

Project: Drinking water supply

Locality: Belkhir, Tunisia

Commissioning: supposed 2014

Feed specification: Well water, TDS 2500 mg/l

Quality of Product: Drinking water, TDS under 1000 mg/l

Capacity of product: approx. 2x 800 m3/day

MEGA technology: 2x RALEX EWTU M45 2xEDR-III/500-0.8;

Mode: Single pass, water recovery 85%

MEGA projects in Desalination: „Project Belkhir“Desalination of well waters to produce drinking water

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Process block scheme

Well water 2,5 g/l

Sand filters

Drinking water supply < 1 g/l

EDR

Evaporation pond 12,2 g/l

Cartridge filters

MEGA projects in Desalination: „Project Belkhir“Desalination of well waters to produce drinking water

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EDI Process – How does it work

The EDI process uses ion-exchange membranes in combination with ion-exchange resin to provide a high purity water.

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MEGA Pure means MPureM36 Product Requirements

Application: industrial high purity water

Reduce system complexity and cost

Equal or better DI & Silica performance vs. state-of-the-art EDI

Improved mechanical construction

Improve stack robustness

Cost competitive also for large flow rates

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M36 Product Requirements

Flow rate 10-15 m3/h per stack

Interconnection up to 3 stacks

High Recovery

Hardness Tolerance

Low system cost

Competitive with MB

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GEAM Demonstration Unit

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Mpure Three Stack System

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Mpure Three Stack System

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Why consider MEGA as supplier?

EXPERIENCE: MEGA has long-term experience in developing, designing, manufacturing and supplying of electrodialysis (since 1985).

PROVEN AND REASONABLE: MEGA has a significant market position in electrodialysis supply for different applications and industries (reference list upon request)

KNOWLEDGE: MEGA has long-term R&D co-operation with reputable institutions concerning whey treatment and MEGA ProfiLine develops new dairy products based on demineralized whey. R&D subsidiary MemBrain Ltd. received budget approval for building and operation of Membrane Innovative Centre in the Czech Republic.

EU ORIGIN, SHORT DELIVERY TIME (for European & CIS customers): MEGA manufactures all key components for ED (membranes, spacers, stacks, equipment) based on own know-how in plant located in Central Europe. MEGA ProfiLine keeps main spare parts and consumables in local warehouse in Russia.

RALEX® - WATER TREATMENT

G11

Thank you for your attention.