Turnkey Plant Projects

Turnkey Plant Projects help reduce the cost of raw materials and also water to decrease their use and thus contribute to the Green Movement. The project is inclusive of primary, secondary, biological, tertiary and sludge treatment as well. It works on the principle of aeration and is low cost, consumes less power and highly effective. The plant functions smoothly according to the industry it is put in use to.

Details :

• Global environmental awareness and environmental legislation requires companies to operate in an environmentally acceptable way. End product users insist upon finest environmental standards in deciding to purchase a product. So an economical solution is needed to install equipment and systems to achieve all these parameters.
• K-Pack offers Turnkey Solution to all Industrial manufacturers to reduce cost of raw material and fresh water while reducing consumption of these valuable inputs.
• We help optimize effluent discharge thus creating efficient and cost effective operation, by reducing waste and recycling water.

We provide treatment plants for industries which include:

• Food and beverage
• Dairies Industry
• Leather
• Petrochemical Plants
• Textile dyers & washer
• Rubber and many more

Wastewater Treatment when run efficiently in a manufacturing unit can give substantial cost savings in all areas including

• Primary Treatment
• Biological
• Secondary
• Tertiary
• Sludge

Our Turnkey Solutions include Water Treatment Plants also in which we offer:

• Drinking / Potable water
• Water softening
•  Lamella clarifier
• Clear flocculation
• Filters
• Reverse Osmosis
• Chlorination units
• Ozone treatment
• Fundamental Principals Of Aeration

The activated sludge method of purifying sewage can be divided into two basic elements :

• The efficient supply of ample oxygen to support the bacteriological processes.
• Sufficient circulation of the tank contents to achieve intimate mixing of the activated sludge and sewage and to avoid practical disadvantages such as the deposition of sludge and slit.
• The action of the Aerating Cone combines these two basic functions with maximum efficiency. It was also recognised that mixing could be achieved most economically by mechanical means and the Aeration Cone is a highly efficient, which, in combination with the stationary uptake tube, and efficient mixing of the contents of the tank.
• The special designed blades of the Cone discharges the circulated liquid in a manner which achieves high uptake of oxygen as the liquid passes through the atmosphere and strikes the surface with great force. A very rapid solution of oxygen is thereby promoted, which is immediately utilised throughout the contents of the aeration tank because of the rapid circulation

• Salient Features Of Aerators
• High intensity Aeration process in the most efficient, economical and trouble free of purifying sewage by activated sludge process.

Outstanding advantages of process are:

•  Lowest Capital Cost.
• Lowest Power Consumption.
•  Lowest Maintenance Cost.
• Flexibility of Plant Design.
• Flexibility of Plant Operation.
• Continues Trouble Free Services.
• Simplicity of Mechanical Equipment.

The continuing development and success of high intensity Aeration process is possible because correctness of fundamental principles and development of Cone.

Clarifier

• Clarifier equipment is suitable for all sewage settlement applications and for the treatment of trade effluents and process liquors. It has, however, been designed with particular reference to the the need for rapid collection and withdrawal of activated sludge, which is accomplished by means of diametrically-opposed, continuous helical scrapers.
• Clarifier Setting Tank employs a fixed bridge which is made in a range to suit tanks from 4mtr to 35mtr.in diameter, with a recommended floor slope of (1:12) or 71/2°.
• In the standard arrangement, an inlet pipe passes under the tank floor and turns upwards at the centre to discharge the incoming liquid through a dispersion pipe into a deflector drum from which an even radial flow emerges. The settled effluent passes over a peripheral weir. Continuous helical scrapers sweep the accumulating sludge into a central well from which it is withdrawn through a sludge draw-off pipe. The scrapers are mounted on framework attached to the rotating dispersion pipe, the drive unit for which is mounted on the bridge structure.

Bridge : For tanks up to 55 ft. in diameter, the bridge is fabricated from channel sections. For tanks of greater diameter, a lattice girder bridge is provided. Steel bridges may be grit-blasted and zinc sprayed before painting if required. Aluminum alloy may be used as an alternative. Where dissimilar metals would otherwise be in contact, insulation strips prevent galvanic and electrolytic action. A walkway is provided on one side of the bridge to give access to the drive unit. Double-row tubular handrailing is supplied in all cases. For steel structures, both handrails and solid pillars are galvanised as standard without extra charge, in view of their susceptibility to corrosion, irrespective of the protection specified for the rest of the plant.
Drive : The drive unit, mounted on the bridge at the centre of the tank, comprises a fractional horsepower electric motor and reduction gearing, the output shaft being attached to the upper end of the dispersion pipe or driving shaft. This output shaft is carried in a robust housing incorporating journal and thrust bearings.
Scrapers and Sludge removal : Scraper arms are attached to the central dispersion pipe or driving shaft, and braced and stayed to prevent distortion. The cross members of each pair of scraper arms are extended as necessary toprovide mountings for a continuous helical scraper blade, fitted with a wearing edge of abrasion re-sistant synthetic rubber, which spans the radius of the tank. Sludge is conveyed by the scrapers to the central well.
Peripheral weir : The most economical type of weir plate is of steel with a machined, plain edge, adjustable for accurate setting. Vee- notched or castellated plates can also be provided, with aluminum alloy or plastic offered as alternative material in each case.
Side-wall scraper : This is available as an optional item and constitutes a framework, fitted with a renewable synthetic rubber wearing edge, mounted on the outer end of the scraper arm.
Scum-skimming device : Where provision for the removal of surface scum is required, a continuous scum-baffle is supported on brackets attached to the tank wall. A radial scum-blade which breaks the water surface is carried from the top of the deflector drum and supported from one scraper arm. A retractable, radial scum-barrier is mounted on the bridge structure. When it is desired to remove scum from the tank, this barrier is lowered to break the water surface immediately after the rotating blade has passed beneath the bridge, it forms an enclosed channel and, in this position, the mechanism is stopped. The collected scum is then withdrawn by operating a flap valve mounted in the scum-removal trough which connects with the outer sludge well.
Lubrication : Care has been taken to ensure that adequate lubrication is achieved with the minimum of attention and no part of the equipment requires lubrication more frequently than twice per year.

Sluice gate Design :

• Suitable for manual operation provision may be made for power operation
• Seasoned castings used for minimum distortion
• Construction of ample weight and maximum rigidity. Robust sections of frame and door and scientific ribbing for additional strength
• Adjustable wedge blocks to ensure positive closure of the shutter under low pressure or even back pressure conditions
• Rising or non rising spindle of mild steel or stainless steel material
• Foundation bolts for erecting the gate frame and operating hoist. A simple or worm geared operation hoist with gun metal nut and fitted with thrust ballbearing
• Wall thimble to enable to remove the frame and shutter without disturbing concrete.
• Adjustale wall brackets having vertical and horizontal adjustments
• Flush bottom closing if desired in-lieu of the bottom seating face can be provided

Specifications :

• Gate Fame: In closing grained homogeneous cast iron or mild steel fabricated with or without seating face secured by screws or rivets. Machined and hand scraped to match a similar face on door., Side guide strip of cast iron or mild steel with tapered wedges on the underside.

• Door: of cast iron with cast reinforcements ribs or mild steel plate with vertical and horizontal stiffeners having seating face secured by screws or rivets, duly machined and hand scraped to match on then back tapered wedges to match tapered side guide strips on frameIntegrally cast-lug to take a strong beating pin for non-rising spindle units on integrally cast pocket to accommodate a Gun Metal nut.

• Headstocks :The common arrangement for operating single faced slice by hand operation. Depending on the nature of the spindle floor mounted head stocks are offered with extension rods, coupled and guide brackets.
  
  • Cast Iron Pillar
  • Handwheel
  • Gun Metal Nut
  • Thrust Ball Bearings
  • Bearings Gun Metal Brushed are the Common Features

Bar Screens for Industrial Applications :

• In the field of Water Management, our establishment offers a wide range of Coarse and Fine Screen which are essentially a pat of the Sewage Treatment Plants and Effluent treatment plants.
• The technology incorporates SCREENING of influents in Sewage Treatment Plants as primary treatment. The primary objective is to remove (screen) considerable amounts of waste such as sand, gravel, cotton buds, plastic bags and pouches, floating rags etc.,.
  The process ensures very high capture rate of materials screened before it proceeds for further primary treatments.
• The design data offers FLEXIBILITY by proper positioning of screens at required degrees of inclination. The spacing of bars is the decisive factor in determining the degree of primary treatment.

Data Required:

• Spacing between the bars
• Channel Width
• Channel Height
• Discharge Height
• Maximum Water Height
• Influent flow in Ltr/sec
• Material of Construction

Feature:

• Bar can be replaced individually.
• Simple, rugged construction
• Heavy accumulation of screening managed easily
• No moving parts permanently under sewage
• All parts easily accessible for lubrication of screen.