What raw data do you need to finalise design?

Raw water lab report: Fe, Mn, pH, TDS, turbidity, hardness, alkalinity, dissolved oxygen, presence of organics or H2S. A jar test is recommended to choose oxidant & media.

How often do filters need backwash?

Backwash frequency depends on headloss rise and turbidity load — typically 12–72 hours. High particulate loads require more frequent backwash; we size backwash systems to local conditions.

Can this be used as RO pre-treatment?

Yes — iron removal upstream protects RO membranes from fouling and staining. Combine with cartridge filters and antiscalant as required for RO feed standards.

3000 LPH Iron Removal Plant Price

Digit-by-Digit Design Calculations (24 hr operation assumed)

Assumptions used:

Plant flow = 3,000 LPH (3.0 m³/hr)
Operating hours = 24 hr/day → daily volume = 3.0 × 24 = 72.0 m³/day
Design oxidation contact time = 15 minutes (0.25 hr) — typical starting point for Fe oxidation
Filter design face velocity = 6 m/hr (typical for pressure media filters)
Filter bed depth (effective) = 0.8 m (800 mm) for manganese-sand or layered media

Step 1 — Convert flows

Permeate (plant) = 3,000 L/hr.
Convert to m³/hr: 3,000 ÷ 1000 = 3.0 m³/hr.
Daily volume = 3.0 × 24 = 72.0 m³/day = 72,000 L/day.

Permeate_LPH = 3,000 L/hr Permeate_m3hr = 3,000 ÷ 1000 = 3.0 m³/hr Permeate_m3day = 3.0 × 24 = 72.0 m³/day = 72,000 L/day

Step 2 — Iron mass to remove (examples)

We show calculations for typical influent iron concentrations so you can pick the right design case. • For Fe = 1 mg/L: mass/day = 72,000 × 1 mg/L = 72,000 mg/day = 72 g/day = 0.072 kg/day. • For Fe = 5 mg/L: mass/day = 72,000 × 5 = 360,000 mg/day = 360 g/day = 0.36 kg/day. • For Fe = 10 mg/L: mass/day = 72,000 × 10 = 720,000 mg/day = 720 g/day = 0.72 kg/day. • For Fe = 20 mg/L: mass/day = 72,000 × 20 = 1,440,000 mg/day = 1,440 g/day = 1.44 kg/day.

Fe_1mg_day = 72,000 × 1 = 72,000 mg = 72 g = 0.072 kg Fe_5mg_day = 72,000 × 5 = 360,000 mg = 360 g = 0.36 kg Fe_10mg_day = 72,000 ×10 = 720,000 mg = 720 g = 0.72 kg Fe_20mg_day = 72,000 ×20 = 1,440,000 mg = 1,440 g = 1.44 kg

Step 3 — Oxidation / contact tank sizing

Contact time chosen = 15 minutes = 0.25 hr.
Required reactor volume V = Q_hr × contact_time = 3.0 × 0.25 = 0.75 m³ (750 L). Add freeboard (20%) → physical tank ≈ 0.75 × 1.20 = 0.90 m³ (900 L).

V_reactor = 3.0 × 0.25 = 0.75 m³ = 750 L V_physical ≈ 0.75 × 1.20 = 0.90 m³ = 900 L

Step 4 — Filter area & vessel diameter (face velocity method)

Design face velocity = 6 m/hr.
Required filter bed area A = Q_hr ÷ velocity = 3.0 ÷ 6 = 0.50 m².
Convert area to circular vessel diameter d: d = √(4·A / π) = √(2 / π) ≈ √(0.6366197) ≈ 0.80 m → choose vessel diameter ≈ 800 mm (practical size: 0.8–1.0 m dia).

A = 3.0 ÷ 6 = 0.50 m² d = sqrt(4×0.50 ÷ π) = sqrt(2 ÷ π) ≈ 0.7979 m ≈ 0.80 m

Step 5 — Media volume (bed depth method)

Bed depth (effective) = 0.8 m → media volume V_media = A × depth = 0.50 × 0.8 = 0.40 m³ = 400 L of media per vessel. For service continuity & easier backwash, many designs use 1 vessel sized for the full flow or two parallel vessels (lead/lag) each sized half the flow. For two parallel vessels: area each = 0.25 m², diameter ≈ 0.57 m, media volume each ≈ 200 L.

V_media = 0.50 × 0.8 = 0.40 m³ = 400 L (2-train option: A_each = 0.50 ÷ 2 = 0.25 m² → d_each ≈ sqrt(4×0.25/π) ≈ 0.566 m)

Step 6 — Backwash rate estimate

Typical backwash (expansion) velocity = 20 m/hr (range 15–25 m/hr).
Backwash flow Q_bw = area × backwash_velocity = 0.50 × 20 = 10.0 m³/hr = 10,000 L/hr = 166.7 L/min. Provide backwash source (raw water booster) or recycle backwash tank with pump.

Q_bw = 0.50 × 20 = 10.0 m³/hr = 10,000 L/hr = 10,000 ÷ 60 = 166.666... L/min ≈ 167 L/min

Design interpretation: The single-vessel design (0.8 m dia × bed depth 0.8 m, media ≈ 400 L) suits the full flow; however, for continuous supply during regeneration/backwash we recommend two parallel filter vessels (lead/lag) each sized for half the flow (recommended for critical potable / industrial supply).

Filter Media & Chemical Oxidants

Manganese Greensand (MnO₄− treated media) — effective for Fe & Mn when properly pre-oxidized and controlled (requires periodic regeneration with KMnO₄ or pre-coating).
Sand + Anthracite layered media — works if iron is largely particulate after oxidation/settling.
Pre-oxidation: Aeration (air diffusers / cascade) is preferred for low cost. For higher Fe/Mn or higher soluble iron, chemical oxidants used: Chlorine (1–3 mg/L) or Potassium Permanganate (KMnO₄) (typical 0.1–1.0 mg/L based on Fe/Mn and site lab tests). Exact dosing to be finalised after raw water lab report and jar testing.
Post-treatment: Activated carbon filter (ACF) to remove residual oxidants/organics; cartridge polishing (1 µm) for clarity; UV for disinfection if potable.

Scope of Supply & Main Equipment

Coarse intake strainer & screens
Aeration / Oxidation tank (0.9 m³ physical for 15 min contact) with air blower / diffusers or cascade arrangement
Flash/settling chamber (optional) for heavy precipitates
Pressure media filter vessel(s) (FRP or SS304) — single or two-train configuration
Filter media: manganese greensand or sand + anthracite layered
Backwash pump or backwash recycle tank & pump
Chemical dosing skids: KMnO₄ / Chlorine / Antiscalant / pH adjusters (as required)
ACF polishing, cartridge filters, flow meters, pressure gauges
PLC control panel, level controllers, valves, sampling points
Piping, valves (UPVC/HDPE/SS), civil anchors, installation & commissioning

MOC (Material of Construction) & Installation Notes

Filter vessels: FRP for cost-effective potable installations; SS304 for high-corrosion or industrial applications.
Piping: UPVC/HDPE for raw lines; SS304 for sample/permeate headers & dosing lines.
Diffusers & blower: fine-bubble diffusers, skid-mounted blower with silencer.
Provide safe chemical storeroom for KMnO₄ / hypochlorite with bunding and PPE instructions.
Ensure accessible manholes, isolation valves, and test ports for jar testing/maintenance.

Expected Performance & Typical Applications

With correct pre-oxidation and media selection, expected iron in treated water: < 0.3 mg/L (often < 0.1 mg/L) depending on influent chemistry. Manganese removal similarly achievable with correct design. Applications: potable water treatment for housing, hotels, schools, hospitals; pre-treatment for RO plants; process water for industries sensitive to iron staining.

Parameter	Typical Influent	Expected Outlet
Iron (Fe)	1–20 mg/L (site dependent)	< 0.3 mg/L (with proper design & O&M)
Manganese (Mn)	0.05–2 mg/L	< 0.05 mg/L (with correct media & regeneration)
Turbidity	Varies	< 1 NTU (after polishing)

Operation & Maintenance

Daily: check inlet/outlet iron, pressures, flow, air blower status, dosing pump operation.
Weekly: inspect pre-filters, backwash filter(s) and check turbidity/colour of backwash water.
Monthly: measure media headloss, perform sample tests for Fe/Mn, check KMnO₄ / chlorine stocks.
Periodic: regenerate or recondition media as per vendor guidance (greensand may need periodic regeneration/coating).
Provide scheduled preventive maintenance, cartridge replacement schedule, and spare parts kit (valves, seals, dosing pump parts).

Common Issues & Troubleshooting

Incomplete iron removal: Check oxidation (air or chemical dose), check media exhaustion or channeling, inspect pH and presence of reducing agents.
High headloss: Check for clogging (suspended solids), verify backwash frequency and backwash rate.
Brown/red stains downstream: Possible media loss or breakthrough — test outlet iron and perform media replacement/regeneration.
Excessive backwash turbidity: Provide settling or recycle options for backwash; consider pre-sedimentation if large particulate loads exist.

Item	Note
Aeration tank & blower	0.9 m³ physical volume (15 min contact)
Filter vessel	FRP vessel ~0.8 m dia (media ≈ 400 L)
Media	Manganese greensand or sand+anthracite layered
Backwash pump	Sized for ~167 L/min (single vessel backwash)
Dosing skid	KMnO₄ / chlorine as required

3000 LPH Iron Removal Plant (3.0 m³/hr)

Quick Summary

Process Flow (text)