SESPI Chloropure® Electrolyzer Overview

  • Low capital cost and low maintenance cost with maximum uptime
  • Low power consumption–high efficiency electrolytic design with fewer bus losses
  • Electrode pack contained within FRP housing – no leaks
  • Routine acid cleaning (once every 3-4 weeks) maintains optimum cell performance and electrode life with changing seawater feeds
  • Small layout footprint – horizontal or vertical
  • Ideal for large land-based applications such as power plants desalinations plants
  • Replacement of single electrode by an easy removal of entire electrode assembly
  • Hypochlorite concentration maximum up to 2000 ppm and over 
  • Need of hydrochloric acid system at site
             

Chloro

 

 

 

 


hypopac pvc framed electrolyser                  

CTE Overview

 

  • No acid cleaning required if minimum flow is maintained
  • Allows easy replacement of cell modules
  • Self-cleaning tubular cell design is suitable for small capacity systems (<5-15kg/hr) and offshore applications
  • High capital cost (more titanium) and high maintenance cost
  • Many connections means frequent leaks which cause further corrosion if leaky modules are not replaced
  • Frequent failures–expensive spares
  • Excessive seawater impurities can cause tenacious scale deposits on electrode surfaces
  • All calcium-magnesium deposits conveyed in to the hypochlorite storage tank with a consequent leaning and removal of deposits to be effected very often that otherwise would damage injection pumps
  • High power consumption
  • Larger layout requirement
  • Hypochlorite concentration maximum up to 1300-1500 ppm


 

concentric tubular electrodes ppe electrolyzer

 

 

Technology Selection

 

 

 

System Availability

Any electrochlorination system must provide continuous/shock dosing to avoid risk of power plant shutdown. Based on recent several plant surveys at CUSTOMERS site, CTE systems are shut down at least once every 2-4 weeks to replace faulty cells or gaskets. Low availability of CTE electrolyzer necessitates 100% standby spare and on-going purchase of spare cells (good business for spare parts supplier)

CTE Availability=                97-98%

Chloropure Availability=   99.5%

CTE Downtime is 5 times greater than Chloropure

 

Capital Cost

  • CTE tubular cell utilizes only one side of titanium surface–more titanium material required
  • Chloropure “intermeshed electrodes” use both sides of titanium surfaces. Entire electrode pack is cased in FRP pressure vessel.
  • Capital cost of Chloropure electrolyzer is 30-40% less than CTE of same capacity

 

Power Consumption

CTE unconventional tubular geometry provides the benefit of self cleaning due to high flow velocities but poor power consumption (more than 5 AC kwh/kg chlorine)

Choropure electrode geometry Is proven industry standard intermeshed Electrode design for efficient gas/liquid separation. Powerconsumptionis only4 AC kwh/kgchlorine

Annual power cost for typical 500 kg/hr system using rate of $0.08/kwh(typicalrate for grid power):

CTE System        $1,750,000

Chloropure         $1,400,000

Annual Power Savings with Choropure=$350,000

 

Susceptibility to Leaks

  • CTE cells operate at high pressure (6-7bar) to induce the high flow velocities of 4 m/s through the annular cells. In essence, the electrolyzer is a long annular pressure vessel thin wall titanium tube for the inner and outer electrodes.
  • In addition, for example a 50 kg/hr CTE electrolyzer contains 300 gasketed joints with threaded PVC unions – each joint is a potential leakpoint.
  • In the field, a small leak at the unions will drip on to the other titanium electrode surfaces to cause electrolytic corrosion and catastrophic leaksas shown on the example below:

CORR

Maintenance Cost

  • SESPI Chloropure electrolyzer is comprised of an intermeshed electrode assembly that is fully enclosed within an FRP housing, as shown

Main

  • Leaks are very uncommon and never noticed
  • CTE cells must be replaced every 3-5 years due to wear of anode coating. Chloropure cells are proven to last 6-8 years in normal operation with routine acid cleaning
  • On average, one faulty CTE cell is replaced every month per electrolyzer due to mechanical problems with leaks, gaskets, and corrosion. In comparison, a Chloropure electrolyzer may need to be repaired 1 or 2 times between the 6-8 year cell replacement cycles.
  • Average annual maintenance cost for 500 kg/hr system (electrolyzer components only - excluding cost of labour):

CTE -                          $ 650,000 (12x10 spare cells + complete replacement for coating)

Chloropure   -          $ 100,000 (Inspection, gaskets, spare anodes & cathodes)

Annual Maintenance Savings with Chloropure®- $550,000

 

 

Layout Requirements

  • SESPI Chloropure® electrolyzer requires 60-75% less floor space than a CTE of the same capacity
  • A smaller footprint results in lower installation costs related to foundations, buildings and utilities

Foortp

Effect of Seawater Impurities

  • Seawater typically contains manganese, calcium, organics and other impurities that can deposit on the surface of the electrodes
  • Routine acid washing of a Chloropure® electrolyzer ensures that the long term negative effects of such calcareous deposits is minimized and power consumption remains low.
  • CTE is designed to handle some level of seawater impurities but for excessive levels of contaminants or during upsets, electrodes can suffer permanent damage and higher power consumption since there is no acid cleaning system

 

Safety and Operability

  • CTE cells have power applied directly to the cell modules using bus bars and cabling – potential electrical shock hazard during operation
  • CTE - Unbalanced cell circuit causes stray currents
  • CTE – Potential for eye irritation due to leaks spraying onto
  • operating personnel
  • Chloropure® cells are completely enclosed in non-metallic casing with bus connections at the end. Bus connections are also enclosed for personnel protection
  • Chloropure® cells can be supplied with clear “transparent view window” for visual indication of electrodes during operation

 

 

 


KSM takes a deep care and assistance to provide a wide range of after sales services. We develop our services to provide the reliable performance as our clients anticipate to serve. Based on our expertise, we can offer our services based on the client’s requirements.

Our commitment and insight with our well work ethic is our strength which is building confidence and insurance of our clients.

KSM is aimed to serve the clients with following after sales services:

 

- Spare Part: 

- Training:

- Optimization:

- Warranty:

- Maintenance:

- Supervision:

- Execution:

- Repair:

- Tel-Support:

 

Defining Spare Part Package

Operator and Maintenance Training

Optimization for individual processes

10-years warranty with full support

Tailor-Made Maintenance Concept

Supervision of Maintenance and Service Contracts

Execution of Repair and Service Contracts

Troubleshooting with Instructions

Task-Force and 24/7 Tel-Support

 


-

KSM WAY

getting results the write way

 

                                                                              The KSM Way explains who we are, what we believe, how we achieve and where we aspire to go.  It establishes a common understanding not only for us, but for all who interact with us.                                                                                          

 

 

 

Vision

 

                                                                               

The vision of KSM is to be a premier Iranian manufacturer of top quality products. We dedicate ourselves to be the supplier of choice when our type of products is being sought. This vision will be accomplished by sharing the responsibilities of planning and decision making with all of our employees. KSM will strive to develop with its suppliers, employees and community as a company of excellence.

                                                                                         

 

  

 

Mission

 

 

                                                                             

 Our mission is to produce and continually develop quality products at a competitive price. We will always strive to service our customer with the utmost integrity, and to their complete satisfaction. It is our goal to ensure our mission by continuous self-improvement, growth in our operations and employees; while maintaining profitability to the benefit of our customers, employees, and community. All employees will work together in combining their efforts and skills to ensure our mission and goals are fulfilled in a courteous manner. 

                                                                                         



 

 

 

 

Values

 

Our company's foundation is built on our values, which distinguish us and guide our actions to deliver results. We conduct our business in a socially and environmentally responsible manner, respecting the law and universal human rights to benefit the communities where we work.

 

V3                   V2                     V1 

 Integrity and Trust

 

                 

 Diversity and Inclusion

 

                   

 High Performance

 

 We are honest with ourselves and others, and honor our commitments. We trust, respect and support each other. We earn the trust of our colleagues and partners by operating with the highest ethical standards in all we do.                  We learn from and respect the cultures in which we operate. We have an inclusive work environment that values the uniqueness and diversity of individual talents, experiences and ideas.                    We are passionate about delivering results, and strive to continually improve. We hold ourselves accountable for our actions and outcomes. We apply proven processes in a fit-for-purpose manner and always look for innovative and agile solutions.

 

 

                                                 V5              V4                                                            
                                               

 Partnership

 

           

Protect people and the environment 

 

                                                           
                                                We build trusting and mutually beneficial relationships by collaborating with our communities, governments, customers, suppliers and other business partners. We are most successful when our partners succeed with us.  We place the highest priority on the health and safety of our workforce and protection of our assets, communities and the environment. We deliver world-class performance with a focus on preventing high-consequence incidents.                                                             

 

 

 

 

Strategies

 

 Our strategies guide our actions to deliver industry-leading results and superior shareholder value in any business environment.

 

 

 

Major Business  Strategies

 

                    S1                                         S2                         S3                             
                   

 Upstream

                                     

 Downstream and Chemicals

                       

 Midstream

                           
                   

Deliver industry-leading returns while developing high-value resource opportunities

                                   

Grow earnings across the value chain and make targeted investments to lead the industry in returns

                     

Deliver operational, commercial and technical expertise to enhance results in Upstream and Downstream & Chemicals

                           

 

 

 

Enterprise  Strategies

 

 S4              S5 S6   S7
 Growth              Execution  People  Technology and Functional Excellence
 Grow profits and returns by using our competitive advantages              Deliver results through disciplined operational excellence, capital stewardship and cost efficiency  Invest in people to develop and empower a highly-competent workforce that delivers results the right way  Differentiate performance through technology and functional expertise

 

 

Our multi-disciplined team of experts possess extensive knowledge of the latest technologies and regulations.  And as an independent system integrator, we have no bias towards any single system or brand. So you can be assured that KSM solutions are designed to deliver fit, form and function, whilst helping to reduce your Total Cost of Acquisition.

 

By teaming with KSM, you’re instituting the most proficient group of engineers to custom design and manufacture modular systems that will not only satisfy your project requirements, but are specially designed to provide you years of trouble-free operation.

 

The successful completion and implementation of your package system derives from our unique methods which allow us to deliver you preassembled and pre-tested modular systems.  KSM guarantees a qualified team to manage your project, advanced technology and superior quality control and support to have your system in full operation in the shortest time possible.

 

 

               IMG 5758          

 

Project Management 

 

With a highly skilled group of engineers, KSM can design and direct the production of your process systems, no matter how complex your project. Each project is assigned a dedicated Project Management Group consisting of a Project Manager, Project Engineer, and Design Team to manage each project from start to finish.

                                   

 

 

               IMG 5726          

Engineering and Design

 

KSM designs modular Electro-chlorination packages, liquid and gas metering skidsand auto backwash filters, fully optimized, integrable, and Engineered-to-Order, delivered to you ready to “plug into” your process flow at your plant.

                                   

 

 

               Picture1            

Modeling

 

KSM utilizes different simulation software for conceptual design, optimizing, and performance modeling of KSM’s proposed solutions to customer requirements. 

 
                                     

 

FE7

 

Our multi-disciplinary engineering staff with chemical, mechanical, instrumentation, electrical & civil engineering expertise, enables us to develop client's concept to fruitful completion.

We have expertise in Hypo Electro-Chlorination packages, Waste Water & Water Treatment Plants, Distillation & Solvent Recovery Systems, Adsorption & Absorption Systems, Pilot Plants, Customized Package Skids and Special Purpose Machines. Our scope of works include below services: 

 

 

Process

  • Unit Operations Design
  • P & IDs, Equipment Layouts, Datasheets
  • Utility Sizing and Distribution Diagrams
  • Line Sizing, Hydraulic Calculations
  • Insulation Calculations with Material Take Off
FE1 

 

Piping & Mechanical

  • 3D Modeling, Piping Layouts
  • Isometric with Material Take Off
  • Stress Analysis using
  • Pressure Vessel & Heat Exchanger Design
  • Fabrication & Assembly Drawings
 FE2

 

Civil & Structural                                                

  • Structure Design, Dynamic Analysis
  • Foundation Load Calculations.
  • Detail Fabrication Drawings
 
FE5  

 

 

Instrumentation & Electrical

  • Instrument Specifications
  • Instrument Hook-up & Standard Installation Diagrams
  • Instrument Locations, Cable Tray Routing
  • Junction Box and Cable Schedule with Material Take Off
  • Control System Design (PLC / SCADA and DCS) & Programming
  • Logic Diagrams, Alarms & Safety Interlocks
  • Plant Wide Power Distribution Drawings
  • Motor Control Center Design
  • Plant Lighting Schemes
 FE6

 

 

Design Software

 

  • AutoCAD
  • SolidWorks
  • CATIA
  • Aspen HYSIS
  • CAD P&ID
  • AFT Impulse
  • PDMS
  • NAVISworks
  • CAESAR II
  • PIPENET
  • PV Elite
  • Compress
  • E-Tank
  • Fluent
  • GAMBIT
  • MS Project
  • Primavera

 

 

Modular Skids Manufacturer

A global Modular Skid OEM approach us for providing support on their

projects. We provide following services

  • 3D Modeling of Skids
  • Piping Spool Drawings
  • Support and Structural Frame Drawings
  • Instrument Datasheets
  • Instrument Location Drawings
  • PLC / MCC Panel Design with Wiring Drawings
  • PLC & HMI Programming
  • Operation & Maintenance Manual
  • Assistance for start-up by our programmers
  • cost effective services to become competitive
FE3

 

 

 

3D Modeling & Drafting

We have experience custom design & reverse-engineering products for different industries and applications. Whether your goal is to develop a cost-saving alternative or equivalent product or to improve efficiency, we demonstrate all of the attributes you need in a source for engineering and design support.

 

Product Development

  • Design concepts based on customer specifications
  • Evaluate concepts for assembly & manufacturing (component cost, count, ease of manufacturing, ease of assembly)
  • System Level Design
  • Evaluate concepts from System Level Design Constraints

 

Detail Design

  • 3D Modeling: parts & assembly
  • Detail drawings for manufacturing
  • Rendering for presentations, catalogues
 FE4

 

 

 

 

The operational responsibility for the company’s activities is assigned to the Board of Directors. Forward thinking are also the guidelines of the Board to ensure the continuity and vitality of the company, defining long-term goals and policies to achieve them, providing management advice and feedback and verifying the results to increase the value of the entire company structure.

 

The Board of Directors is committed to ensure that KSM runs in a sustainable, legal and ethical style worldwide, in accordance with law, people and the environment.

 

Our people are a primary reason encourage our clients to work with us. Their unique skills and motivation help our clients focus on what they want and build their capability and confidence to create winning firms of the future.

 

The board of director of KSM Company is as following:

 

 

Saeed Aliashrafi, Chairman of the board

 IMG 5949

          

Mr. Aliashrafi as a chemical engineer, is the owner and managing Director of Petrosadid Group. He is also the chairman of the board of KSM Company. He has registered KSM as a subsidiary of Petrosadid Group in 2014. Petrosadid is an engineering and Procurement Company, registered on 2009 to supply high quality equipment with full engineering support for Iranian projects in all industries mainly Oil, Gas, Petrochemical, Water, Wastewater and Power plant. Prior to joining Petrosadid, Mr. Aliashrafi was managing director of Asia Water company from 2007 to 2009 which is the owner of Bandar Abbas desalination plant. Mr. Aliashrafi had served on South Pars Gas Field Development Phases 15 and 16 as an Engineering Manager of Seawater Intake & Desalination Unit from Jan 2005 through  Feb 2007. He was also managing director of Axon Sima Part Company from Aug 2005 to Jan 2007 which is an Engineering Consultancy in utility projects.

 

Ebrahim Torabian, Managing Director

 IMG 5934       

Mr. Torabian as a mechanical engineer is the managing director and member of the board in KSM Company. He also is a technical sales manager of the Petrosadid Group as a mother company of KSM. He has worked at basic and detail design, bidders evaluation, tender stage and procurement engineering for wide range of equipment such as  pumps, compressors, loading arms, buoy mooring, air and nitrogen generator packages in different projects such as Kish Gas Field Development plant, Kavian Petrochemical Plant, Phases 15&16, 17&18, 13 and 22~24 of South Pars Gas field developments, Kangan Petro-refining Company, Kharg Gas gathering and NGL Recovery Plant and NGL 3200. During 12 years of working as a mechanical engineer, engineering manager, sales manager and project coordinator, he could extend his professional experiences and now he has an effective role in Petrosadid group and other affiliated companies.

 

Davood Seydi, Technical Sales Manager

IMG 5920   

Mr. Seydi as a process engineer is the engineering manager of KSM. Mr. Seydi joined KSM in 2014. Prior to joining KSM, Mr. Seydi was a Process Expert at an Iranian catalyst and chemicals manufacturer from 2011 to 2013. Mr. Seydi had served on Chemical and Nano-Material manufacturer from May 2013 to Nov 2014 as a Technical & Production Expert.

 

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