HRUSHIKESH - TURNKEY PHARMACEUTICAL WATER TREATMENT SYSTEM Started in 1995, Hrushikesh Water Sciences Pvt. Ltd. has developed into a leading turnkey process engineering company specializing in purified water, highly purified water, water for injection (WFI), ultra filtration, pure steam, CIP/SIP and UV Sterilizers systems to the pharmaceutical industry.

KEY FEATURES:

• Full Recirculating RO/EDI System per cGMP’s
• Flowrates from 300L/hr to 10,000L/hr
• Sophisticated GAMP4 PLC based control System with large colour, touch screen HMI
• USP28 compliant for purified water and WFI
• EP compliant for purified and highly purified water
• Integrated CIP system
• RO/EDI recycles to minimise water sent to drain
• Water quality of < 1.0 µs/cm, < 250ppb TOC, < 50 cfu/ml and < 0.25eu endotoxins
• Hot water sanitizable membranes.
• Hot water sanitizable electro-deionisation unit (EDI).
• Multi-Stage 316 SS Reverse Osmosis Feed Pump
• Sanitary 316L SS Diaphragm Valves / Sample Valves
• Sanitary 316L SS RO Vessels
• ASME BPE compliant 316L SS Hygienic Product Piping beginning at the RO permeate ports
• Product Conductivity Monitors at RO & EDI outlets with 3-way diversion valves.
• Polished SS Frame
• 50Hz/415V/3-PH
• Full FAT, IQ and OQ prior to shipment.
• Validation Documentation

OPTIONAL FEATURES

• Custom Pretreatment
• SKADA / Recorder for on-line monitoring
• Integration with Storage & Distribution System
• Installation Qualification & Operational Qualification Protocol Templates
• Any national and international electrical standard, i.e. 380v/50hz
• Electropolished product contact piping
• cGMP welds video borescoped
• Site Training
• Sanitary UV Disinfection Unit

Our Products Includes:

• Clarifiers
• Clari-floculators
• Solids Contact Clarifiers
• Inclined Plate Clarifiers
• Sand Filters
• Dual Media Filters
• Activated Carbon Filters

We sincerely take up the initiative of setting up water treatment plants. While installing, our major criteria not only lies in meeting with the time specifications, but also the highest level of engineering standards. All the required equipment are very well installed and we make sure that these are user-friendly. Adding to the user-friendliness, we ensure that minimum maintenance is required though we are always there to support at the site.


Through our set up, our major aim lies in identifying quality & quantity requirement of the client. We ensure that we never compromise in the appropriate selection of equipments and identify the required level of automation.

R.O is a membrane process that acts as a filter to remove up to 95 - 99 % of all dissolved minerals, 95 - 97 % of most dissolved organics, and more than 98 % of biological and colloidal matter from water

The water is passed over a membrane under pressure. Depending on raw water quality a larger or smaller part of water goes through membrane, leaving most of the dissolved solids behind. These solids and leftover water (reject) leaves membrane surface and is piped to drain. The water which goes through membrane and gets purified is called permeate. The equipment which accomplishes the process is called a Reverse Osmosis (R.O) Unit

An R.O Unit only passes some of Total Dissolved Solids (TDS) through membranes. The percentage which gets through is called TDS-passage or salt-passage. At a given value of salt-passage TDS, or “quality” of permeate will change as feed TDS changes.

An approximation of TDS in water can be attained by using a conductivity meter.

Along with the amounts of solids passing through membranes, to be considered is the amount of purified water retrieved from feed water. This is called recovery which is usually stated as a percentage. Normal recoveries are in the range of 40 - 80 % for brackish water and 10 - 40 % for sea water.

The recovery of R.O system is preset during commissioning. When recovery is changed, so is the salt-passage. On the other hand, if system is run at a lower recovery, there is a better permeate water quality.

The amount of water passed through membranes is directly proportional to the net pressure on them. Increasing system pressure increases permeate flow rate. Thus, if pressure is raised and reject flow rate is held fixed, the recovery goes up.

Similarly, if system pressure is held fixed and reject flow rate is made to decrease, the recovery also goes up. If, at a constant pressure, reject flow were stopped altogether, the recovery would be 100 %. There must always be enough reject flow to flush out rejected salts.
The temperature of feed water can change the output by as much as 50 % in the range from nearly freezing to 40??? C. Unfortunately, it is not always possible to control temperature of the water, which varies depending on the location and time of the year.

Pre-Treatment for R.O Systems
The physical and chemical nature of many natural waters is such that it is not suitable to be treated directly by reverse osmosis. The process and equipment required to “condition” the feed water are referred to as pre-treatment.

The presence of very fine particles can cause severe blockage to the membranes. A measure of concentration of these fine particles in the feed water can be assessed by performing a “Silt Density Index” test of the water. To do this an SDI test kit is needed.

Some of the potential problems which may require pre-treatment include limited solubility of some salts, suspended solids and membrane degradation in the presence of, for example, strong acids, excessive concentration of chlorine or biological growth.

Typically, pre-treatment consists of:

• coagulation and filtration to remove large particles
  
• adjustment of solubility parameters to prevent precipitation of sparingly soluble salts (scaling) as a result of the concentration action of the R.O process
  
• chemical treatment to prevent biological growth
  

We provide RO Systems from 250 Liters/hr to 200 m³/hr with Multiple Unit Arrays.

Systems are provided complete with instrumentation for flow, conductivity, pH, TOC, etc. And complete automation with PLC / DCS /SKADA and intigration with up-stream / down-stream equipments.

We also provide the complete Pre-treatment designed as per feed water quality for enhanced and trouble free life of RO unit

Taking all the specifications of the clients, we set up the ultrafiltration plant. The plant project is executed by assigning the respective jobs to the vendors for proper electrification, pipe fitting, fabrication, erection, automation and other works. While working, time specification, location and other important aspects are taken into consideration.

Ion exchange technology is used to remove salts (cations and anions) from the water Soluble chemical compounds, when dissolved in water, become ionized; that is their molecules dissociate into positively and negatively charged components called ions. Consider common table salt, sodium chloride. In its solid form, this compound consists of one sodium atom (Na) and one chlorine atom (Cl) tightly coupled together (NaCl). When dissolved in water, however, the compound splits into two ions, Na and Cl-

Ion Exchange
A process in which Contaminant ions are exchanged from water is called ion exchange. This process occurs in ion exchange resin
Initially, resin is loaded with hydrogen (H ) ion for cations and hydroxide (OH-) ion for anions. As water passes through the resin, the contaminant ions in the water displace the loaded ions from the sites on the resin. This is because the resin has a greater affinity for the contaminant ions. Affinity for most resins is based loosely on ionic size and charge

Regeneration
Over a period of time most of the cation resin gets converted into Ca, Mg, Na form and it has no Hydrogen Ions (H ) to replace Ca, Mg, Na ions and the anion resin gets converted into Cl, SO4, SiO2 form and it has no Hydroxyl Ions (OH-) to replace Cl, SO4, SiO2 ions.. This is called the resin exhaustion or end of service cycle. The exhausted resin has to be brought back into Hydrogen (H ) Hydroxyl (OH-) form to continue the process and use it again and again. The procedure of converting exhausted resin into Hydrogen (H ) Hydroxyl (OH-) form is called regeneration

Separate Bed DM Systems
Ion exchange occurs across at least two different columns. The first is a cation column, which is filled with resin loaded with positive hydrogen ions (H ). As water passes through this column, the positively charged impurities in the water are exchanged for the hydrogen ions
A similar exchange takes place in the second column, the anion column. This column is filled with resin loaded with negative hydroxide ions (OH-). As the now cation-free water from the cation column passes through, any negatively charged contaminants are removed from the water and replaced by hydroxide ions from the resin. The water now has a neutral pH. hydroxide [OH-] and hydrogen [H ] ions exchanged in the columns combine, forming water [H2O)

Mixed Bed DI Systems
In a Mixed Bed DI System water is purified by removing all ions in one pass through an ion exchange bed. The bed consists of cation and anion resins in mixed condition, so that ions are actually removed in the same two step ion exchange process. All the traces of Cations and Anions of the dissolved solids and silica in the water are replaced by Hydrogen ion (H ) and Hydroxyl Ion (OH-) respectively. We get very high purity de-mineralized water at the outlet of the MB

Water Quality
The conductivity of pure water has been calculated to be 0.018 micro-siemens/cm @ 20 degree C. The conductivity of treated water from Seaprate Bed DM / DI Systems is about 1-2 micro-siemens/cm and a Mixed Bed System is usually less than 0.2 micro-siemens/cm

Applications

• Boiler Feed Water
  
• Process Water
  
• Chemical Industries
  
• Pharmaceutical Industries
  
• Fertilizer Industries
  
• Textile Industries
  
• Food Processing Industries
  
• Breweries
  
• Electronic Industries
  
• And many more, where pure water is required
  

We provide DM plants from 2 m3/hr to 200 m3/hr. All plants are designed as per good engineering practices. Mechanical designs are made as per IS / ASME or required international standards. We provide manual, semi-automatic or fully automatic plants with PLC / DCS / SKADA
 

Process of Electrodeionization
The Electropure EDI design combines two well-established water purification technologies electrodialysis and ion-exchange resin deionization. Through this revolutionary technique, dissolved salts can be removed with low energy cost and without the need for chemical regeneration; the result is high-quality pure water of multi-M_.cm resistivity which can be produced continuously at substantial flow rates. EDI removes ions from water by forcing them out of the feed stream into adjacent streams via an electric potential. The resins operate in steady state; they act not as an ion reservoir but as an ion conduit.
Benefits of EDI

• The primary environmental and economic benefit of EDI is the elimination of the use of resin regeneration chemicals
• The primary quality benefit of EDI is the continuous process eliminates spikes and upsets.
  
• EDI Produces Ultrapure Water up to 18.1 Megohm
  
• EDI enables a Simple System (no concentrate recirculation)
  
• No Regeneration Chemicals Required
  
• Compact, Lightweight.
  
• Consistent and predictable results
  
• Continuous, simple operation (no DI batch changes)
  
• EDI is cost effective
  
• No hazardous waste (and cost associated)
  
• No regeneration chemicals (and cost and risk)
  
• Reduced facility requirements
  

 
We provide EDI Systems from 50 Liters/hr to 200 m³/hr with Multiple Unit Arrays. EDI Systems are provided complete with DC power supplies, instrumentation for flow, conductivity, pH, TOC, etc. And complete automation with PLC / SKADA and intigration with up-stream / down-stream equipments.

Our Ultraviolet Water Treatment equipments for pure and ultrapure applications meets the most stringent specifications in a variety of industries ranging from food, beverage, semiconductor to pharmaceutical.

Light is electromagnetic radiation, or radiant energy traveling in the form of waves. UV energy is found in the electromagnetic spectrum between visible light and x-rays and can best be described as invisible radiation. The energy employed for UV water treatment is further categorized into two primary levels measured as wavelengths - 254 nm and 185 nm, where nm = 1/1000 of a micron. For disinfection and ozone destruction applications, the 254nm wavelength is utilized. For TOC reduction and chlorine destruction applications a unique wavelength of 185 nm is utilized.

UV systems feature low pressure mercury discharge lamps. The lamps are constructed with a special quartz envelope material that looks like glass, but is actually a discriminating filter. This design allows predominantly 254 nm or 185 nm UV energy to be transmitted into a water stream as it flows through the UV treatment chamber.

Applications:

• Disinfection
  
• TOC Reduction
  
• Ozone Destruction
  
• Chlorine Destruction.
  

Our models:

Lo-Flow Economy – 0.2 to 9.1 m3/hr
These units provide a compact design and economical ultraviolet water treatment for low-flow applications, such as laboratory and medical facility water, pharmaceutical make-up processes, final electronic component rinsing and recirculation loops, to name a few. The little change in water temperature, even after prolonged periods of no water flow, makes them ideal for such applications as water for vending machines. These models may also be configured for TOC reduction or ozone destruction applications found in high purity or ultra pure water processes. These are available with flow rates ranging from 0.2 to 9.1 m3/hr.

In-Door – 9 to 118 m3/hr
The In-Door Series features a compact design that incorporates a UV treatment chamber with an electrical cabinet that contains all electrical components and instrumentation. These compact, UV models are engineered for indoor installations and controlled operating environments. The In-Door series is used in laboratory, hospital, and hotel installations, as well as cosmetic, pharmaceutical and semiconductor manufacturing processes. UV disinfection flow rates for the standard In-Door models range from 9 to 118 m3/hr, with TOC reduction and ozone destruction configurations also available.

Sanitary Design Model – 2 to 118 m3/hr
UV models are for highly critical industrial water treatment systems. Developed for use in biopharmaceutical applications, this series is perfect for any pure water application with stringent quality or performance criteria. With different models ranging from 2 to 118 m3/hr can serve most any medium flow rate process.
This also comes standard with completely sanitary inlet/outlet connections. Systems suitable for hot water sanitization or steam sterilization.
 
FEATURES AND OPTIONS

• UV Dosage: > 30,000-Microwatt Seconds/cm2
  
• Standard Operating Pressure (6 bar)
  
• 316 Stainless Steel Treatment Chamber
  
• 240 VAC, 50 Hz Electrical Circuit
  
• Optional 304 Stainless Steel Cabinet Housing
  
• Optional Ra 15 (240 grit) Internal Finish
  
• Optional Running Time Indicator
  
• Optional Temperature Safety Control
  
• Optional 4-20 mA Output Signal
  
• Optional Lamp Out Alert Circuit
  
• Optional Voltage Stabilizer
  
• Optional UV Intensity Display