Engineering, construction and commissioning of a brine treatment plant in Germany

In this project, a brine treatment plant with a total capacity of 165 m³ / h was designed and installed in Germany. The plant consists of three ion exchangers. Two ion exchangers soften the brine and a downstream ion exchanger removes heavy

metals from a partial stream of brine. The complexity caused by high operating temperatures, high operating pressures and aggressive media was successfully solved.


Scope of the brine treatment plant (main components):

  • 3 ion exchanger/ co-current (Ø 2.700 mm * 3.000 mm)
  • 1 fully automatic regeneration station
  • 2 resin traps
  • Piping system completely prefabricated
  • Armatures and measuring devices
  •  Pneumatical and electrical components

After the process design, the customer's HAZOP was accompanied by KB.tec. Based on the designed dimensions and materials, all process steps were developed for the safe operation of the plant. The ion exchangers are regenerated fully automatically in a cycle of 72 hours. After the production of containers, pipe parts and supports, the system was partially pre-assembled at the KB.tec GmbH plant.


The system logic (connecting lines with all automatic fittings) was pre-piped and wired in two robust stainless steel frames. GRAFCET step chains were transferred to the customer to describe the control sequence for this subsystem. The customer was thus able to order a control system for the entire plant.

After filling the filter material, the plant was commissioned under supervision and support of KB.tec GmbH. All process procedures were tested with water. The last adjustments of the step chains could therefore be carried out several times without any danger. Following the test run, the plant was filled


with brine and put into operation. In the later operation of the plant, the regeneration steps were observed and optimized.


Engineering, Design and Supervision of a brine treatment plant in Colombia (75 m³ / h)

For this project a brine treatment plant with a total capacity of 75 m³ / h was constructed and realized in Colombia. The complexity caused by high operating temperature, high operating pressure and aggressive media has been solved successfully.

A special feature of the plant: During the commissioning one out of three ion exchangers acts as a mercury trap and the following two ion exchangers serves to soften the salt brine. In the further course of commissioning all three ion exchangers serves to soften the salt brine for the downstream chlorine-membrane-electrolysis.

 

Scope of the brine treatment plant (main components):

  • 3 ion exchanger/ co-current (1.700 mm * 3.000 mm)
  • 1 fully automatic regeneration Station
  • 1 resin trap
  • Piping system completely prefabricated
  • Armatures and measuring devices
  • Pneumatical and electrical components

 

Project course

KB.tec GmbH undertook the tasks of engineering, construction and supervision for the project. Thus the plant components were designed, manufactured, packaged and shipped to Colombia by KB.tec GmbH. In Colombia the plant was installed by the client. But the assembly and commissioning works were supervised and supported by KB.tec.

The commissioning of the plant was made in two steps: Initially, one out of three ion exchangers’ acts as mercury absorption and the other two were used in the lead-leg process to soften the salt brine. After an operation period of approx. two months, the brine circuit is free of mercury and the operation was switched to three ion exchangers for softening.

After the change of the ion exchanger material of the first column the plant was commissioned successfully in cooperation with the client. In addition various operation modes have been tested successfully. Since August 2016, the plant successfully produces softened salt brine.


A decarbonisation plant for the complete process water of the company Henkel at the Düsseldorf-Holthausen location

For the Henkel company, a new decarbonisation plant with a total capacity of 2 x 600 m3/ h was design, installed and commissioned. The difficulty of the task consisted in the fact that at the beginning the existing rapid-decarbonisation plant had to remain partially operating.


 

Scope of the decarbonisation plant (main components):

  • 3 pressure boosting pumps (300 m3/h, 15 kW)
  • 2 regeneration station for acids
  • 2 CO2 deaerator incl. fan (3000 mm x 4000 mm)
  • 4 ion exchanger co-current (2800 mm x 2500 mm)

Project Course

The components were installed in two construction phases. After the first components in the first construction phase were installed and commissioned, a part of the existing plant could be disassembled and the second construction phase could be started.

 

The installation and commissioning of the plant took place in close cooperation and coordination with its operating personnel.

 

After the successful commissioning of the new decarbonisation plant in 2013, the existing plant could be closed down and disassembled.



Brine treatment plant for chlorine-alkali electrolyses

For the company Vinnolit an existing brine treatment plant was scaled up from a total capacity of 250 t/h to a total capacity of 450 t/h. The task was difficult because of

the existing framework conditions.

 

The Upscale took place of the existing limited area and should recycle as much existing Equipment as possible. Further the construction measures time was limited to 5 days (from the reconstruction of the old plant to the start up of the new plant).

The assembly started on the 1st of june and ended with the report ready on the 6th

of june in 2008.

 

Since then the plant is successfully in operation.

 

The execution of this project is another evidence of the qualification and performance of the company and ist employees.