Mamba Cement Reduce Hardness in Water Case Study

PROJECT TITLE:

Cement Industry
Process Water Treatment Plant – 2.6MLD

Problem Statement

This leading cement manufacturer in South Africa is making use of 2 water sources in its processes, Borehole and River. The challenge faced is high hardness levels in the source waters which causes scaling in heat exchange units such as condensers, coolers, cooling towers and boilers. Scaling reduces the work rate of equipment and systems. Hardness differs in all sources: River up to 350mg/l, Borehole up to 1000mg/l.

Solution

The solution was to build a water treatment plant that would reduce the hardness in the water via a chemical softening process providing soft water for the processes which in turn would increase the working capacity of all heat exchange units. This also increased the output of the waste heat recovery system increasing power output.

Plant Feed

Hardness level between 250 to 1000mg/l

Performance Target

● Up to 110 m3/hr plant production
● Hardness <50mg/l
● Conductivity <250microsiemens/cm
● RO recovery rate of 70-75%

Process

Chemical addition
Reaction tanks
Settling
Sand filtration
Reverse Osmosis
Sludge handling

Sustainability

The Cement production site has its own Waste Heat Recovery unit that generates power for the plant. Since the running of the new water treatment plant, the customer’s power generation has increased from 3MW to 5.5MW and 6MW.

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