Komal delivers customer value by improving quality and the performance of the product and by reducing operating costs and extending equipment life in a broad range of products and services. These products and services are used to optimize total water/process system performance, safeguard customer assets from corrosion, fouling and scaling, and protect the environment through water and energy conservation.

Pharmaceutical Water Systems

Purified Water and WFI Distribution Systems

Fully Assembled “ready to install” compact PW Generation Systems

KOMAL PW storage tank

ultra-pure water systems

Reverse Osmosis systems

Demineralization systems

Pretreatment water systems

multicolumn distillation plant

Pure Steam Generator

Disinfection Systems

Ozone Generators

KOMAL manufactures a Corona Discharge Ozone Generator and Ozone application Engineering Including dissolution column, air preparation unit and Ozone destruction. ‘OZ1 series of Ozonator Generator operate exclusively on oxygen feed gas, Eliminating the need of Air preparation unit. For the smaller requirement of ozone ‘OZ’ Series Ozone Generator is very efficient, reliable and very cost – effective.

Ozonator is provided with all the accessories including filters, dielectric glass cell. High Voltage Transformers, Flow meters, Pr. Gauges, Safety shut – off valve, Pr. Regulator, etc.

Applications

  • Eliminate Chemical Cost
  • Eliminate Cost of Transportation and disposal
  • Ozone leaves no residue, its only by – product is Oxygen
  • Precipitate heavy metals
  • Enhance Taste / Freshness of Water

Ozone Production

Ozone producing electrodes are of the Corona discharge type, having a 316 Stainless Steel tubular outer shell, with an Internal Cylindrical dielectric assembly. The dielectric has a conductive material that is applied to the inner surface and is connected to the high voltage, low or medium frequency power supply with the S.S. Tubular outer shell acting as the ground between the S.S. Tubular outer shell and the dielectric assembly is an air gap Ozone” Corona” discharge gap. The oxygen enriched feed gas stream passes through the air gap and the intense corona converts a percentage of the oxygen to Ozone.

Komal Ozone Generator

Ozone System shall include all necessary components and controls to constitute a completely functional and operational generation system intended for 24 hrs. Operation

Generator shall include the following:

  • Stainless Steel Ozone generating cell
  • Medium frequency power supply inverters with transformers and control
  • Optional PLC for various controls
  • Ozone Dissolution Column with non corrosive diffuser
  • The generator is powered by 230 V AC 1 phase or 440 VAC 3 phase 60 cycle service
  • Alarm and safety features
  • Optional dissolve ozone monitor
  • Optional Ozone destruct module
Model No Ozone Output Oxygen Flow at 2%wt.(l/mt.)
0Z-1 1 gm/hr 0.6
0Z-2 2 gm/hr 1.2
0Z-3 3 gm/hr 2.03
0Z-5 5 gm/hr 3.5
0Z-10 10 gm/hr 6

Ultraviolet Disinfectants

Perfect Germs Killer

Ultra – Violet (UV) Rays lie just beyond the visible light band on the shorter wavelength end of the Electromagnetic spectrum. The high – energy UV-Cray Wavelength ranges between 200 nm and 280 nm (nm = 10-9 m). These rays, particularly the 253.7 nm Wavelength upon contact (see graph). The destructive UV rays strike and enter the body of germs -bacteria, viruses, yeast, algae and certain protozoa. Once inside, the rays are absorbed by the organism DNA This kills it at once It is the simple and swift action that has made UV disinfection the world’s most effective and most economical method of obtaining germ – free water for a Wide range of end – uses. UV disinfection is utterly simple-easy to install, easy to operate, and easy to maintain. It takes up very little space, work non-stop over long periods and gives Ready-to-user process water instantly. Since on chemicals are required, there are not hazards of storage and over-dosage of toxic and corrosive chemicals. This raises the safety level considerably. What’s more the UV rays leave, water in this natural state without causing any change in its color, smell, taste temperature, pH level and mineral content. That’s why UV disinfection is so universally popular.

Komal Disinfectors

Energy – Efficient Design Komal disinfectors are built around a very energy- efficient design. Naturally, this also makes them highly cost – efficient. In Komal disinfectors, the killer UV wavelength 253.7nm is produced in the low –pressure mercury vapour lamps. An electric arc strikes an inert gas and the resultant heat vaporizes the mercury inside the lamp envelop. As the mercury atoms excited to high energy states begin to return low energy states the 253.7 nm wavelenght UV rays ere radiated straight in ti the water flow. the high energy UV lamps are rated for 9000 hours non – stop use. The UV lamps are isolated from the water flow by placing them inside specially fused quartz glass sleeves. The typically transmits 95% of the incident UV radiation consumption leading to total destruction of all waterborne micro – organisms. The reliable killing of micro-organisms is achieved primarily with a sufficient UV radiation dosage. The dosage is measured in micro watt second/ cm2 most bacteria are completely annihilated by a 1300 ms cm2 dosage in excess of 30000 m w-s / cm2 ensure absolute bacteria kill.

Maintenance

Almost Maintenance Komal disinfectors ask for very little maintenance. There user-friendly design allows for ultra-quick Disassembly, cleaning, and parts replacement without any appreciable downtime. The UV lamps are replaced in less than five minutes without having to discontinue operations. The quarts sleeves, which need only annual look-over, can be cleaned equally fast. The disassembly of the outer housing requires only common tool. The entire units is made of sturdy 304/316 stainless steel. The housing highly polished. Inside parts are < 0.8 Ra value electropolished. This sanitary finish reduces surface profile variations while greatly enhancing wetted surface passivity.

Applications

Wide Range fF End – Uses Komal disinfectors have found wide acceptance in these fields:

  • Drinking Water
  • Mineral Water
  • Textile Industries
  • Demineralised Chemical
  • Plants Breweries
  • Petroleum Industry
  • Distilleries
  • Soft Drinks
  • Lon Exchanger
  • Bottling Plants
  • Filters
  • Canneries
  • Reverses Osmosis
  • Pharmaceuticals
  • Swimming Pools
  • Hospitals
  • Laboratories
  • Aquaria
  • Cosmetic

Accessories

Add-ONS & Optionals

Every Komal disinfector is provided with these auxiliary instruments to help monitor and optimize its performance.

UV Optical Sensor & Alarm

A Photo-optical probe with automatic low level alarm to Monitor the relative intensity of the 235.7 nm UV radiation inside the disinfection chamber. With Additional circuitry for separate alarm.

UV Lamp Operating Display

A direct-driven LRD display panel for continuous visual Indication of the UV lamp operating status. When a UV lamp goes out inside, its corresponding LED display goes out too. These instruments are available on option:

Running Time Meter

Measures and display the disinfector operating hours.

Thermistor Safety Control

Protects the disinfector from high heat build-up Resulting from prolonged operation without water flow Ideal where the disinfection cannot be connected to the pump circuit.

Printing

A thermal printer for printing the dosage and the number of hours the lamp is running.

Water System Conrtoller

Helps operating personnel monitor the water system Operations by automating these routine tasks:

  • Monitoring raw water level in supply tank,
  • Monitoring conductivity of outlet water.
  • Monitoring and controlling level of demineralised water in storage tank.
  • Protection against accidental collection of outlet Water when the plant needs regeneration (high conductivity) or when UV disinfection is defective.

Komal TOC Reduction UV

Komal Ultraviolet Disinfection equipment is designed to reduce TOC levels by means of high energy wavelength that cause Photooxidation. Photooxidation with UV radiation occurs by the generation of hydrogen free radicals in the water stream. The hydroxy free radical oxidising capacity is more powerful than Ozone. The Photooxidation process that takes place in the UV contact chamber required high energy level of UV radiation. The shorter the wavelength spectrum,the higher the amount of UV energy generated, thus rapidly oxidizing the organic molecule by braking chemical bond. UV oxidation processes are the most reliable means of meeting the new standards. UV system offers substantial capital and operating cost saving compared with other conventional treatment process.

TOC Reduction system by KOMAL are designed Specifically for the reduction of total Organic Carbon (TOC)

Features

  • Use Of Highest Putity Quartz Tubing
  • Consistent dose, delivers
  • Electro polished stainless steel 316 reactor.
  • 9000 hour Guaranteed lamp life.

Ideal Germicidal

ULTRAVIOLET ENERGY at 2537 Angstrom units wavelength required for 99.9% destruction of various microorganisms (UV energy in microwatt- sec / cm2)

Bacteria
Bacillus anthracis 8700
Eberthella typosa 4100
Escherichlia Coli 7000
Micobcterium Tuberculosis 10,000
Neisseria Catarrhalis 8500
Pheudomonas Aeruginosa 3900
S.Typhimurium 15,200
Salmonella 10,000
Dysentery Bacilli 4200
BSraphylococcus Aureus 7000
Streptoccus Hemolyticus 5500
Streptococcus Viridans 3800
Alage
Chlorella Vulgaris 22000
Virus
Bacteriophage (E.Coli) 6600
Tobacco Mosaic 4,40,000
Influenza 6600
Hepatitis Virus 8000
Polio Myelitis 21,000
Protozoa
Parmecium 2,00,000
Nematode Eggs 92,000
Yeast
Saccharomyces Elliposideu 13,200
Brewers’ Yeast 6600
Bakers’ Yeast 8800
Model No. Flow Rate Max Flow Rate No. of UV Power Treatment Housing Inlet UV Dosage Lamps Life
(Lit/hr) ( Distilled /RO Water) Lamp Consumption (Watt) Material Outlet Size mw/sec/cm2 hrs
UV-Plus** 75 120 1 14 pp 6mm >16000 5000
UVH-B 500 700 1 48 ss-304/316 15mm >35000 9000
UVK-1 1200 2200 1 70 ss-304/316 25mm >35000 9000
UVK-2B 2500 4000 2 140 ss-304/316 25mm >35000 9000
UVK-2 3500 6500 3 190 ss-304/316 40mm >35000 9000
UVK-3 5000 8500 4 260 ss-304/316 50mm >35000 9000
UVK-4 6000 10000 5 320 ss-304/316 80mm >35000 9000
UVK-5 8500 15000 7 440 ss-304/316 80mm >35000 9000
UVK-7 10000 18000 9 560 ss-304/316 100mm >35000 9000

* Output of 2537 A with new lamp at 80 F with an absorption coefficient at 0.10
** UV Plus comes with 5 micron filter with A. Carbon in a P.P. House.
*** Optional S.S. 316/ S.S. 316 L.

Sterilising Chamber Construction

Sleeve to End Plate O-ring :High Purity Quartz Maximum Working Pressure :Silicon Rubber Pressure Loss at Average Flow :3.5 gk/cm2 : < 3 psig Temp Range :5 0 C – 80 0 C ` Supply Voltage : 220-240 V, 50 Hz Input Water Requirement : Free From Particulate Matter

Ballast Control Unit is Provided with each unit.

Electrode-ionisation Systems

KOMAL “ED” series of Electrodeionisation unit employs EDI technology to produce high purity water. EDI process systems replace conventional Dl mixed bed resins unit to produce deionised water. KOMAL EDI does not require shutdowns to regenerate the resins with chemicals or replacing resins. Consistent high purity Ultrapure water having resistivity of 12-15 Mohm .cm can be produced.

Reverse Osmosis followed by electrodeionisation and then by ultrafiltration or another stage of RO complies with USP requirement meeting the specifications for the final Rinse of primary conditioning and for non-sterile production of ointments, Liquid and Tablets. Complete unit is mounted on a single stainless steel skid. Hot water sanitizable models that shorten the time necessary for sanitization of the RO and EDI unit and Eliminates need of messy chemicals. RO-EDI is the safest and most reliable chemical free process to produce Purified Water and is well proven.

Hot water sanitization is a perfect solution to prevent microorganism growth and biofilm development without utilizing unacceptable biocide chemical. Two pass RO system with intermediate EDI or RO-EDI with final stage of UF are also an option.

UF is used for final rinse to remove pyrogens (bacterial endotoxins) from water. The UF membrane has a mol. wt. Cutoff on 10000 Dalton. Pure water permeates the membranes but partical, pyrogens, colloids, silica, bacteria and high Mol, weight organics are rejected.

Both the versions of KOMAL High Purity water system produce water of considerably better quality than current requirements of USP with conductivity less than 1 µs/cm, and TOC typically less than 500 ppb. Microbial contamination is less than 100cfu/ml.

Standard capacities are available of 250 lit/hr. to 5000 lit/hr. with custom units available for up to 25000 lit/hr

Softening Plants

Strong, Long Lasting KOMAL WATER SOFTENER- engineered for the most demanding industrial, commercial and residential needs.

Base Exchange Softening Process

In these days Softening of Water is almost exclusively effected by lon Exchanges. In this process the calcium and magnesium ions are exchanger by sodium ions, so that the hardness forming components are converted into soluble sodium salts. Softening is carried out by simple filtration through the exchange material.

When the exchange material is exhausted, it requires regeneration with sodium chloride (Common Salt)). The calcium and magnesium ions which were taken up before are then, displaced by sodium ions and flow out together with the regeneration water. The capacities between regeneration will, however, vary according to the raw water.Water product will have commercial Zero hardness. These systems have a proven excellence in performance for application like textile, Boiler Heat Exchanger, Laundry etc.

  • Softeners are available in rust and corrosion proof FRP as well as sturdy M.S.Unit.
  • Control Valve: state-of-the-artdesignand with in –built ejector system, multi port valve for compact design.
  • Unit with Individual valves of Cast Iron are safe for outdoor application.
  • Completely Automatic is also available.
  • Compact Sturdy FRP Softening Unit
Model No Flow Rate (lit/hr) Capacity Bet. Reg.
KSF – 6 600 6
KSF – 8 900 10
KSF – 10 1400 18
KSF – 12 3000 30
KSF – 15 4500 40
KSF – 18 7500 70
KSF – 21 9500 100