SCALE-BAN TM

A Non Chemical Water Treatment Equipment

A Sustainable Solution For

Achieving Zero Liquid Discharge (ZLD)

Say No to RO Plant and Evaporators

(MEE) for achieving ZLD.

Utilize R. O. Reject water, ETP Treated

effluent and Raw water in cooling tower.

Achieve above 20 COC in cooling tower.

Maintain Cooling Tower Hardness over

10,000 ppm and TDS over 50,000 ppm.

Say No to conventional regenerating

Softeners.

Say No to expensive Anti - Scaling

chemicals.

SCALEBAN SCALEBAN
Say No to hard scale permanently in heat
transfer equipment.

Optimize energy consumption, maximize

production and avoid recurring/Hectic
maintenance of heat exchangers.
SCALEBAN installed at Siemens make 130 MW X 3 Nos.
Power plant Condenser of M/s BPSL Jharsuguda, Orissa, India

BE
REVOLUTION IN WATER TREATMENT... PROUD TO
INDIAN
 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

PANKAJ KUMAR
Managing Director

ABOUT US:

SCALE-BAN EQUIPMENTS PVT. LTD. (SEPL) was established in the year 1999 with its office
and manufacturing setup at Indore which is the largest Industrial & Commercial hub in central
India.

Today, the company has established itself well in the market and is known for its commitment, on
time Delivery, product performance, customer relations and after-sales-support. We offer
customized product for varied applications and with the experience gained in various industrial
segments, we have fine tuned our product specification for excellent results.

We manufacture patented (Patent Number 2335/MUM/2009) non-chemical water treatment

equipment by the name of SCALEBAN. This equipment eliminates deposition of hard scale in the
heat exchangers even when RO reject, ETP Treated Effluent or Raw water is used for Cooling
purposes. Thus SCALEBAN have proved as the most cost effective and sustainable solution for
achieving ZLD.

This online equipment which does not require any energy input and is to be installed in the
existing cooling water inlet line of heat exchangers. It does not require any regeneration or
maintenance and resulting in zero downtime of heat exchangers and zero performance
deterioration.

Having been in market for over a decade and a half, M/s SEPL have developed a vast data base of
satisfied clients, in various sectors like: POWER PLANT/ DISTILLERY PLANT / SOLVENT
EXTRACTION PLANT / HVAC / CHEMICAL PLANT / PAPER PLANT etc which have benefitted
by achieving substantial operational savings with our proven technology. The client credentials,
performance certificates, the projects we have undertaken are listed at our website
www.scalebanindia.com.

We are very optimistic and confident that SCALEBAN will not only continue to achieve Zero
liquid discharge (ZLD) across industrial spectrum but also save huge amount of water across
the globe.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

A FACT:
Only 0.007% of total water available on earth is potable which is being shared by all types
of Industries, Agriculture & House holds.

OUR VISION:
Our vision is to provide a Self Sustainable, Most Efficient and Cost Effective Zero Liquid
Discharge (ZLD) solution.

OUR MOTTO
Optimizing Production
Maximizing Water Conservation
Minimizing Water Pollution
WATER AND ITS PROPERTIES:
Water is nature's most wonderful and most useful substance. It is estimated that two-thirds of
earth's surface constitutes water. It also occupies a unique position in industries. It plays a very
important role as a coolant in heat exchangers. Water is very complex in nature and it contains a
lot of salts and minerals in dissolved form. Calcium and Magnesium salts present in water
determine the hardness of water and it is this hardness of water, which is the main cause for
insulating HARD SCALE formation in heat exchangers in various industries.
INSULATING PROPERTIES OF HARD WATER SCALING:
Scale formation is a common phenomenon in any industry using water as a coolant or for steam
generation.
Scaling has high thermal insulating properties, thus resulting in poor heat transfer efficiencies
(see graph below).
Apart from causing this drop in thermal efficiency, it also causes overheating of heat exchange
equipment and results in frequent shutdowns because of equipment choking or performance
deterioration. The cleaning process is recurring, tedious and it also greatly reduces the life of
various heat exchangers.

100
90
Efficiency Loss In %

80 74

60
60
48

40 38
27

20 18
11
4 7
0
0.3 0.5 0.71 3.1 4.7 6.3 9.5 12.7 15.8 19

Thickness of scale in mm

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

CHEMICAL CHARACTERISTICS OF WATER:

EFFECT OF RISE IN TEMPERATURE OF WATER/FLUID ON SOLUBILITY OF
CALCIUM AND MAGNESIUM SALTS:

As is known, the main cause responsible for formation of scale inside any equipment is the rise in
temperature of water/fluid flowing through it, since at higher temperatures, fluid has a tendency to
precipitate dissolved Calcium and Magnesium salts. A graphical representation of solubility of
these salts in water vis-a-vis it's temperature indicates that with the rise in temperature of water
from T1 to T2 the solubility of these salts reduces from S1 to S2.

Thus, with higher temperatures of water/fluid as it comes in contact with any heat exchange
surface, Calcium and Magnesium salts precipitate out and form scale on the surface of heat
transfer area.

SCALEBAN precipitates out these salts much before the water attains this critical temperature
due to its coming in contact with the heat exchange surface.

EFFECT OF INCREASE IN THE pH VALUE OF WATER/FLUID ON SOLUBILITY OF

CALCIUM AND MAGNESIUM SALTS:

Similar to its tendency to precipitate out dissolved Calcium and Magnesium salts at higher
temperature, water/fluid also tends to precipitate out dissolved Calcium and Magnesium salts at
its higher pH value i.e. when it tends to be slightly alkaline. A graph plotted above to illustrate
solubility of Calcium and Magnesium in water/fluid vis--vis its pH value indicates that, with the
rise in pH value of fluid from P1 to P2, the solubility of these salts reduces from S1 to S2 causing their
precipitation at higher pH values.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

HOW DOES SCALEBAN PREVENT SCALING IN YOUR EQUIPMENT?

A ++
Cu++ Zn

H2SO4

WORKING PRINCIPLE:
The working principle of SCALEBAN is very simple and proven. It incorporates use of Galvanic
Principle, Chemical Characteristics of water/fluid and Fluid Dynamics. SCALEBAN exploits
solubility characteristics of Calcium and Magnesium salts in fluid with change in its pH value.

SCALEBAN locally increases pH value of water/fluid before it reaches high temperature zone
and then precipitates out hardness causing salts as water/fluid flows through SCALEBAN.

HOW DOES SCALEBAN EXPLOIT THESE PRINCIPLES AND CHEMICAL

CHARACTERISTICS OF WATER/FLUID?
SCALEBAN is an online pipe shaped mechanical device which houses very specially designed
core that is Sintered with number of electronegative elements in their order of increasing electro-
negativity in the direction of water/fluid flow. As feed water/fluid passes through SCALEBAN, it
acts as an electrolyte while it comes in contact with the core placed inside SCALEBAN.

SCALEBAN makes use of Galvanic principle by locally enhancing the pH value of feed water/fluid.
Due to the Galvanic action, the core gets negatively charged and attracts the lightest ions present
in the fluid i.e Hydrogen ion towards itself. The relationship between pH of water/fluid and H+ ion is

expressed by the formula pH 1/H .
+

+
Thus, with the concentration of H ion becoming comparatively less in the water/fluid inside the
equipment, pH value increases, there by precipitating Calcium and Magnesium salts before it
comes in contact with hot tubes. Consequently, once the precipitation of these hardness causing
salts has taken place, further precipitation due to temperature variation is not possible.

SCALEBAN precipitates out Calcium and Magnesium bicarbonates in the colloidal form of
Argonite crystals much before the water/fluid attains the critical temperature of super saturation
due to its coming in contact with hot tubes.

These precipitated salts are in the colloidal form (small particles dispersed in another substance)
and are suspended in water/fluid, and because of their very small size and lighter weight, the
water/fluid owing through SCALE-BAN carries away these precipitated salts. THE NET RESULT
IS TOTAL PREVENTION OF HARD SCALE IN THESE SYSTEMS.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

SAVINGS & BENEFITS

a) IMPROVEMENT IN THE PLANT LOAD FACTOR (PLF):- SCALEBAN gives guaranteed
zero scale in condenser and other coolers resulting in constantly maintained efficiency of
the heat exchangers thus helps in improvement of PLF. Due to it's unique ability to
precipitate scale forming salts into very ne particles of colloidal nature, SCALEBAN does
not allow the deposition of these salts in heat transfer area, Moreover the precipitated salts
get re-dissolve in water/fluid as soon as they reach the zero velocity zone in cooling tower
basin, thus keeping the complete cooling tower circuit scale free.

b) REMOVAL OF EXISTING SCALE:- Due to the reduction of the free Calcium and
Magnesium from solution by the formation of their Carbonate crystals and the solubility
being constant, water/fluid can dissolve more salts, which it tends to pick up from the
existing scale in the system, thereby desalting scaled up systems. However, it is not
marketed as a scale remover, but as a scale preventer.

c) REDUCING WATER CONSUMPTION & WATER WASTAGE:- SCALEBAN has been

tested successfully to operate at very high level of hardness (10000ppm). This unique
ability of SCALEBAN gives freedom to use RO Reject & ETP treated water in Cooling
tower as make up water and allows it to increase cooling tower COC above 20, thus
reducing blow down quantity almost equivalent to drift and windage loses. This can make a
very unique, practical & most economical zero discharge condition.

d) PREVENT WATER POLLUTION:- With the reduction in blow down & consumption of
efuents like RO Reject & ETP treated water in cooling tower as make up water
SCALEBAN provides a great help in minimizing surface water pollution. Further,
elimination of dosing of chemicals like anti-scalant and stopping use of Softener,
SCALEBAN offers great help in reducing the water pollution.

e) ZERO RECURRING & MAINTENANCE EXPENSES:- SCALEBAN does not have any
operating & maintenance expenses thus is a t & forget system. Due to special design of
the core, SCALEBAN creates heavy turbulence in water/fluid owing through it, which
makes it a self cleaning & maintenance free equipment. Further since SCALEBAN does
not incorporate any moving part and any external energy source, it is a totally maintenance
free Equipment.

f) NO CHANGE IN CHEMICAL COMPOSITION OF WATER:- SCALEBAN does not change

the chemical composition of water, but instead, changes the nature of the scaling salts from
a dissolved state to a suspended state, thereby preventing scale build up.

g) NO RISK OF CORROSION:- Water softeners necessitate use of corrosion inhibitors, as

soft water tends to be corrosive. Similarly, chemical dosing reduces the pH of water,
thereby increasing the risk of corrosion. SCALEBAN on the other hand has the unique
advantage of preventing scale deposition without increasing the risk of corrosion.

h) NO INVESTMENT RISK:- SCALEBAN is sold with a 20 years Performance Guarantee. In

view of this, there is no investment risk on part of the user of the equipment. It also offers a
low pay back period, depending upon the type of industry and present means of water/fluid
treatment.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

POWER PLANT
SCALEBAN can be very gainfully installed in condensing type thermal power plants.
Typically, a 1000 MW power plant would require approximately 98000 M3 of water per day,
much of which is wasted resulting in higher operating costs for the plant. SCALEBAN
offers a huge saving potential by way of:
Saving this precious water.
Improving the Plant Load Factor (PLF) by optimizing condenser vacuum thus resulting in higher
power generation with better efficiency.
Reducing the plant down time required for condenser cleaning.
As one might expect, with millions of liters of circulating (cooling) water flowing through the
condenser tubes, anything that is contained within the water and flowing through the tubes, can
ultimately end up either on the condenser tube-sheet or within the tube itself. Tube side fouling for
surface condensers is caused mainly due to SCALING, which are crystalline forms of Calcium
and Magnesium salts.
Depending on the extent of this fouling, the impact can be quite severe on the condenser's ability
to condense exhaust steam coming from the turbine. As fouling builds up within the tubing, an
insulating effect is created and the heat transfer characteristics of the tubes are diminished
requiring the turbine to be slowed to a point where the condenser can handle the exhaust steam
produced. Typically, this can be quite costly to power plants in the form of reduced output,
increased fuel consumption and increased CO2 emissions. This "de-rating" of the turbine to
accommodate the condenser's fouled or blocked tubing is an indication that the plant needs to
clean the tubing in order to regain the turbine's rated capacity.

EFFECT OF EXHAUST PRESSURE/ VACUUM IN POWER PLANT:

Higher exhaust pressure i.e. lower vacuum, increases the steam consumption in the
turbine, keeping all other operating parameters constant. Exhaust pressure lower than that
specified, will reduce the steam consumption and improve the turbine efficiency. Similarly exhaust
vacuum lower than that specified, will lower the turbine efficiency and increase the steam
consumption.
Figures below represent the effects of exhaust vacuum on steam consumption and turbine
efficiency respectively, keeping all other factors constant for the condensing type turbine.

100 34.8
99 34.5
Steam consumption, %

98
34.2
Turbine efficiency, %

97
33.9
96
33.6
95
33.3
94
33
93
92 32.7
0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.93 0.92 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83

Exhaust vacuum, Kg/cm2 Exhaust vacuum, Kg/cm2

1. Effect of exhaust vacuum on steam 2. Effect of exhaust vacuum on turbine

consumption in condensing type turbine efficiency in condensing type turbine
2
These figures also indicate that an improvement in exhaust vacuum by 0.014 Kg/cm , reduces the
steam consumption in the turbine by about 1.1% and improves in turbine efficiency significantly
from 0.24% to 0.4%.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN
TO ACHIEVE MOST EFFECTIVE AND ECONOMIC ZERO EFFLUENT DISCHARGE PLANT
SCHEME FOR ZLD WITH SCALE-BAN A COMPARISON WITH CONVENTIONAL METHOD

SOFT RAW
AUXILLARIES BOILER AUXILLARIES SCALEBAN BOILER
WATER WATER

CONDENSER SCALEBAN
SCALE-BAN TM

DM PLANT CONDENSER DM PLANT

A Non Chemical Water Treatment Equipment

MAKE-UP WATER

MAKE-UP WATER
COOLING PUMP COOLING PUMP
TOWER DM / RO TOWER DM / RO

SOFTNER REJECT
REJECT REJECT
BOILER BLOWDOWN

BOILER BLOWDOWN
4COC 15-20COC
NEUTRALISATION

REVOLUTION IN WATER TREATMENT...

PIT
NEUTRALISATION
E.T.P PIT
BLOWDOWN
NEGLIGIBLE BLOW-DOWN

TREATED
WATER RO PLANT MEE ASH COOLING
RO
REJECT
WATER

WITHOUT SCALEBANTM WITH SCALEBANTM

Works only on soft / RO water. Can work on Raw / R.O. Reject / ETP treated / Sea / Bore well water.

Limitation of hardness & TDS. Already tested up to 10000 ppm Hardness and 50000 ppm TDS.

Recurring Expenses for preparation of soft water as make-up-water in Cooling tower. No Recurring and maintenance Expenses.

Fresh soft water consumption is more due to restricted COC. Tremendous SAVING of water as our equipment Works on higher COC.

Despite use of soft water and anti-scalant chemicals, scale is formed in Condenser / heat exchangers. ZERO SCALE Guarantee in Condenser / heat exchangers.

Cooling efficiency loss and poor vacuum due to scale formation. No efficiency loss and maintained vacuum due to ZERO SCALE.

Reduced power generation due to scale formation. Optimum power generation.

No guarantee against scale formation. 20 years performance Guarantee for ZERO SCALE.
 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

Estimated savings after installation of SCALEBAN

Plant Data
Power Plant Capacity in MW. 100
Flow of Re-Circulating Water M/Hr . 20000
Status prior to installation of SCALEBAN:
COC Maintained 5 COC
Evaporation Losses (L-e-) @1.5% of circulation rate [A] 300 M3 /hr
e
Blow Down from Cooling Tower = {Le / (COC-1)} [B] 75 M3 /hr
Total consumption per hour = [A]+[B] [C] 375 M3/hr
3
Total water requirement per Day = [C] x 24 as make up to cooling tower [D] 9,000 M /Day
Softener Regeneration Losses @ 5 % of total water requirement [E] 450 M3/Day

Status Changed after installation of SCALEBAN:

COC Maintained 15 COC
Evaporation Losses (L-e-) @1.5% of circulation rate [A1] 300 M3 /hr
Blow Down from Cooling Tower = {L e / (COC-1)} [B1] 21 M3 /hr
Total consumption per hour = [A1]+[B1] [C1] 321 M3 /hr
Total water requirement per Day = [C1] x 24 as make up to cooling tower [D1] 7,714 M3 / Day
Total savings of water per day = [D - D1] + E [E1] 1,736 M3 / Day

Total savings of water per year [E1] x 350 days / year [F1] 6,07,500 M3 / Year

1. TOTAL DIRECT SAVINGS AFTER INSTALLATION OF SCALEBAN

A. Saving due to less consumption of water, stoppage of softener operation and non
usage of anti-scaling chemicals
Cost of water saved = [F1] x Rs. 15/- per M3 [G] 91,12,500 Rs. Per Year

Cost Saved in ETP and R. O operations by reducing Blow-down for achieving [H] 90,00,000 Rs. Per Year
zero discharge = (B-B1) x 24hrs X Rs. 20/- X 350 days

Cost Saved on Softener Operation @ Rs. 2/-per M = D X Rs. 2/- X 350DAYS [I] 63,00,000 Rs. Per Year

Cost of Resin in softener (Top up) [J] 2,00,000 Rs. Per Year

Cost of Anti-scaling chemicals saved = Rs. 45000/- per month [K] 5,40,000 Rs. Per Year

Total Savings per Year (A) = [G+H+I+J+K] Rs. 2,51,52,500 Rs. Per Year

B. Savings due to proper HEAT EXCHANGE inside condense and lesser consumption
of High Pressure steam:

Profits reduced due to increase of 0.1Te of steam consumption per

MW for an average 75 days in a year due to scaling in condenser. Rs. Per Year
1,08,00,000
Considering normal consumption of 3Te of steam and cost of Steam
@ Rs. 600/- per Te

TOTAL DIRECT SAVINGS = A+B Rs. 3,59,52,500 Rs. Per Year

2. TOTAL INDIRECT SAVINGS AFTER INSTALLATION OF SCALE BAN:

Loss of fixed overheads due to forced plant shutdown of 3 days for De-
scaling:
Rs. 1,08,00,000 Rs. Per Year
Considering fixed profit to be Rs. 1500/- per MW;
Loss of profits = 1500x100MWx24 hrs.X3 days =

TOTAL [ DIRECT+INDIRECT] SAVING = Rs. 7,19,05,000 Rs. Per Year

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

DISTILLERY PLANT

Complete quantity of Condensate (Distillery & Sugar plant) /

Spent lees water can be consumed as make up water in
cooling tower along with RO Reject & raw water. Hence, costly
RAW WATER system like CPU can be bypassed & ZLD can be achieved in a
sustainable. Most efficient & Cost effective manner with
DISTILLERY SCALEBAN technology.
PLANT SPENT LEES

SPENT WASH
MAKE UP WATER
MULTI EFFECT PROCESS
EVAPORATOR CONDENSATE SCALEBAN

COOLING
SUGAR MILL SUGAR CANE JUICE TOWER
CONDENSATE

RO REJECT WATER SCALEBAN

CONDENSER
DISTILLERY & CO-GEN PLANT
RO PLANT / COOLERS

RO PERMEATE
Negligible Blow Down due to high CONDENSER
COC. Hence, it can be directly taken SCALEBAN
for ash cooling / dust suppression. / COOLERS
PROCESS
APPLICATIONS

SCHEMATIC DIAGRAM TO CONSUME CONDENSATE / SPENT LEES IN DISTILLERY & CO-GEN PLANT
COOLING TOWER TO ACHIEVE ZERO LIQUID DISCHARGE WITHOUT CPU (ZLD WITH SCALE-BANTM)

Advantages of using SCALEBAN are listed below:

Condensate (Sugar & Distillery) / Spent lees can be directly used in cooling tower as
makeup water without treating it further in C.P.U. (Condensate Polishing Unit).
Direct use of RO Reject & Raw Water in CT [Cooling Tower] as make up water.
Cooling tower will be operated at higher COC of 15-20 resulting in almost NIL blow down.
Reduced blow down and use of effluent quality water will reduce water Consumption thus
reduced water wastage & reduced water pollution.
Higher COC & Use of effluent quality water in cooling tower as makeup water will lead to
reduced load to MEE or use of MEE can be eliminated.
No need to use Soft water & anti-scalant chemicals in cooling tower.
Permanent relief from formation of Hard water scaling in tubes of Condensers & other heat
exchangers.
Due to scale free condition in condenser; recovery and quality of spirit/ENA is improved.
Increase in overall production from Distillery Unit because of better recovery of spirit/ENA
and as no shutdown of the plant is required for de-scaling of condenser.
No mechanical or chemical de-scaling required for condenser & other coolers; leading to
improved plant and machinery life.
SCALEBAN has zero operating and maintenance expenses (no electrical power and no
spares) and hence is a truly FIT & FORGET equipment.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

REFRIGERATION PLANT
Total elimination of hard water Scale in the cooling system of Refrigeration plant by
installation of our SCALEBAN Equipment.

CONDENSER WATER
COOLING
TOWER

CHILLER
Qout

SCALEBAN
CONDENSER
REFRIGERANT

MOTOR

EXPANSION
VALVE COMPRESSOR

EVAPORATOR
VFD

Qin
PRIMARY SUPPLY PRIMARY RETURN

Our Equipment SCALEBAN has been established in the market to give the following
savings in Refrigeration plant / cooling tower operation.
Zero Scale in condensers.
Optimum Head Pressure maintained in Refrigeration plant.

SCALEBAN Equipment is an online equipment which is fitted just before water cooled
condensers/ Heat Exchangers.
A brief description given below, will easily establish the benefits that can be achieved
by installing SCALEBAN:
Anti-scaling chemicals are not required in cooling water.
Descaling of heat exchangers is not required.
No Softening plant is required.
No shutdown of plant is required for cleaning of condenser / heat exchangers tubes, In
conventional water treatment system shut down of plant is required frequently to clean the
tubes Chemically / Mechanically, as the case may be.
Cost of manpower, Chemicals and Loss of production for a large number of days due to
shutdown is saved every year.
Due to repeated cleaning of the hard scales in tubes with rod & acid, the tube surface becomes
weak and prone to leakages. Any leak in condenser/cooler causes shutdown of plant and adds
cost of replacing tubes.
Head pressure in Refrigeration plant remains maintained which gives Considerable savings of
electricity.
Due to scale free system, optimum approach is maintained thus plant runs at optimum
efficiency.
REVOLUTION IN WATER TREATMENT...
 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

SOLVENT EXTRACTION PLANT

MAKE UP
MAKE UP RAW WATER / RO WATER
WATER REJECT / ETP
SOFTENER TREATED WATER
SCALEBAN
SOFTENER
REJECT COOLING COOLING
TOWER CONDENSER TOWER SCALEBAN CONDENSER
/ COOLERS / COOLERS
SOLVENT PLANT SOLVENT PLANT
EFFLUENT
TREATMENT PLANT
CT BLOWDOWN WATER
CONDENSER SCALEBAN
CONDENSER
/ COOLERS / COOLERS

CONVENTIONAL TREATMENT FOR COOLING WATER SCALEBAN TREATMENT FOR COOLING WATER

Total elimination of hard water Scale in the hexane condenser of extraction unit by
installation of our SCALEBAN Equipment.

Advantages of using SCALEBAN:

Zero Scale in condensers and other coolers.

Vacuum in condenser in plant remains improved which gives good efficiency of plant
and better hexane recovery, higher oil extraction with better quality, thus improving
profit.
Constant vacuum in stripping column.
Anti-scaling chemicals are not required in cooling tower.
Descaling of heat exchangers is not required.
No Softening plant is required.
RO reject water can be used as make up water in cooling tower, thus reduction of
effluent load of plant and saving fresh water equivalent to RO reject can be used
everyday.
No shutdown of plant is required for cleaning of condenser tubes, In conventional water
treatment system, shut down of plant is required frequently to clean the condenser
tubes Chemically (Caustic Circulation) / Mechanical Cleaning, as the case may be.
Cost of manpower, Chemicals and Loss of production for large number of days due to
shutdown is saved every year.
Due to repeated cleaning of the hard scales in tubes with rod, the tube surface becomes
weak and prone to leakage. Any leak in condenser/cooler causes shutdown of minimum
three days and adds cost of replacing tubes.
Due to scale free system, no drop in plant efficiency as happens with conventional water
treatment systems & plant continues to works at full loads.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

MULTI EFFECT EVAPORATOR

Condensate
injection
SCALEBAN

1st 2nd 3rd

effect effect effect
SCALEBAN

SCALEBAN
1

3
2
PUMP

SCALEBAN

Condensate Concentrate Product

Prevention of Hard Scale in your MULTI EFFECT EVAPORATOR by use of SCALEBAN

EQUIPMENT at Fluid / Effluents feed inlet lines and Fluid / Effluents re-circulating inlet
lines of Calandrias (each body of evaporator).

As Multi Effect Evaporator are the heart and soul of any fluid concentration process plant, any
scaling in its tubes causes tremendous loss due to excess consumption of Steam / fuel and also
reduction in capacity of production. Further descaling of these tubes through CIP (Cleaning In
Place) in itself is a time consuming, costly and tedious task.

In this context, we have introduced a non-chemical hard scale prevention equipment named
SCALEBAN Equipment for preventing hard scale formation in the tubes of Multi Effect
Evaporators and thus improving the efficiency of operation and delay the frequency of CIP and
time required for CIP.

As primary purpose of Multi Effect Evaporator is concentrating or thickening of fluid, preventing

hard scale formation result in delayed soft deposition which is very easy to clean.

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

OPERATING GUIDELINES FOR SCALEBAN:

pH value of the re-circulating cooling water should be maintained between 7.0 to 8.5 for optimal
results of SCALEBAN.
There should not be any Zero velocity zone between SCALEBAN and heat Exchanger /
Condensers to be protected.
There should not be any valve or strainer between SCALEBAN and Heat
Exchanger/Condensers.
Cooling tower sump should be cleaned for any sludge/debris etc. before start of operation.
Side Stream filter should be operated regularly with open top back wash regularly.
pH should be maintained by dosing pH maintaining Chemicals or by commercial grade H2SO4.
The Quantity of Sulphuric Acid (H2SO4) dosing can be finalized on commencement of the
operation as it is dependent on the Sump holding capacity, quality of water, pH of makeup
water, flow rate, evaporation and drift losses etc.
Continue with anti corrosive treatment & Bio fouling prevention treatment as per requirement.

PERFORMANCE TEST AFTER SCALEBAN INSTALLATION

Analysis of test result

CHLORIDE TEST FOR SCALING CONFIRMATION

TYPE OF TEST RAW WATER RE-CIRCULATED WATER

Total Chloride C1 C2
Total hardness H1 H2
Analysis of test result
If
C2 / C1 = H2 / H1 10% SAFE; SYSTEM NOT SCALING

C2 / C1 > H2 / H1 UNSAFE; SYSTEM IS SCALING

C2 / C1 < H2 / H1 SYSTEM IS DE-SCALING

REVOLUTION IN WATER TREATMENT...

 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

SCALEBAN INSTALLATION

Ensure that the Heat Exchanger / Condenser is properly

De-Scaled and thoroughly cleaned before installation of
SCALEBAN.

Identify the location for installation of SCALEBAN, (which should

be nearest to the Heat Exchanger / Condenser inlet) and there
should not be any valve or strainer between SCALEBAN and heat
exchanger.

First measure the length of SCALEBAN to be installed.

Cut the equivalent length from inlet line at a point nearest to the
heat exchanger. Weld both the matching flanges provided with
SCALEBAN on both cut ends of the inlet line.

Properly place SCALEBAN between these two flanges such that

direction arrow on SCALEBAN is in the direction of water flow.

Complete the installation by inserting gaskets and properly

tightening all the bolts and nuts supplied with SCALEBAN.

Incase of any query regarding installation please consult us.

REVOLUTION IN WATER TREATMENT...
 COMPARISON BETWEEN CHEMICAL DOSING &
WATER SOFTENER Vs SCALEBAN

S.No. Parameters SCALEBAN Chemical Dosing Water Softener

Composition of Chemical composition of Chemical composition of water Chemical composition of water changed.
1 changed due to dosing of chemicals. Nature of water becomes corrosive.
Water water remains same.
SCALE-BAN TM

Heavy monthly expenses in procurement,

No Recurring Cost Only One Heavy recurring expenses. inventory, storage, handling and supervision
2 Recurring Cost
A Non Chemical Water Treatment Equipment

time investment. of chemicals and salts to be dozed.

already tested up to 10000

Limitation varies as per chemical Restricted level of chlorides in re-circulation.
3 Limitation ppm Hardness & 50000 ppm
suppliers.
TDS.
Requires daily maintenance and Requires regular maintenance and

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4 Maintenance No maintenance required.
check of water quality. supervision.
No man power required as
5 Requires extra manpower for Special manpower required for regeneration
Man Power SCALEBAN is an online
monitoring and dosing of chemicals. of resin and operation.
equipment.

Power No Power required for power is consumed to operate

6 operation thus saves the Needs electrical energy for operation.
Consumption dosing pumps.
electricity bills.
Increases water pollution. Disposal of untreated Brine water is a major
7 Pollution No pollution.
problem.(increased pollution of water).
No space is required as it is Space for softener and storage of salt is
8 Space Extra space for storing chemicals. required.
installed online.

No extra inventory to Minimum one month inventory to be Minimum one month inventory to be
9 Inventory
maintain. maintained maintained.
10 COC In CT 15 To 20 2 To 6 (depends on Makeup) 3 to 5
11 Pay back Low payback period. NIL. NIL.
20 Years Performance NO Performance Guarantee against Scale
12 Guarantee NO Performance Guarantee
Guarantee for zero Scale. Formation.
 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

UNSOLICITED LINES OF PRAISE FROM FEW OF OUR MANY SATISFIED

CUSTOMERS ON THE BENEFITS OF SCALEBAN EQUIPMENT ACHIEVED BY
THEM....

SCALEBAN INSTALLED IN 2 x 490 MW POWER PLANT SCALEBAN INSTALLED IN 3 X 300TR VAM, VACUUM PUMP,
(UNIT 5 & 6) OF NTPC LIMITED, DADRI (UP), INDIA TG-PHE UNIT OF NTPC LIMITED, DADRI (UP), INDIA

SCALEBAN STALL AT NTPC O & M CONFERENCE SCALEBAN INSTALLED IN 130 MW X 3NOS, 60MW, 40MW
ON 13-14 FEB, 2015 IN DELHI, INDIA AND 8MW POWER PLANT OF M/S BPSL (OR), INDIA

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 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

SCALEBAN INSTALLED IN 90KLPD DISTILLERY UNIT OF SCALEBAN INSTALLED IN 45KLPD DISTILLERY UNIT OF
M/S WAVE INDUSTRIES LTD., ALIGARH (U.P.), INDIA M/S OAISIS ALCOHOL LTD., SATARA (M.H.), INDIA

SCALEBAN INSTALLED IN 1380TR VAM UNIT OF SCALEBAN INSTALLED IN 1000TR VAM UNIT
M/S CCL PRODUCTS LTD., DUGGIRALA (AP), INDIA / VIETNAM OF M/S ALEMBIC LTD., BARODA (GJ), INDIA

SCALEBAN INSTALLED IN 3 X 44TR CHILLER UNIT SCALEBAN INSTALLED IN MEE UNIT

OF M/S AARTI INDUSRIES LTD., PITHAMPUR (MP), INDIA OF M/S YASHASHWI FISH MEAL LTD., MANGALORE (KA), INDIA

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 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

SCALEBAN INSTALLED IN 2 X 1350 TPD UNIT OF SCALEBAN INSTALLED IN 8MW X 2NOS, 10MW X 1NO & 16MW X 1NO
M/S CHAMBAL FERTILIZER, KOTA (RJ), INDIA POWER PLANT UNIT OF M/S SHREE BAJRANG POWER & ISPAT LTD.,
Borjhara, Urla, Raipur (CG), INDIA

SCALEBAN INSTALLED IN 3MW POWER PLANT UNIT OF SCALEBAN INSTALLED IN 1000, 600 & 400 TON SOLVENT UNIT OF
M/S SAINSONS PAPER INDUSTRIES LTD., KURUKSHETRA (HR), INDIA M/S VIPPY INDUSTRIES LTD., DEWAS (MP), INDIA

PERFORMANCE CERTIFICATE

SCALEBAN INSTALLED IN 40MW POWER PLANT UNIT M/S MAHAKALI FOODS PVT. LTD. M/S BALAJI POWER M/S PEARL DISTILLERY LIMITED
OF M/S BENGAL ENERGY LTD., KHARAGPUR (WB), INDIA (SOLVENT PLANT) (BIOMASS PLANT)

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 SCALE-BAN TM
A Non Chemical Water Treatment Equipment

SELECTION
SCALEBAN is selected on the basis of:
[A] Water flow (M3 per hour) rate,
[B] Diameter of Cooling Water line.
Pipe Diameter Minimum Flow Maximum Flow Pipe Diameter Minimum Flow Maximum Flow
Model Model
(Inch) (M3/Hr) (M3/Hr) (Inch) (M3/Hr) (M3/Hr)

SEB-01 3/8 0.5 1.1 SBE-10 24 2810.0 3475.0

SEB-02 1/2 1.0 1.7 SBE-11 26 3297.8 4078.3

SBB-01 3/4 1.5 3.3 SBE-12 28 3824.7 4729.3

SBB-02 1 3.0 4.8 SBE-13 30 4390.6 5429.7

SBC-01 1-1/4 4.5 8.0 SBE-14 32 4995.6 6177.8

SBC-02 1-1/2 7.5 13.3 SBE-15 34 5639.5 6974.1

SBC-03 2 12.0 21.0 SBE-16 36 6322.5 7818.8

SBD-01 2-1/2 19.0 27.5 SBE-17 38 7044.5 8711.6

SBD-02 3 25.0 44.0 SBE-18 40 7805.6 9652.8

SBD-03 4 40.0 93.0 SBE-19 42 8605.6 10642.2

SBD-04 5 85.0 143.0 SBE-20 44 9444.7 11679.9

SBE-01 6 133.0 210.0 SBE-21 46 10322.8 12765.8

SBE-02 8 198.0 375.0 SBE-22 48 11240.0 13900.0

SBE-03 10 360.0 590.0 SBE-23 50 12169.2 15082.5

SBE-04 12 565.0 850.0 SBE-24 52 13191.4 16313.2

SBE-05 14 820.0 1170.0 SBE-25 54 14225.6 17592.2

SBE-06 16 1135.0 1530.0 SBE-26 56 15298.9 18919.4

SBE-07 18 1490.0 1940.0 SBE-27 58 16411.2 20295.0

SBE-08 20 1880.0 2400.0 SBE-28 60 17562.5 21718.8

SBE-09 22 2320.0 2910.0

NOTES:
1. Approximate Length of SCALEBAN is one meter.
2. SCALEBAN is supplied in flanged or screwed end connections with matching flanges.
3. The equipment is tailor made as per specific requirements of the application.

Manufactured & Marketed by :

SCALE-BAN TM Equipments Pvt. Ltd.
212, 2 nd Floor, Silver Sanchora Castle, JV PARTNER
8/2, R.N.T. Marg, Indore, Madhya Pradesh (INDIA), 452001
Phone : 0731 4044059, 3042456, 6542550,
Telefax : 0731 4084402, 4041974,
Email : info@scalebanindia.com, scaleban@gmail.com
Website : www.scalebanindia.com

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