Industry Background and Problems
The power and energy sector is a water-intensive industry critical to national infrastructure, relying heavily on high-quality water for cooling towers, boiler feed, steam generation, and process operations. Thermal power plants, gas turbines, and renewable energy facilities require stringent water quality control to prevent scaling, corrosion, fouling, and equipment failure, which can lead to costly downtime and reduced efficiency. Additionally, the sector generates large volumes of wastewater, including cooling tower blowdown, boiler blowdown, and flue gas desulfurization (FGD) effluents, containing contaminants such as dissolved solids, heavy metals, oils, and suspended solids.
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Stringent regulations require power plants to manage and treat these wastewater streams effectively to avoid environmental pollution and comply with discharge norms. Water scarcity and sustainability mandates further pressure the industry to maximize water reuse, reduce freshwater intake, and implement zero liquid discharge (ZLD) solutions. Challenges include treating variable and complex effluent streams, energy-efficient operations, and managing residue safely, all while minimizing operational costs.
Our Approach to Solving the Problems
Sarvo delivers customized, reliable water and wastewater treatment solutions tailored to the specific needs of the power and energy sector. Our systems incorporate advanced water purification technologies such as multimedia and activated carbon filtration, water softening, reverse osmosis (RO), electrodeionization (EDI), and ultrapure water generation to provide high-quality boiler feed and cooling water. For wastewater, we offer integrated effluent treatment plants (ETPs) combining chemical-physical treatment, biological processes, ultrafiltration (UF), and membrane-based technologies.
Our energy-efficient Mechanical Vapor Recompression (MVR) evaporators enable ZLD by concentrating blowdowns and regenerating waters, minimizing freshwater usage and effluent discharge. Automated PLC controls, AI-based monitoring, and predictive maintenance systems enhance operational performance and cost efficiency. Sarvo’s modular plants support easy scaling and retrofit, ensuring compliance with stringent environmental regulations, reducing carbon footprint, and supporting sustainable power generation.
Key Points
About Our Tech in Pointers
- High-purity water generation for boiler feed, turbines, and cooling systems, preventing scale and corrosion.
- Advanced ETPs for efficient removal of TSS, dissolved solids, heavy metals, and oils from blowdown and process effluents.
- Integrated ultrafiltration, RO, EDI, and demineralization for reliable water quality.
- Energy-efficient MVR evaporators and ZLD systems to minimize wastewater discharge and maximize water recycling.
- Automated process control and AI-driven performance monitoring for reduced downtime and optimized OPEX.
- Modular, compact designs that facilitate rapid deployment and future expansion.
- Comprehensive sludge handling and safe disposal solutions compliant with environmental norms.
Relevant Technologies
Multimedia and activated carbon filtration
Water softening and demineralization
Reverse Osmosis (RO) and Electrodeionization (EDI)
Ultrafiltration (UF) and Membrane Bioreactors (MBR)
Mechanical Vapor Recompression (MVR) Evaporation for ZLD
Chemical-physical treatment (coagulation, flocculation)
PLC/SCADA automation and AI analytics
Sludge dewatering and handling systems
Customer Case Study: IFFCO Power Plant, Bangalore
Sarvo executed a comprehensive water and wastewater treatment solution for the IFFCO power plant in Bangalore, addressing their critical need for high-quality cooling tower makeup, boiler feed water, and effluent management. The project encompassed a 270 KLD water treatment plant integrating advanced multimedia filtration, softening, ultrafiltration, RO, electrodeionization, and biological treatment units.
To tackle blowdown and process effluents, Sarvo installed a state-of-the-art effluent treatment plant (ETP) followed by an energy-efficient MVR evaporator combined with an Agitated Thin Film Dryer (ATFD) to achieve zero liquid discharge. This system treats cooling tower blowdown, boiler blowdown, and process water rejects, recovering valuable water while minimizing waste.
The modular plant design and automated controls ensure continuous, optimal operation with minimal manual intervention. This turnkey solution reduced the plant’s freshwater consumption dramatically and enabled near-complete recycling of wastewater streams, ensuring compliance with stringent CPCB norms while lowering operational costs and enhancing sustainability. Sarvo continues to provide operation and maintenance support, ensuring long-term reliability and performance.
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