K Pack Systems Pvt. Ltd.

www. kpack.in
Vision : Sustainable, lasting solutions for a better environment

What we do
• Efuent Treatment Plant
• Oil Water Separators
• Sewage Treatment Plant
• Waste Water Treatment Plant
• Water Treatment Plant
• Serve all Industries,
Water Treatment Companies & EPCs
• Reverse Osmosis (RO) and
Ultra ltration (UF) systems

Why Us

• We have 25 year experience of working with 400+

clients across industries in Indian and Global markets
• We have successfully completed 2500+ installations
• Tie ups with multiple reputed international rms
• Provide tailor made solutions
• Client experience and satisfaction is a key goal
• Quality focused – ISO 9001:2008 certied
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

API Oil Water Separators

The K-Pack API Series, oil/water separators are a gravity differential separation device for removal of free and
dispersed oil droplets from only waste streams. The design follows the American Petroleum Institute’s (API)
Design & Operation of Oil/Water Separators Manual.
We have experience using various MOC’s and a strong Engineering team to support demands

Gravity Separation
The API steel/RCC design is just a type of oil/water separator designs from K-pack that can be used singularly
or in combination with other treatment processes such as emulsion cracking, DAF & clarier pretreatment.
The API can be installed above, ush with or below grade. Conversion to a DAF can also be accomplished for
otation where needed.
The API separator separates via gravity and the density differential of liquids as per Stokes law, which denes
the rise rate of an oil droplet based on its density and size. Typically the difference between the specic
gravity of the oil and water is much closer than the specic gravity of the suspended solids and water.
therefore, the design of the API separator is based on the specic gravity of the oil to be separated and the
waste water. Using this criteria results in most suspended solids in the API. API efuent is then treated further
in more renery waste water treatment plants.
API Performance: 100mg/1, 150 -micron free, dispersed and non-emulsied oil droplets.
The typical use of the API separator is to reduce inlet loads of oil and suspended solids in renery waste water.
Following the API further treatment may be required, i.e. coalescing oil water separator as a polishing step
and treatment of dissolved organic materials with biological treatment, and/or other treatment technologies
(DAF etc.).

Typical Applications :
l Ground water remediation l Mobile separation system l Daf/clarier pretreatment l Power plant water
treatment l Renery process water l Aircraft wash racks l Machining coolant oil removal l Tank farm tank
bottoms l Vehicle wash water treatment l R.O. Filter pre-treatment Oil spill recovery l Trench water
treatment l Bilge water treatment l Hydraulic uid tank de-watering

Features :
l All the K-Pack series of API are completely
customised to client requirements.
l We have experience in working with all MOCs:
carbon, steel, RCC, stainless steel as with non
metallic components.
l APIs come with standard components.
l Oil and Sludge are collected through to the bottom.
l They can also be a scrapper mechanism customised
to ensure VOC handling.
 Cross Flow Separator (PCI)

K-Pack specializes in this technology, we have supplied over 400 such installations across various industries
from small scale Laundries to Steel. All K-pack separators are custom built with respect to the number of
plates in the pack, the length of the plates, the distance between the plates and the plate incline.The
number and the length of plates is determined as a function of the raw water ow rate to be processed in
the separator.
The Cross ow separator system permits simultaneous separation of oating and settling materials like oils,
bers, sand and heavy particles. Individually applicable as oil and solids separators.
Working Principle
The raw water containing oil and/or suspended solids passes in horizontal direction between the closely
spaced plates in the plate pack. Completely laminar ow conditions are established while the water ows
across the plate pack from the inlet to the outlet side. Laminar and stable ow conditions are essential
conditions for the effective gravity separation of the water, oil and/or the suspended contaminants. Our
Engineering team will design the system such that this is always attained and maintained
In the course of passing through the plate pack from inlet to outlet, the oil oats upwards into the tops of
the corrugations and rises up the incline of the plate to the surface of the separator, where it is removed by
a skimmer.
The solids move towards the bottoms of the corrugations and slide down the incline of the plate. From there
the separated solids are collected in the sludge compartment of the separator to be partially dewatered
and transported by a shaft less spiral conveyor and intermittently discharged through a blow- off valve
(optional). Settled sludge cannot decontaminate the treated water. Oil and solids move in separate
directions. but both perpendicular to the ow of water, eliminating particle re-entrainment completely.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

Design Principle

The Design Principle is depending upon the concentration of solids / sludge in the raw water. The incline of the
plates is set between 45 and 60 degrees depending upon the general nature of the oil and /or sludge, (density,
viscosity, concentration).
The solids separators are optionally with a shaft less conveyor in the sludge compartment.In the corrugation
tops a very high oil concentration is established. This is the ideal condition for oil coalescing to take place
(formation of large oil droplets out of many small oil droplets). In the corrugation bottoms a high sludge
concentration is established. This is the ideal condition for particle agglomeration to take place (formation of
heavy particles from small and relatively light particles). The oil is separated using a suitable oil skimming
mecahnism based on efuent. The solids are separated via a hopper

Applications :

l Most suitable where both Oil

and TSS are present
l Mineral oil industry
l Edible oil industry
l Metal industry
l Ceramic industry
l Galvanic industry
l Mines
l Sand separation after washing
l Electronics
l STP
l Desalination
l Textiles
l Cement
l Food Industry

Cross Flow
Separation
Principle
 Dissolved Air Flotation Units [DAF]
K-Packs DAF is customised highly compact & efficient gravity separation device. We gurantee atleast 90%
removal of oil and solids.
Suspended solids, grease and oil are very efficiently removed by DAF, and a combination of screening and DAF
results in BOD / COD removals upto 60% depending on the application.
However, a combination of flocculation and floatation can result in BOD removals of around 80-90%.
Dissolved Air Flotation (DAF) technology works by using a process where suspended solids, oil & greases, and
other insoluble impurities are separated from water slurries. The Dissolved Air Flotation device dissolves air
into water under pressure. Upon release of the pressure, micro bubbles form. These micro-bubbles interact
with the particles to causing them to float to the surface of the vessel where they are skimmed and separated.
K-Pack Systems continuously focuses on research and development to ensure the DAF is easiest to use,
compact and most efficient. The original Dissolved Air Flotation (DAF) system was tested side by side several of
the most well known DAFs in the market. It completely outperformed the competition. K-Pack's Dissolved Air
Flotation (DAF) system completely changes how liquid/solids separation is achieved. Dramatically higher
removal efficiencies, lower operational costs, smaller footprint and a longer life-span make it the ideal
Dissolved Air Floatation technology in the marketplace.
K-Pack's DAF can be effectively used to remove emulsified oil, grease, TSS, BOD, COD and other impurities
from a liquid stream.

Areas of Applications

l Oil Refineries l Ceiling Tile Plants

l Food Processing and Dairy Pulp & Paper Mills l Potable Water Plants
l Vegetable oil Processors l Municipal STP's
l Steel Mills and power plants l Chemical Processing
l Textile Plants l Beverage Manufacturers
l Pharmaceuticals
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

PWF Series

The PWF Floatation unit is a compact, highly efficient, parallel plate separator.
The PWF Flotation unit incorporates a large separation area in a small volume due to the use of parallel plate
technology.
All devices are modular and custom made and our smallest size is 1m3/hr and our largest size has been of
10000m3/hr.
We work with various MOCs like carbon steel, staineless, RCC and even non metallic compounds.
Size of the tank and plate packs are determined based on water parameters provided ensuring the best quality
of treatment.
The saturation of air into water is done using a compressor and pump for smaller flow rates. For larger flow
rates a tailor made saturation vessel is manufactured.

Features :
l Very compact modular construction
l Maximum pollution load reductions
l low maintenance costs
l easy operation
l high dry solids content
l expandable to larger capacities
l auger transport system for sludge
l competitive to other processes

Applications
l Mineral oil industry
l Edible oil industry
l Poultry and meat processing
l Fish processing
l Mining industry
l Offshore - onshore
l Petro-chemical industry
l Pulp and paper industry
l Others
 PWL SERIES

K-Pack’s PWL -DAF Is customised, highly compact, and efficent gravity separation device. These systems come
in retangular and circular shape and are completely designed as per clients needs. As with PWF, this can also be
made of various MOCs
Suspended solida, grease and oil and very efficiently removed by DAF, and a combination of screening and DAF
results in BOD / COD removals upto 60% depending on the application.
However, a combination of flocculation and floatation can result in BOD removals of around 80-90%.
For waste water containing high solids content, it is necessary to create a sufficient retention time for
prewatering of the skimming.
The PWL Series Flotation Unit have been designed for capacities upto 200 m 3 / hr. (as standard). Higher
capacities are realized by combining or expanding systems.
These systems do not use plate packs and are tank, low unit separator with aeration points in the in the inlet as
well as the sides of the tank to ensure excellent aeration along the entire tank length.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

PWL
To ensure high dry solids contents of the skimmings, the solids loading(kg solids/m3free unit unit surface) is in
important design factor. For wastewaters containing high solid contents, it is necessary to create sufficient
retention time for predewatering of the skimmings. The PWL

The aeration systems can be either executed with
The sludge collection compartment
is optional and can be replaced by
: - a multistage side channel pump-> K1
- air saturation vessel (K2)
: - a discharge chute
- a spiral conveyor discharge for heavy sludges

Features : Applications
l Very compact modular construction l Poultry processing,
l Maximum pollution load reductions meat processing and packing
l High dry solids content of separating l Fish processing
materials l Mining industry
l Easy operation l Petro-chemical industry
l Low maintenance costs l Pulp and paper industry
l Easy to expand to larger capacities l Textile industry
l Extremely competitive to comparable process l Tanneries, other industries.
l Circular as well Rectangular
l Multiple MOCs available
 PFR Pipe Flocculator

Coagulation and Flocculation by controlled Turbulence

The PFR pipe Flocculator is a plug flow reactor in which process such as coagulation, flocculation,
demulsification, precipitation and pH control can take place under highly controlled and well defined
conditions.
The above mentioned processes take place under turbulent flow conditions. At the chemical injection points
the pipe diameter is adapted to ensure instantaneous mixing of chemicals and wastewater. Through the cross-
section of a pipe the mixing intensity is virtually homogeneous. Reaction time is determined by the pipe length
and flow rate and based on the exact requirements, no excess is required . In the plug flow reactor the process
can be influenced at any time as opposed to tank reactors, where only condition per tank can be maintained.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

Generally speaking a pipe flocculator is used where a

coagulant, a flatulent and optionally a chemical for pH
correction are dosed in sequence for the remove al of
turbidity and / or COD or precipitants.
The use of a pipe flocculator in combination with a flotation
system can give COD removals of up to 95%.
K-pack Systems has a wide experience in chemical
treatment, particularly in the use and selection of
coagulants and flocculantsin combination with a PFR pipe
flocculator. The PFR pipe flocculator is exceptionally
suitable for our latest developments in the non-toxic bio-
degradable coagulants and flocculants range.

Specific details and characteristics

l High quality and durable materials like HDPE, PVS, MS pipes.

l No short-circuiting and hardly any back mixing.
l No retention time distribution.
l Homogeneous mixing throughout the cross section.
l Completely predictable and controlled mixing environment.
l No moving parts.
l No addií ional energy source.
l All required process conditions and chemical additions in a single unit.
l Uniform floc growth.
l Small space requirements.
l Exchangeable mixing pieces.

K-Pack Systems engineers can preform onsite tests to determine

l Process parameters for coagulation.

l Flocculation - separation.
l Chemical and additive requirements.
l Maximum achievable reductions in pollution load.

Available models

l Standards units are available upto a flow of 400 m3 / hr.

l Customized units for special applications.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

The TPI Separation Principle

In the modern TPI System, the separating surface area is increased vertically by the addition of a number of
parallel plates mounted at an inclination. This not only affords a dramatic space saving but also facilities very
small separating diameters.
0
The K-pack TPI consists of a plate pack constructed of closely spaced corrugated plates inclined at a 45 angle
or more, depending on the application. Waste water flows through these plated either parallel to the
corrugations in “Counter-current Flow” or at right angles to the corrugations in “Cross Flow”. Under laminar
flow conditions, the short distance between the inclined plates is now the only distance over which the
pollutants have to raise or sink before they are intercepted and separated from the mother fluid.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

The Corrugated Plate Packs

The corrugated plate pack represent the very heart of our various purification systems consisting of a number
of parallel corrugated plates (see photograph). These are framed in a housing and the whole pack is stiffened
by a frame made from plastic material and / or steel.
The liquid to be treated flows through the spaces between the corrugated plates. Flow through the pack is
laminar thus allowing the separation to take place under ideal conditions. In addition, much attention has
been given to the profile of the corrugated plates. These have been chosen so that a smooth transfer and
compaction of the separated particles is effected. To promote equal and uniform supply to the plates,
specially designed flow baffles are used.
In order to reduce the frictional resistance between the separated material and the corrugated plates to the
minimum, particular attention was paid to the smoothness and hardness of the plate surface. The corrugated
plates as well as the casing are made from glass fiber reinforced isophtalacid polyester resin. This material is
resistant to the most frequently used chemical additives and temperatures. For applications under more
aggressive conditions bishenolic acid polyester resin or another suitable material is used. For erection and
inspection purposes the plate pack has been fitted with lifting eyes so that it can be easilyremoved from or
replaced into the installation. Upon request these plates can be made of other GRP resins like Orthopthalic
acid, Bisphenol and Vinyl Ester Resins. Stainless steel packs have also been supplied as a special case.

The TPI System for OIL-WATER Separation

The TPI System is the ideal method of removing free oil from water. The plate pack (constructed of Stainless
Steel, FRP, etc, depending on the application) is installed in an RCC basin or specially designed steel tank. The
oily water flows into the interceptor through a flow distribution baffle, then into the plate pack. Here the oil
droplets are intercepted and coalesce into large droplets as perfect laminar condition are created and
maintained throughout. In the case of counter-current, the droplets leave the pack rapidly, subsequently
flowing upwards against the liquid flow to the surface for eventual removal through the skimmer pipe. Any
sludge is also effecively separated by the reverse process.

Applications :

l Mineral oil refineries; oil extraction;

offshore platforms
l Tank storage farms
l Ballast water treatment
l Petrochemicals
l Galvanizing metal; mining industry
l Edible oil refining
l Foodstuffs industry
l Paper & pulp industry.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

PCS Lamella Settlers

Lamella settlers are basically cross flow plate separators designed for removal of settleable solids. The water
containing solids flows in a horizontal direction between the closely spaced plates in the plate pacj.
Completely laminar flow conditions are established while the water flows across the plate pack from the inlet
to the outlet side.
Solids with the higher density than the carrier fluid will settle down
into the sludge compartment to facilitate removal of the solid
particles.
The number and size of the plates is governed by the water flow rate
and the settling velocity of the solids, which in turn are proportional
to the diameter of the solids to be settled.
The distance between the plates is depending upon the concentration
of solids sludge in the raw water.
The plate distance can be varied, usually between 20 and 50mm, to
allow for the different sizes of the settling particles, and to prevent
clogging of the plate packs.
The systems are fabricated in mild steel and other materials are
available on request.
All K-pack separators are custom built with respect to the number of
plates in the pack, the length of the plates, the distance between the
plates and the plate incline.
The incline of the plates is set between 45 and 60 degrees depending upon the general nature of the Oil and /
or sludge. (density, viscosity, concentration).
The systems are fabricated in mild steel, and other materials are available on request. The oil separators are
standard with oil and skim pipe and 45 degree shaped compartment. The solids separators are optionally with
a shaftless conveyor in the sludge compartment.

TYPE 10 20 30 40 60 110 220 330 440

PCS (CAPACITY)
PLATE DISTANCE 30 30 30 30 30 30 30 30 30
EFFLUENT PLATE AREA 15 29 43 58 86 157 314 472 15
A-LENGTh mm 2414 2414 2414 2414 2414 3514 3514 3514 3514
B-WIDTH mm 1274 1714 2214 2714 3714 2214 4214 6214 6214
C-HEIGHT mm 2490 2490 2490 2490 2490 3125 3125 3125 3125
D-INFLUENT NW 80 80 150 100 100(2x) 200 200(2x) 200(2x) 250(2x)
E-EFFUENT NW 100 100 100 150 200 250 300 400 450
F-DRAIN NW 100 100 100 100 150 150 150 200 200
G-SKIMMER NW 100 100 100 100 100 100 150 150 150
EMPTY WEIGHT 1600 1600 1750 2000 2500 2750 4000 5200 6400
FULL WEIGHT 4500 6000 7700 9500 14000 15000 28500 42000 55000

APPLICATIONS
- Mineral oil industry
- Edible oil industry
- Metal industry
- Ceramic industry
- Galvanic industry
- Mines
- Sand separation after washing of
contaminated soil
- Food industry
 AQUAFLOAT

Aquafloat aerators and systems

AQUAFLOAT Induced Air Flotation (IAF) aerators & associated plant from PCPL provide an efficient & cost
effective air flotation system for the removal of fats, oils, greases and other solids from industrial & municipal
water and wastewater.
AQUAFLOAT is also suitable for the thickening of sludges from other water & wastewater treatment processes.
AQUAFLOAT is also suitable for the efficient diffusion of externally supplied gases (such as ozone or nitrogen)
into liquid.
Aquafloat can provide an effective and simple alternative to more traditional dissolved air flotation (DAF)
plants.
Operation
The range is based around the Aquafloat IAF micro
bubble aerators. These aerators are capable of inducing
large volumes of atmospheric air (or introduced gas) and
presenting it via a specially designed rotating disc into a
vessel or body of liquid as extremely fine micro bubbles.
These micro bubbles effectively attach to solids
particles in the liquid and float them gently to the
surface of the liquid for concentration and mechanical
removal, allowing clarified liquid to pass out of the
vessel to discharge or further treatment.
This aeration function is performed with very little
induced turbulence making the Aquafloat an excellent
unit for flotation applications.
Simplicity
Unlike more traditional DAF aeration, the Aquafloat aerator produces it's air via atmospheric induction at
atmospheric pressure. As such, there is no need for pressure vessels, recycle pumps and associated pipework
and controls.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

System Sizing: Aquafloat systems based around the Aqua

float aerators have been made to treat as little as a few hundred
litres per day in a small tank, right up to single vessels treating 10
megalitres per day in large industrial oil refinery applications.
Retrofit Capability and Flexibility
The Aquafloat range of IAF aerators lend themselves to retrofit
applications very readily. Where there is an underperforming DAF
or existing flotation plant, a simple Aquafloat aerator installation
can boost it's operation immediately at low expense. This can mean
immediate savings in operating consumables and discharge costs.
Likewise, existing pits and separation vessels or clarifiers can be
very quickly turned into flotation cells by the simple introduction of an Aquafloat IAF aerator or aerators.

Multicell High Flow Units

The Aquafloat has been particularly successful in very high flow applications such as oil refinery wastewater
applications. This is effected by a special multi flotation cell plant design allowing for in-line controllable air
quality in a number of sequential flotation cells.
These systems can be provided to the very high specifications required by the oil and gas industry.
Low Noise Operation
The Aquafloat aerators are very quiet units, with aeration activity
taking place below the surface of the liquid in any installation. No
noisy air compressors are required for Aquafloat aeration.
Australian made - World class
The Aquafloat range is designed and manufactured wholly within
Australia with local parts support - and has been exported all over
the world.
For further information or an application design using Aquafloat -
please contact PCPL or your local Aquafloat representative.

Aquafloat Specifications
AQUAFLOAT Aerators AQF-1, AQF-2,
Ranges (50 Hz, 415 V models typical values stated, 60 Hz and variable voltages data available on request)

Model No. kW rpm FLC Noise Weights (kg)

(Amps) dB(A) Aerator Only
AQF-1-1.5 1.5 2870 3.2 66 35
AQF-1-2.2 2.2 2850 4.4 66 38
AQF-1-3.0 3.0 2890 5.7 60 40
AQF-1-4.0 4.0 2870 7.2 61 50
AQF-1-5.5 5.5 2910 9.9 62 60
AQF-2-5.5 5.5 2910 13.3 62 75
AQF-2-7.5 7.5 2900 13.3 62 80

* Note : Specs are correct at time of publication, but may be changed at any time - please
confirm specification data with PCPL or your local representative
** Note: Aquafloat system specifications available on application.
 K-PACK SYSTEMS
PRIVATE LIMITED
WATER TREATMENT

#3,9th Main, 9th Cross, Ex-Servicemen's Colony,

Vasanthnagar, Bangalore - 560052 | INDIA
Mobile: +918040731300, +918040731301, Email: info@kpack.in

Mumbai Ofce: #305, Konark Shram, 3rd Floor, Behind Everest Building,
Tardeo Main Road, Tardeo, Mumbai-400 034
Mobile: +(91)-22 66333272, +(91)-22 66333273

Baroda Ofce: #A 1/121, Associated Society, Opposite HDFC Bank,

Off Old Padara Road, Akota, Vadodara - 390020 | INDIA
Mobile: +(91)-265 2324666, +(91)-265 2342745, +(91)-265 2342905