1000 LPH Iron Removal Plant
Flow: 1000 LPH (1.0 m³/hr) — suitable for small industries, institutional campuses, borewell or surface water iron removal. Treatment: Aeration / oxidation → Clarification (if required) → Pressure filter with Greensand or MnO₂ media → Hypo post-disinfection (optional) → Treated water tank.
Process Flow
For low Fe only (no heavy turbidity), clarifier can be bypassed and directly feed pressure filter after aeration and floc dosing.
Design Basis & Flow Calculations (digit-by-digit)
Plant flow = 1000 LPH = 1,000 litres per hour.
Convert to cubic meters per hour: 1,000 L/hr ÷ 1,000 = 1.000 m³/hr.
Daily volume = 1,000 L/hr × 24 hr = 24,000 L/day = 24.000 m³/day ß wait calculate carefully.
1,000 × 24 = 1,000 + 1,000 + ... (24 times) = 24,000 litres. Convert to cubic meters: 24,000 ÷ 1,000 = 24.000 m³/day.
Filter Area & Vessel Sizing (worked example)
Calculation:
Flow Q = 1.000 m³/hr.
Filtration velocity v = 6.0 m/hr.
Required filter area A = Q / v = 1.000 ÷ 6.0 = 0.166666... m².
A = 0.166666... m² ≈ 0.167 m² (rounded).
• Area of 450 mm dia = π×(0.45/2)² = 3.1416 × 0.225² = 3.1416 × 0.050625 = 0.1590 m² (slightly less than 0.167 m²).
• Area of 500 mm dia = π×(0.50/2)² = 3.1416 × 0.25² = 3.1416 × 0.0625 = 0.19635 m² (exceeds 0.167 m²).
Recommendation: use one **500 mm dia FRP pressure vessel (approx area 0.196 m²)** to give margin for head loss & lower filtration velocity, or two 300–350 mm vessels in parallel for redundancy.
Backwash & Waste Calculations
Using required filter area A = 0.167 m² (design), backwash flow Q_bw = A × backwash velocity = 0.167 × 20 = 3.333... m³/hr = 3,333 L/hr.
Provide a backwash tank / drain and either use a backwash pump sized ≥ 3.5 m³/hr (duty) or use elevated raw water gravity if available. Include air scour option for small vessels to improve cleaning.
Media & Chemical Details
| Item | Specification / Notes |
|---|---|
| Main Media | Greensand (MnO4-coated) or MnO2-based media (vendor grade) |
| Bed depth | 700 – 900 mm (typical); we recommend 800 mm |
| Effective size (ESD) | 0.4 – 0.8 mm (vendor dependent) |
| Support layer | Gravel + coarse sand as per standard filter design |
| Pre-oxidant | Potassium permanganate (KMnO₄) dosing OR pre-chlorination depending on influent |
| Regeneration | Periodic KMnO₄ regeneration if using greensand; frequency depends on raw iron & manganese loading |
If raw Fe is high (>5 mg/L) we recommend stronger pre-oxidation and clarifier before filters. For low-Fe (<2 mg/L) direct aeration + filter is usually fine.
Equipment List (Scope of Supply)
- Raw water pump (1 no duty + 1 no standby) — capacity 1.5 m³/hr @ required head
- Aeration cascade / Air blower (if using aeration) or cascade diffusers
- Flash mixer / chemical dosing skid (KMnO₄ dosing pump)
- Lamella clarifier (optional for high turbidity)
- Pressure filter vessel FRP (500 mm dia × suitable height) with multiport valve (or automatic valve)
- Backwash pump (3.5 – 4 m³/hr) or automated WASH line
- Pressure gauges, sample ports, valves, flowmeter
- Control panel (simple PLC / timers) and level sensors
- Treated water tank (buffer) and piping
- Sludge drain and neutralization for spent regeneration liquor
Expected Performance
| Parameter | Raw (typical) | Treated (expect) |
|---|---|---|
| Iron (Fe) | 0.5 – 10 mg/L | < 0.3 mg/L (typical) — <0.1 mg/L with good regeneration & dosing |
| Manganese (Mn) | 0.05 – 1.0 mg/L | < 0.05 – 0.1 mg/L (site dependent) |
| TSS | 5 – 50 mg/L | < 5 mg/L (after filtration) |
| pH | 6.5 – 8.5 | 6.5 – 8.5 (adjust as required) |
Final guarantees depend on raw water sample & jar tests. We include site sampling & trial run in our proposal.
Commercial Snapshot (example split)
| Item | Quote (INR) — Example |
|---|---|
| Supply: Filter Vessel (FRP 500 mm) + Greensand Media | ₹ xx,xxx |
| Raw water pump + backwash pump | ₹ xx,xxx |
| Air blower / aeration arrangement | ₹ xx,xxx |
| Control panel & installation | ₹ xx,xxx |
| Installation & commissioning (optional) | ₹ xx,xxx |
| GST | Extra |
I will create a detailed Excel quote with exact prices once you confirm supply-only or supply+installation and share site details.