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www.polutech.com www.murugappa.com

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Business

ProfilePolutech Ltd(a Murugappa Group Company)


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About the Murugappa GroupThe making of the Murugappa GroupThe Murugappa Group, headquartered in Chennai, India, isa Rs. 15,907 Crore (USD 3.14 billion) conglomerate withinterests in Engineering, Abrasives, Finance, Generalinsurance, Cycles, Sugar, Farm Inputs, Fertilizers,Plantations, bio-products and Nutraceuticals. It has 29limited companies under its umbrella, with manufacturingfacilities spread across 13 states in India. Together, they haveover 32,000 employees. The Group, which has forged strong

joint venture alliances with leading international companieslike DBS Bank, Mitsui Sumitomo, Foskor, Cargill andGroupe Chimique Tunisien, has consolidated its status as

one of the fastest growing diversified business houses inIndia.

From acorn to oakThe business has its origins in 1900, when Dewan Bahadur aM Murugappa Chettiar established a money-lending andbanking business in Burma (now Myanmar), which thenspread to Malaysia, Sri Lanka, Indonesia and Vietnam. Inthese 100-plus years, it has withstood enormous vicissitudes,including strategically moving its assets back to India andrestarting from scratch in the '30s, before the Japaneseinvasion of Burma in the Second World War. Starting with asandpaper plant, the Group forayed into making steel safes,and then into manufacturing. It set up an insurancecompany, and bought a rubber plantation; making a smallbut significant beginning. The rest is history.

Today, it is one of the country's biggest industrial houses.Group turnover crossed the USD 1 billion mark in 2003-04,with an impressive growth of 25 per cent over Rs 4,206 Crorein 2002-03, and a 40 per cent jump in profit before tax overthe previous year. Consolidated Group turnover for 2004-05crossed USD 1.44 billion, a growth of 20 per cent over theprevious year. In 2005-06, combined turnover increased by17 per cent to USD 1630 million (Rs 7,340 Crore) and netprofit (PBT) by 45 per cent to USD 177 million (Rs 800Crore). The Group ended the year 2006-07 with a turnover ofRs 8,446 Crore, and profit before tax of Rs 649 Crore. TheCrore) and has the Group well on its way to achieving itsvision of becoming a USD 4 billion conglomerate by 2010.

The management has also set in motion long-term growthplans for all of its key businesses. Capital expenditure rosefrom Rs 579 Crore against Rs 570 Crore the previous year.

Changing times, constant valuesToday the Murugappa Group is firmly rooted in itshomeland, and is poised to take on the world. Building onthe same business acumen, modern and innovative outlook,as well as vision with which the founder of the Group lefthis native land to seek his fortune in Burma, the MurugappaGroup is on the threshold of the global business arena today,

backed by 100 years of experience in diverse fields, soundtraditional values and high ethical standards.

The group is a market leader in India across a spectrum ofproducts like fertilisers, abrasives, automotive chains, cardoor frames and steel tubes. Neemazal, a neem-basedorganic pesticide, is the market leader in bio-pesticides.Some of the country's best-known brands like BSA andHercules in bicycles, Parrys Spirulina and Parrys BetaCarotene in nutraceuticals, Ballmaster and Ajax in abrasives,Gromor and Paramfos in fertilisers, and many more comefrom the Murugappa Group.

Its companies have tie-ups with Wendt GmbH of Germany,Morgan Crucible Company plc of the UK, the ChinaEngineering and Exploration Bureau (CEEB), Cerdak Pty Ltdof South Africa, Mitsui Tsumitomo Insurance Company Ltdof Japan, DBS Bank of Singapore, Borg Warner Morsetec ofUSA, Foskor Ltd of South Africa , Groupe Chimique Tunisienof Tunisia, and Cargill International SA of Geneva. It hasregistered 43 international patents for its research anddevelopment innovations.

The group has grown consistently through its decisive andvisionary response to changing times. Its pioneering efforts,steadfast commitment to ethical business practices and itsdogged pursuit of new areas to extend its business acumenhave brought in its wake several prestigious national andinternational awards.

The Group's business philosophy can be summed up in this couplet from the ancient Indian treatise on wealth creation andgovernance, theArthashastra:

"The fundamental principle of economic activity is that no manyou transact with will lose, then you shall not."

Conducting business by a clear set of values and beliefs, the Group has observed very high standards of ethics and transparency. Itsbelief in organisational renewal has allowed the Group to adapt itself to changing economic contexts and grow from strength tostrength. The Management Development Institute (IMD) of Lausanne, Switzerland, conferred the 'IMD Distinguished FamilyBusiness Award' on the Group in 2001.


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POLUTECH maintains an intensive quality assurance programme through all phases of design

and manufacture of equipment it supplies.

POLUTECH is totally committed to quality and excellence and produces plants and systems

confirming to very high engineering standards. All raw materials, components, subsystems,

and systems are subjected to rigorous in-house quality control to ensure that the customer

receives only the best equipment.

Quality Control &

Testing procedures

are followed in

accordance with the

various Indian

standards as well as

international

standards such as

ASME, BS, DIN or

other standards

specified by the

customer.


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ORGANIZATION

Quality Control Department consists of a team of qualified Engineers in various disciplines

such as Mechanical, Electrical and Instrumentation and is headed by General Manager.

The functions of the Department can be broadly listed as under -

Vendor Evaluation and Development Inspection of all items from different vendors right from procurement of raw material

to finished product for conformance with required standard/ specifications

Issue of Inspection Report certifying quality of the job

Liaison with the Clients / Consultants Inspection AuthorityVENDOR EVALUATION AND DEVELOPMENT

Adding new vendors helps to increase supply sources and to meet committed delivery

schedules. In this respect, vendor evaluation and development become a very important

function of the Quality Control Department. Capability of new vendors requesting registration

is first ascertained especially with respect to manpower quality, availability ofmachines/equipment and quality monitoring facilities. Rigorous inspection is carried out

during the trial order before according final approval. All Quality Control Engineers through

Log Sheets and Weekly Reports maintain the performance record of registered vendors.

ORGANISATIONAL PHILOSOPHY

For specific projects, a team is organized under the leadership of the Project Manager. Each

department (Purchasing, Engineering, Estimating, Construction, Accounting, Process, etc)

supplies personnel to the project team as required. Dependent on the project size and

requirements, personnel are delegated to the project full time or assigned as needed. The

functional managers are responsible for supplying the proper personnel to the project them.

The project team member reports to the proper project person (project manager or engineer) for

their project execution functions. They continue to report to their functional department heads

with regard to quality, standards and methods. The Project Manager is totally concerned with


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and dedicated to the execution of the project. The department managers are responsible to

ensure that quality and method are comparable with the schedule and cost objectives

established in the project plan.

PROJECT ORGANIZATION

In accordance with the previously described procedure, a project team is formed for each

project. Overall responsibility for the project execution rests with the Project Manager. Projects

are assigned to an experienced project manager who is the principal contact with the Owner.

This organization provides single-point responsibility for the performance of the entire project

staff, both in the office and field. The Project Manager is personally responsible for conduct of

the overall project. He places special attention on front-end planning, scheduling, and cost

control. Engineering for the project is the responsibility of the Project Engineers.

PROJECT PROCEDURES

POLUTECH LIMITED uses a Project Activity Chart to define the tasks to be performed in a

project and to define the parties responsible for execution, review and approval of each task.

The personnel to be used on a project have used the Activity Chart on previous occasions and

are thoroughly familiar with the division of responsibility.

PROGRESS REVIEW

Project scheduling is a system of planning, reporting, and forecasting by which the Project

Manager and his staff control all the activities of a project with regard to time. There is a master

project schedule, which is backed up by more detailed departmental schedules. The project

schedule is generally prepared as a bar chart. However all of the input data necessary make thebar chart can also be used for a computerized critical path schedule, should this be advisable or

desired. The project schedule is prepared in sufficient detail to identify all of the principal

activities affecting project completion. These include engineering and drafting by disciplines,

major items of equipment individually bulk materials with appropriate breakdowns, and shop

fabrication. The department head responsible for each of these activities makes his detailed

department plans and schedules consistent with the Project Schedule.


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The first issue of the Project Schedule shows the planned starting and completion dates of each

principal activity in the project. These planned dates are never changed unless the job is

rescheduled. The schedule is continually updated showing the times of actual performance in

comparison with the original plan. The updated schedule sounds the alarms for the Project

Manager and department heads to take corrective action. The updated schedule is issued

monthly for management and customer review.

DOCUMENTATION CONTROL

A code of accounts for each project is established from the general accounting code. The

accounting code is divided by material and design functions. During the estimate, each area of

the plant is referenced to the code of accounts.

COMPUTER-AIDED DESIGN AND DRAFTING (CAD)

POLUTECH LIMITED employs computers for the following design/ project activities:

1. Project

Project scheduling - bar chart and CPM. Cash flow requirements for projects. Progress reports.

2. CAD Drawings

Process flow diagrams Engineering flow diagrams (P&IDS) Equipment arrangements and layouts Plot plans Civil and structural Architectural Drums, towers, vessels and other mechanical Piping


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Electrical Instrument logic and loops Computer logic and ladder diagrams

RANGE OF PRODUCTS

High Speed Floating Aerators - 1 to 40 HP Low Speed Floating Aerators - 1 to 40 HP Low Speed Fixed Surface Aerators - 3 to 50 Hp Clarifier Mechanism - Fixed type and Traveling type Clariflocculator Mechanism - Fixed and Traveling type Flash Mixer Flocculator Mechanism Agitators - High Speed and Low Speed Bar Screen - Manual & Automatic Type Oil skimmer - Manual

Thickener mechanism Parallel Plate Clarifier / Tube Settler Pressure Sand Filter Activated Carbon Filter Diffused Aeration System (DAS) High Speed Floating Mixers


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MECHANICAL BAR SCREEN

POLUTECHs Mechanized bar rake screen suitable for

installation in RCC channel. The screen shall be

provided with bar opening of 5mm 20mm with bars

of SS304 construction. It shall have rake frame,

sprockets & chain, shafts, adjustable bearing blocks,

deck plates, discharge arm apron. All material in

SS304 construction.

ROTARY FINE SCREEN

POLUTECHs Rotary fine screen of opening 2 3mm

in SS304 construction.

FLASH MIXER

POLUTECHS Flash mixers are specially designed

and fabricated for the process requirement of water

and wastewater treatment. The mixer design ensuresefficient, minimum energy consumption and long

life. This equipment blends coagulants and other

chemicals with water / wastewater prior to

flocculation. The aggressive agitation results in

instantaneous and effective mixing of chemicals. This

unit is also useful for general mixing.


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FLOCCULATOR

POLUTECHS Flocculator provides gentle agitation by

slow moving paddles. This action serves to break up the

mass rotation of liquid and promote mixing. The specially

designed flocculating paddles enhance flocculation of the

feed solids. Agglomeration of the destabilized colloids is

achieved as a result of particulate transport in the

flocculation compartment. Increased particle contact will

promote floc growth and aids faster settling.

CLARIFIER MECHANISM

POLUTECHS Clarifiers are extensively

used for continuous mechanical removal of

settleable solids from water / wastewater.

These can be either Bridge or Center column

supported. In a center feed design the water

/ wastewater is carried to the center of the

tank, the water / wastewater enters a circular

well designed to distribute the flow equally

in all directions. The sludge removal

mechanism revolves slowly and may have

two or four arms equipped with scrapers.

The drive unit can be central or peripheral andalso manufactured with half/full scrapping

arm. They can also be equipped with scum

removal system. Besides conventional

clarifiers, high rate clarifiers with parallel plate

separators and tube settlers are also offered.

CLARIFLOCCULATOR MECHANISM


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POLUTECH Clariflocculator unit is a combination of both flocculation and clarification in a single tank.

This unit is consisting of concentric circular

compartments. The inner compartment is the flocculation

chamber and the outer compartment is the clarifier. The

chemically dosed water is uniformly distributed over the

surface of the flocculation compartment for effective

utilization of the available volume for flocculation.

The specially designed flocculating paddles enhance

flocculation of the feed solids. As heavy particles settle to

the bottom, the liquid flows radially outward and

upward and the clarified liquid is discharged over a

peripheral weir into the peripheral launder. The

deposited sludge is raked to the bottom near the central

pocket from which it can be easily discharged.

Both central driven and peripheral driven mechanisms

are available in the manufacturing range. They can also

be equipped with scum removal system. These units are

widely used in potable water treatment and industrial

wastewater treatment plants.

THICKENER MECHANISM

This unit is similar to clarifiers in construction but developed to produce a denser and thicker sludge,

which substantially reduces the plant requirement for solid

handling. High torque balanced drives and rugged structural

raking arms assure continuous operation during peak solidsloading without operator attention and maximum under-flow

concentrations for optimum solids de-watering. Both manual

lifting and automatic rake lifting devices are available in the

manufacturing range. They can also be equipped with scum

removal system and special arms are provided for dense

slurries.


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PRESSURE FILTERS

POLUTECH offers a full line of pressure filter designs to

handle a wide variety of applications. These include vertical

and horizontal single or multiple systems. Filters can be

offered with or without air-scour. Media types can be single,

dual and multiple. POLUTECH filters also feature state of the

art distribution and collecting systems for low pressure drop

operation.

FLOATING AERATOR of POLUTECH design will have thefollowing feature

A properly designed and balanced propeller of twobladed designs in stainless steel.

The throat of venturi shaped is designed to providethe most efficient fluid convergence and

divergence.

The integral ballast and large float body filled withrigid polyurethane foam to give better stability.

SLOW SPEED FIXED SURFACE AERATORS

POLUTECH Aerators are the most efficient, economical and trouble free mechanical surface aeratorsspecially designed to suit all types of biological reactors. Some of the highlights of the aerator are

Low Capital cost Low Maintenance cost Flexibility of operation Trouble free continuous service Simplicity of equipment Rugged design

The entire unit is manufactured to keep maintenance time and cost at the very minimum. The impeller is

specially designed to have self-cleaning feature, makes the equipment very robust, reliable and capable of

giving un-interrupted service over many years. These aerators provide vigorous agitation and mixing in

the wastewater to disperse the oxygen and keep the solids in suspension.


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DIFFUSED AERATION SYSTEM

The Diffuser consists of a porous Membrane made

of EPDM material. The diffuser is designed to

ensure uniform permeability and to produce a flow

of fine air bubbles. The fine uniform pore size

ensures minimal head loss across the diffuser. Since

the bubbles are of extremely small size the total

surface area that interfaces with the liquid is large.

The high contact area provided by the fine bubbles

and the high contact time provided by the slow rise

rate of the bubbles make this system very efficient

in terms of oxygen transfer efficiency.

TUBE SETTLER

POLUTECH offers lamella / tube separator, which is a versatile

clarification cum separation arrangement in which solids, oil and

grease can be removed from the feed water. The Lamella /

tube separators can be offered in steel or concrete arrangements.

An integrated flash mixer cum Flocculator is provided for

chemical treatment.


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REACTIVATOR CLARIFIER

POLUTECH Reactivator clarifier is a high rate

solids contact clarifier used for water clarification

and or softening. This unit combines flash

mixing flocculation, clarification and sludge

thickening into a single operation. It provides

selective or simultaneous removal of turbidity,

color, organic matter, odor, iron, manganese,

hardness and alkalinity


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RANGE OF SYSTEMS

OFFEREDWATER TREATMENT

Raw Water Treatment Plant Filtration plant Chlorination Plant Iron Removal System Fluoride Removal System Desalination System

INDUSTRIAL WASTEWATER TREATMENT

Physico Chemical Treatment Chemical Treatment Anaerobic Reactor Aerobic System Biological Fixed Film submerged Aeration System Membrane Bioreactor (MBR) Conventional aerobic treatment Anaerobic Treatment System Package sewage treatment plant

TERTIARY TREATMENT & EFFLUENT RECYCLING

Recycling of Waste water Reverse Osmosis System Tertiary treatment system for Recycling of Sewage Lime - Soda Softening System Carbonation and Re-carbonation System UF / RO / NF Systems


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ULTRA FILTRATION SYSTEM

POLUTECH offers UF System, which is a one-stop solution for

most of the pretreatment requirement for Reverse Osmosis (RO),

which ensures consistent, cost effective RO performance, by

producing water with

silt density index (SDI)

less than 1.0

UF - HF Membrane

removes the following RO fouling materials like

Particulate matter, Suspended solids, bacteria andviruses.

Colloidal materials (non-reactive silica, iron, aluminium,silt etc)

High molecular pollutant organic compounds. Thisminimizes RO cleaning protocols and reduces

operating pressures and enhances membrane life.

REVERSE OSMOSIS

POLUTECH RO systems employ reverse osmosis

process to dematerialize water without the use of

regenerant chemicals and associated waste

disposal. POLUTECH RO units are used for

treating brackish water and seawater to produce

potable and industrial water.

Custom RO Units

POLUTECH offers custom designed large reverse

osmosis plants for meeting the requirements of pure water for industrial units. These units are designed

in multiple modules with computerized software programme for selection and optimization of

membranes. Advanced PLC controlled monitoring systems are offered for controlling the operation and

maintenance of the unit round-the-clock.


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ANAEROBIC HYBRID REACTOR

POLUTECH develops innovating technologies-

in-house. We have installed many anaerobic

reactors for Bio-degradation of wastewater.

POLUTECH LIMITED reactors are designed with

fill media.

These units are extensively used for biological

degradation of organic pollutants in waste water

generated from distilleries, sugar mills, food

processing units, tanneries, meat and fish processing units, etc.

The concept of high-rate anaerobic reactors is based on three fundamental aspects:

1. Accumulation within the reactor of biomass by means of settling and attachment to solids. Such

systems allow the retention of slowly growing microorganisms by ensuring that the mean solids

retention time becomes much longer than the mean hydraulic retention time.

2. Improved contact between biomass and wastewater. Overcoming problems of diffusion of substrates

and products from the bulk liquid to biofilms or granules.

3. Enhanced activity of the biomass due to adaption and growth.


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AHR will incorporate packed bed packed with plastic media and an unpacked zone beneath the media to

permit accumulation of granular sludge. The purpose of the media will be to retain biological solids

within the reactor either as a fixed-film attached to the media. as solids entrapped within the interstitial

voids within the media matrix or as suspended within or beneath the media as a granulated or

flocculated sludge mass. Therefore, the media acts as a gas-solids separator, helps to provide uniform

flow through the reactors improves contact between the waste constituents and the bio-mass contained

within the reactor and permit accumulation of the large amounts of bio-mass needed to produce long

solids retention times.

CD RO UNITS

POLUTECH offers CD Ro Units for wastewater with high

scaling or biofouling potentials. CD - module combine the

advantage of the open channel technique with the high

membrane packing density (density rises factor 5 against tubular

modules).

The very low

energy demand

because of the

optimized and

lower feed volume. In comparison to the other disc

modules, the CD modules avoid the sharp 180 deg

turns, have a continuous flow velocity, dont change the

diameter of the channel and have therefore a drastically

reduced pressure loss over the module

The new outstanding fluid form of CD Modulehas the following

advantages:

Avoidance of frequent sharp reverse turns of 180 (inconventional disc modules 2 turns per plate level)

Defined flow in the complete membrane stack, Defined velocity without slow down or accelerating sections Avoidance of sections with low velocity (danger of fouling), In all parts diminished pressure losses at higher velocities.


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MEMBRANE BIOREACTOR SYSTEM (MBR)

Reinforced submerged hollow fiber membranes are employed in the filtration stage to separate purified

effluent from waste compounds, providing disinfected effluent of very high quality. The unique patented

design of these membranes incorporates braiding to significantly improve the membranes ability to

withstand the harsh operating environment of a Membrane Bioreactor and thus increases lifespan.

Special feature of the membrane design are bundles of membrane fibers that are only fixed in a single

header at their lower ends.

The upper ends of the fibers are individually sealed and free to move laterally.

MBR Tank at Sandoz Private Limited, Navi Mumbai, India

We have installed another MBR system at M/s. Silk Road Sugar Limited at Kakinada to treat the effluent

generated from their sugar refinery. By this installation we have reduced the foot print required and huge

civil cost was reduced for the similar conventional treatment plant. Here the MBR outlet water is directly

fed to the Reverse Osmosis unit, thereby removing

the filtration and Ultrafiltration system.

PACKAGE SEWAGE TREATMENT PLANT (AEROPAK)

POLUTECH manufactures and supply package sewage treatment plants

incorporating extended aeration activated sludge system.Depending upon the

quantity of waster water,the tank can be either rectangular or circular in

configuration.the clarifier compartment is located as central portion of the tank.The

waste water is aerated by means of diffused aeration in the annular portion of the

tank.POLUTECH package plants are pre-engineered to keep down the cost to the

minimum.The package plants are also supplied incorporating mechanical surface

aerators in place of compressed air system.

Aeropak installation at Mauritius

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