Iron Removal Plant: Working process, key equipment, and updated price in Bangladesh — all in one quick guide.

iron-removal-plant

Iron Removal Plant || Working Process|| Price|| 01714404000

What is an iron removal plant in water treatment?

An Iron Removal Plant (IRP) is a specialized water treatment system designed to remove excess iron, manganese, and other related impurities from water sources, especially groundwater. In many regions—particularly in South Asia, including Bangladesh—groundwater often contains naturally occurring iron in high concentrations. Although this type of water may appear clean at first, the dissolved iron becomes visible when exposed to air, causing discoloration, unpleasant odor, metallic taste, and staining. An Iron Removal Plant is installed to solve these problems and ensure that water becomes safe, odorless, colorless, and suitable for domestic, commercial, and industrial use. Iron contamination is one of the most common water quality issues in countries that depend heavily on tube wells, deep wells, and bore wells. When iron levels exceed the recommended safe range, water becomes unsuitable for drinking, cooking, household use, and industrial operations. An IRP provides a complete purification solution by converting dissolved iron into a removable form and then filtering it through specialized media.
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iron removal plant

Why Iron Removal Plant Is Important?

The significance of an Iron Removal Plant (IRP) extends far beyond mere water purification; it is a vital safeguard for public health infrastructure, economic longevity, and environmental sustainability, particularly in areas reliant on ferruginous groundwater. Unlike general filters, an IRP is engineered to specifically manage the complex chemistry of iron, transforming the clear, dissolved ferrous ion into a removable particulate ferric hydroxide precipitate . This targeted oxidative filtration prevents a cascade of costly and disruptive issues. For households, it preserves the aesthetic quality of life by eliminating the metallic taste, preventing the notorious reddish-brown staining of ceramics and fabrics, and ensuring clothes retain their true colour. Economically, an IRP protects vital infrastructure by preventing the premature scaling and corrosion of industrial equipment, boilers, and domestic plumbing, thereby significantly reducing maintenance costs and extending the lifespan of water conveyance systems. Ultimately, by ensuring water quality meets strict potability standards, the IRP underpins sustainable water management, turning an unusable or high-maintenance water source into a reliable, high-quality resource for both consumption and commerce.

The removal process consists of the following steps

Different mechanisms of iron removal plant (Physical, biological and chemical) dominate iron removal plant on the physical and chemical characteristics of the water and process condition.

1. 🧪 Chemical Mechanism: The Core Transformation
The chemical mechanism is the core process in most Iron Removal Plants (IRPs), where soluble ferrous iron is converted into insoluble ferric hydroxide for easy removal. This begins with oxidation, the essential chemical step, in which water is aerated to introduce atmospheric oxygen that naturally oxidizes, When iron concentration is high or the water’s pH is low, additional chemical oxidizers such as Chlorine (NaClO) or Potassium Permanganate (KMnO₄) are injected to accelerate the reaction. Because the oxidation rate is strongly pH-dependent, adjusting the water’s pH using lime or caustic soda significantly enhances both the oxidation efficiency and the precipitation of ferric hydroxide.
2. 🧱 Physical Mechanism: Removal of Solids
The physical mechanism handles the actual separation and removal of the solid, insoluble iron particles formed during the chemical stage. First, in flocculation and sedimentation, the tiny ferric iron particles (flocs) join together to form larger, heavier aggregates. In systems designed to treat high iron concentrations, these dense flocs are allowed to settle at the bottom of a sedimentation basin before the water moves to the filtration stage. Filtration is the primary method of physical removal, where water passes through layers of media such as sand, gravel, or anthracite that physically trap and retain the precipitated ferric hydroxide particles. In addition, some systems use adsorption-oxidation, a physico-chemical process in which catalytic media like Manganese Greensand or Birm adsorb ferrous iron onto their surfaces, where it rapidly oxidizes and precipitates. This mechanism effectively combines physical capture with accelerated chemical reaction for enhanced iron removal efficiency.
3. 🦠 Biological Mechanism: Utilizing Natural Processes
In certain conditions, Iron-Oxidizing Bacteria (IOB) such as Gallionella and Leptothrix can be utilized to enhance iron removal efficiency. These bacteria perform bio-oxidation, converting ferrous iron into ferric iron as part of their natural metabolic process. The resulting ferric iron accumulates within their slimy capsules or extracellular sheaths, forming dense, compact particles that can be easily removed through filtration. Biological iron removal offers advantages such as reduced chemical usage and the ability to handle higher iron loads compared to conventional chemical processes. However, successful operation requires precise control of water quality parameters, particularly maintaining the pH between 6.0 and 8.0 and ensuring adequate dissolved oxygen levels.

Iron removal plant (IRP) working process

  • Raw water distribution cycle
In this stage, the bypass valve is adjusted to direct water toward the distribution network. The raw water, containing naturally occurring iron and arsenic from the overhead tank, is routed through the distribution line without any prior treatment. This process ensures that the untreated water reaches the designated points in the system, allowing for subsequent treatment stages or monitoring as needed.
  • Filtration cycle / Stage -1

In this cycle, the bypass valve is set to bypass the line. At this stage, the raw water is passed through the iron filter the iron gets removed and iron-free water is sent to the arsenic filter

  • Filtration cycle / Stage -2

At this stage, the iron-free water is sent to the Arsenic filter where the arsenic content is removed the then sent to the polishing filter for further removal of residues if any.

  • Filtration cycle / Stage -3
At this stage, the arsenic-free water is sent to a polishing filter for removal of residues, the treated water is set to a distribution line through a booster pump and a part is stored in a tank for backwash.
  • Backwash cycle

During this cycle, the treated water stored in the tank is pumped to an iron filter for backwashing and the backwashed water is sent to a soak pit for further use in watering trees, etc.

Iron Removal Concept

  • Oxidation
  • Filtration
  • Optional Chemical Assistance
  • Aeration 
  • Forced Aeration with compressed air
  • Contact bed oxidation

Iron Water Treatment Features

 1. Efficient Iron Removal

2. Manganese and Turbidity Removal

3. Advanced Oxidation

4. Multi-Layer Filtration

5. Automatic Backwashing

6. Optional Polishing Stage

7. User-Friendly Operation

8. Durable and Reliable

Our state-of-the-art Iron Removal Plant (IRP) is designed to provide efficient and reliable iron-free water for a wide range of applications. It is suitable for:

  1. Households and Residential Buildings
  2. Commercial Establishments
  3. Industrial Applications
  4. Community and Municipal Water Supply
  5. Agricultural and Irrigation Use

Problems with Iron in Water:

Discoloration: Water may appear rusty, reddish-brown, yellow, or cloudy when the dissolved iron (ferrous iron) is exposed to air and oxidizes into solid particles (ferric iron, or rust).

Staining: Iron concentrations as low as 0.3 mg/L  can cause reddish-brown or orange stains that are very difficult to remove on:4Sinks, bathtubs, and toilets.Laundry, especially after using bleach (which is an oxidizer and converts the dissolved iron to a staining particle).Dishware and utensils.

Unpleasant Taste and Odor: Iron can give water a metallic, disagreeable taste. It can also affect the taste and color of beverages (like tea and coffee, which may turn black) and food cooked in the water.

Sedimentation: Reddish-brown or yellow particles (rust) may settle at the bottom of a glass or water storage tank.

Clogging and Reduced Water Flow: Over time, oxidized iron particles and deposits can accumulate in pipes, filters, and valves, leading to reduced water pressure and eventual clogs.

Appliance Damage: Iron buildup in water-using appliances like water heaters, dishwashers, and washing machines reduces their efficiency and lifespan, leading to costly repairs and replacements.

Iron Bacteria: Iron provides a food source for certain non-pathogenic bacteria (“iron bacteria”). These organisms create a slimy, reddish-brown or yellow biofilm (sludge) that clogs plumbing and filters and can cause a foul, sometimes musty, odor.In general, iron in drinking water is not considered a health hazard at typical levels and is an essential nutrient. Most iron required by the body comes from food.

However, excessive long-term intake from water, particularly concentrations over172mg(L) (or mg per dose) of elemental. can sometimes lead to gastrointestinal issues like constipation, nausea, or vomiting.18 iron ,Individuals with rare genetic conditions like hereditary hemochromatosis (iron overload disorder) are at a higher risk, as their bodies cannot regulate iron absorption effectively.

 

We found customer questions and solve them.

⇒ How much does installation cost?

 Depend on plant capacity and water test.

⇒ Which Country Products?

 China, India, Bangladesh

⇒ How many days are guaranteed?

1-year plant guarantee.

⇒ Do you do outside Dhaka?

 Yes, I do it all over Bangladesh.

⇒ Where is your office?

Rampura, Dhaka, Bangladesh.

⇒ how much electricity consumption?

Depend on plant and pump.

⇒How many days after water media need to be changed?

 20-25 months

More info please contact our phone No: 01714404000

CORPORATE OFFICE

377/1,DIT Road, East Rampura Dhaka -1219, Bangladesh

01714-404-000

info@mhtwater.com

Office Hour: 9:00 AM to 6:00 PM (Everyday)

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ABOUT MHT FILTRATION LIMITED
MHT Filtration Ltd. is Bangladesh’s first and leading water technology company. Since 2017, we've been dedicated to providing complete water treatment solutions and guaranteeing access to clean, safe water nationwide through our range of premium imports like RO membranes, purifiers, and industrial pumps.
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