DM PLANT LECTURE.ppt

DM PLANT OPERATIONS AND RESINS

1. DMPLANT LECTURE
OPERATION, RESIN
MAINTENCE & TROUBLE
SHOOTING

2. SOURCE
RAIN.
SURFACE
UNDERGROUND
SEA

3. Impurities in Water.
Natural water are seldom pure
Whatever is source-Water gets
contaminated with Salts ,Gases or
Non-Ionic impurities by coming in
contact with air,soilor industrial
effluents.
Major impurities
Ionic-Dissolved
Non-Ionic-Suspended
Dissolved Gases.

4. Conti...
Inorganic
Silt / Mud
Salts, Na, Ca, Mg -Cl, SO4, HCO3,
OH, H+
Organics
Slime / insoluble organics.
Alcohol, Aldehydes, Acids
Gases
O2, N2, CO2
Ammonia , H2S

5. MAJOR IMPURITIES OF WATER

Ionic &Dissolved

Cationic Anionic
Nonionic and
Undissolved
Gaseous
Turbidity,silt Carbon dioxide
Calcium Bicarbonate Mud ,dirt and Hydrogen
Sulfide
Magnesium Carbonate other suspended
matters.
Ammonia,
Sodium Hydroxide Colour, Methane,
Potassium Sulphate Organic matter, Oxygen
Ammonium Chloride Collodial Silica, chlorine
Iron Phosphate Micro-organism,
Manganese Silicate & Plankton,bacteria
Organic matter Oil and corrosion
products

6. INDUSTRIAL WATER
TREATMENT
Wateristhemostimportantraw
materialusedinindustry.
It has good heat capacity.
It is a universal solvent.

7. HARMFUL EFFECT OF
IMPURITIES
Scale Deposition.
Corrosion
Discolouration of Product
Taste ,Odour ,
Microbiological contamination
imparted due to impurities

8. Interpretation of
Analysis
.......Contd
Hardness
Total Hardness =Calcium + Magnesium
Temporary Hardness = Ca / Mg bicarbonate
Permanent Hardness = Ca / Mg Chloride /
Sulphates
CaH = 60 -80% Total Hardness
•Iron
Soluble = Low pH, Low hardness
water
Insoluble = High pH, Tube well water
•Nitrate, BOD, COD
Contaminated -Polluted water

9. PARAMETER SIGNIFICANCE METHOD OF
ANALYSIS
1. pH pH varies according 1. pH paper
to acidic or alkaline2. pH indicator
content.water shows solution.
corrosive or scaling 3. pH meter
tendency.
2. Conductivitycorrosion tendency conductivity
increases. meter.Expressed
as micromho/cm
PARAMETERS

10. PARAMETER SIGNIFICANCE METHOD OF
ANALYSIS
3.Suspended Deposits in the water Gravimetric
solids line, heat exchanger etcanalysis
4. Alkalinity Combines with divalentTypes : p & m
cations to form scales.alkalinity.
Analysed after
titration with std.
acid.
expressed in
ppm as CaCO3
PARAMETERS

11. PARAMETERS
PARAMETER SIGNIFICANCE METHOD OF
ANALYSIS
5. Hardness Chief source of Types : Ca,Mg
scale in Hx, pipe and total.
lines etc. Titration with
EDTA. soln.
Expressed in
ppm as CaCO3.

12. PARAMETERS
PARAMETER SIGNIFICANCE METHOD OF
ANALYSIS
6. Chlorides Adds to solid content Titration with
& increase corrosive AgNO3 with
character of water. chromate
indicator, exp
ressed in ppm as
chlorides.
7. Phosphates Evaluation of phosphateColorimetric
levels in cooling water.Analysis on
Classified as ortho, polyspectrophotometer.
and total phosphates

13. PARAMETERS
PARAMETER SIGNIFICANCE METHOD OF
ANALYSIS
8. Sulfates Adds to solid content & Colorimetric analysis
combines with calcium on spectrophotometer.
to form calcium sulfate expressed in ppm as
scales. CaC03.
9. Silica Very hard silicate scale Colorimetric analysis
are formed. on spectrophotometer.
Expressed in ppm as
SiO2.

14. PARAMETER SIGNIFICANCE METHOD
OF ANALYSIS
10. Iron Discoloration of water. Colorimetric analysis
Deposits in low velocity onspectrophotometer
area in pipelines and Hx.Expressed in ppm as
Fe.
11. Zinc Evaluation of our Titration with EDTA
treatment programme. with dithizone
indicator.
12. FRC Chlorine demand & biocidalTitration with FAS
activity. or with chlorotex
reagent.
PARAMETERS

15. PRE TREATMENT PLANT
RAW WATER TREATMENT IN
CF-3 BY POLYALUMINIUM
CHLORIDE GEN FORMULA
ALnCL3Nn-m(OH)m OR AL2 CL
(OH)5 MANUFACTURING BY
REACTION ALUMINIUM WITH
HCL

16. PAC QUALITY
SL.NO.PARAMETER VALUE AS PER
P.O.
TEST
CERTIFICATE OF
THE PRODUCT
1 ALUMINIUM AS AL2O3 % BY
MASS
10.2 (min) 10.72%
2 BACICITY %BY MASS 64% (min) 68 .00%
3 CHLORIDE AS CL % BY MASS 10.5 % (max) 10.02
4 SULPHATE AS SO4 % BY
MASS
02.5 (max) 02.07 %
5 SPECIFIC GRAVITY AT 25 0C 01.08 (min) 01.191
6 Ph OF 5 %SOLUTION W/V 02.5TO 04.5 02.85
7 INSOLUBLE % BY MASS 0.50 0.024

17. FILTER WATER QUALITY
S.No.Parameter
Raw water analysis
Filter Water Analysis
Main Stream
Filter Water Analysis
DM Stream
1pH 8.01 7.71 7.78
2Free cl
2
mg/L as cl
2
0 0.2 0.1
3Turbidity NTU 5.4 1.0 1.0
4
Conductivity micro
mho/cm 211 222 219
5M Alkalinity as CaCO
3
104 100 102
6
Total Hardness as
CaCO
3
94 96 94
7Ca Hardness as CaCO
3
54 56 54
8Mg Hardness as CaCO
3
40 40 40
9Silica mg/L as SiO
2
11.5 11.4 11.3
10EMA mg/L as CaCO
3
16 22 20
11
Chloride mg/L as
CaCO
3
12 16 16
12
Sulphate mg/L as
CaCO
3
4 6 4
13
KMnO4 Value mg/L as
O
2
2.7 1.6 1.6
PAC dosing at 7-8 ppmis being continued during the day.

18. Filter Water Tank
A&B
Capacity=5500M3Each P1
-
1,2,3 Output-2880M3
ACF
-
1AB C
Output-2400M3
Max. Pr.-5.5Kg/Cm3
Normal Flow-150M3/Hr
WAC -1ABC
Output-2400M3
Max.Pr.-5.0Kg/Cm2
Nor.Flow-150M3/Hr
SAC
-
1AB C
A & B
B-1
A,B,C
P2-
1,2,3
Output-2400M3
Max.Pr.-6.0Kg/Cm2
Nor.Flow-150M3/Hr
WB A
-
1AB C
Output-2400M3
Max.Pr.-6.0Kg/Cm2
Nor.Flow-150M3/Hr
Degasser
Tower
B -1
A,B,C
Air Blower
SBA -1AB C
D.M.Tank A & B
Capacity
-
1694M3
Each
P-4
1,2,3
Output-21600M3.
Nor.Flow-150/215M3/Hr.
Polished Water
Tank
1 & 2
Capacity
-
3182M3
Each. Poished
Water
Tank
-
3
Capacity
-
2640M3.
P
-
5
1,2,3,4
Ammonia-I&II,Urea-I&II
CPP and for different
purposes in the Plant.
DM W ater Pump
Capacity-230M3/Hr
Filter W ater Pump
Cap:-280M3/Hr Each.
Degassed W atePump
Capacity -240M3/Hr.
Output-1680M3.
Nor.Flow-70/80M3/Hr.
Max.Pr. -7.0Kg/Cm2.
Output-10080M3.
Nor.Flow-70/80M3/Hr.
Max.Pr. -8.0Kg/cm
SAC
-
2AB C
Output-10080M3.
Nor.Flow-70/80M3/Hr.
Max.Pr.-8.0Kg/Cm2.
MB
-
2ABProcess &
Turbine
Condensate
from Urea-1
P
-
5
5 & 6
Booster Pump
Cap.300M3/Hr. Boost-up the
Boiler Feed
Water for CPP
through Amm.
Economizer
Degassed Water
Tank
Capacity
-
301.7M3.
Polished WaterPumpCap.230M3/Hr.

19. ACTIVATED CARBON FILTER
•1 REMOVE OIL GREASE
•2 REDUCE TURBIDITY
•ORAGANIC MATTER REMOVED UPTO
TRACES .
•3 ADSORPTION IS A SURFACE
PHENOMENA OF GASES LIKE CHLORINE
•ADSORPTION IS USED FOR
DECHLORINATION OF COMBINED AND
FREE CL2
•C+2CL2+H2O = 4HCL +CO2

20. DETAILED SPECIFICATION
FOR ACTIVATED CARBON
•1. Grade : Dechlorination
•2. Appearance : Black granular
•3.Iodine absorption: : 850 mg/gm, Min.
•4.Bulk density : 500 Kg/M
3
+/-50 Kg/m3
5.Ash content : 7% by Weight.Maximum.
•6. Moisture content : 5% by Weight. Max.
•7. Particle size : 95% between 1.5 -3.0
mm (6/12 Mesh BSS)

21. CONTINUE
•8.Operating pressure : 8.0-9.0 Kg/cm
2
g
•9.Flow normal/Max. : 150/180 M
3
/Hr.
10.Packaging 50 Kg. HDPE bags

22. 2.0 Feed Water ANALYSIS
(ACF Inlet)
•Calcium as CaCO3 Mg/Ltr. 90
•Magnesium " 34
•Sodium & Potassium " 9
•Total Cations " 133
•Total Alkalinity " 113
•Chloride " 12
•Sulphate " 8
•Nitrates “ –
•Fluride " -

23. Treated water analysis
•1. Activated Carbon Filter(ACF):
•Free Chlorine : Traces
•Iron as Fe Mg/Ltr. : 0.01 (Maximum.)
Turbidity NTU : 1.0
•Organic matter Oil & oily prod. :Traces

24. DEGASSER
•IT IS FILLED WITH PAUL RINGS TO
INCREASE SURFACE CONTACT AREA
•TO REMOVE FREE CO2 AND REDUCED
ANIONIC LOAD ON WBA AND SBA
•H2CO3 IS FORMED IN OUTLET OF SAC IT
BREAK INTO H2O AND CO2
•H2CO3=H2O+CO2
•HENNERYS LAW-AT CONSTANT TEMP.
THE SOLUBILITY OF GAS IN A LIQUID IS
DIRECTLY PROPORTIONALTO THE
PARTIAL PR. OF GAS IN THE MIXTURE

25. Ion Exchange
•WhatisIonExchange
Dictionarydefinitionofionexchangeresinisapolymer
madeupofmonomerhavingatleastonebenzenering

26. Ion Exchange
•InsolubleSolidmaterialwhichcarries
exchangeableions.
•Areversiblestoichiometricprocess.
•Everyionwhichisremovedfromthe
solutionisreplacedbyequivalentamountof
anotherionofsamecharge.
•Aftertheionexchange,theexchanger
materialcanbebroughtbacktooriginal
formbyprocesscalledregeneration.

27. Ion Exchange.
•Manufacturing.
•Styerne + DVB
–Beading
–Drying & sieving.
•Sufficiently Crosslinking.
•Sufficiently Hydrophillic.
•Sufficiently Accessible exchangeable groups.
•Structure must be chemically stable.
•Density.

28. Ion Exchange
•Preparation of resin matrix.
•Polymerization of Styrene & DVB.
CH = CH2 CH = CH2
CH = CH2
+
Styrene -DVB
Copolymer
CH -CH2-CH -CH2
CH -CH2-CH -

29. Ion Exchange
•Copolymer
–Sulphonation H2SO4 / Oleum.
–Conversion Na / H form.
–Strong Acid Cation

30. Ion Exchange
•Manufacturing of Cation resin.
•SAC
•Sulphonation.
CH2 -CH
-
CH2 -CH-
CH-CH2
SO3 H+
SO3 H+
Strong Acid Cation
resin.

31. WAC
Methacrylic acid + Ethyl Acrylate + DVB =
R -COOH

32. STRONG ANION Exchange Resin
•Copolymer
–Chloromethylation. reaction(AlCl3)
–Amination
–Type of Anion resin.(Amination)
– CH3
– I
–Type -I R—N—CH3 and
– I
– CH3

33. SBA ANION RESIN TYPE--II
• CH3
• I
• R------N---CH2 CH2OH
• I
• CH3
•ONE METHYL GROUP REPLACED
WITH ETHONOL GROUP IN TYPE II

34. Ion Exchange
•Manufacturing of Anion resin resin
•Copolymer beads subjected to
Chloromethylation.. .
CH2-CH -CH2-CH -
CH-CH2
CH2Cl
CH2C
l
----Amination
Conversion in Chlorideform.

35. Ion Exchange
•Amination Dimethyl Ethanol Amine.
CH2 -CH -CH2 -CH
CH2 -N -CH3 Cl
CH3
CH3
Strong Base Anion Type -I

36. Ion Exchange
•Amination Dimethyl Ethanol Amine.
CH2 -CH -CH2 -CH
CH3 -N -CH3 Cl
CH2
C2H4 OH
Strong Base Anion Type -I I

37. Ion Exchange
•Amination Dimethyl Amine gives WBA.
CH2 -CH -CH2 -CH
CH2 -N : HCl
CH3
CH3
Weak Base Anion

38. Resin Weak acid Cation(phy)
•Type Gel
•Physical Form Moist Beads
•Particle size 0.3-1.2 mm
•Effective size 0.5-0.6 mm
•Osmotic Strength Good
•Mechanical Strength Good
•Moisture Content 47-54 %
•Volume change H
+
to Na
+
, Approx +100%
•Voids Approx. 40%

39. WAC Chemical properties
•Ionic Form H
+
•Max. Operating Temperature 100
o
C
•Effective Operative pH 5-10
•Resistance to Oxidizing & Reducing
Agents Generally Good
•Exchange Capacity 4.0 meq./ml.

40. Resin Strong acid Cation:
•Type Gel
•Physical Form Moist Beads
•Particle size 0.3-1.2 mm
•Effective size 0.4-0.6 mm
•Osmotic Strength Good
•Mechanical Strength Good
•Moisture Content 47-54 %
•Volume change H
+
to Na
+
, Approx. ~6%
•Voids Approx. 40%

41. SAC(Chemical)
•Ionic Form H
+
•Max. Operating Temperature 120
o
C
•Effective Operative Ph 0-14
•Resistance to Oxidizing & Reducing
Agents Good
•Exchange Capacity 2.0 meq./ml.(Na
+
form)
& 1.8 meq./ml.(H
+
form)

42. Resin Weak Base Anion(PHY:
•Type Macro porous
•Physical Form Moist Beads
•Particle size 0.3-1.2 mm
•Effective size 0.4-0.6 mm
•Osmotic Strength Excellent
•Mechanical Strength Excellent
•Moisture Content 47-55 % (Cl
-
)
•Vol.change Free Base to ClApprox.+20%
•Voids . 40%

43. WEAK BASE ANION(Chemical)
•Ionic Form Free Base
•Max. Operating Temperature 80
o
C
•Effective Operative Ph 0-7
•Resistance to Oxidizing & Reducing
Agents Good
•Exchange Capacity 1.5 meq./ml.

44. Strong Base Anion(Phy):
•Type Gel (Iso porous)
•Physical Form Moist Beads
•Particle size 0.3-1.2 mm
•Effective size 0.4-0.6 mm
•Osmotic Strength Good
•Mechanical Strength Good
•Moisture Content 47-55 %
•Vol.change OH
-
to Cl
-
, Approx. 7 to17%
•Voids . 40%

45. SBA CHEMICAL PROPERTIES
•Ionic Form Cl
-
•Max. Operating Temperature 60
o
C
•Effective Operative Ph 0-14
•Resistance to Oxidizing & Reducing
Agents Good
•Exchange Capacity 1.2 meq./ml.

46. Ion ExchangersInsoluble solid material carrying exchangeable
cations or anions
WAC SAC
Cation Exchange
WBA
Type IType II
SBA
Anion Exchange
Ion Exchange Resins

47. Ion Exchange Resins
•Properties of ion exchange resin.

48. Properties of Ion Exchange Resins
•Particle Size :
Purelyhydraulicandkineticinfluenceontheionexchangeprocess.
0.3-1.2mmsizeissatisfactoryforindustrialapplications
•Effectivesize =Sieve(mm)onwhich90%ofbeadsare
retened.
•UniformCoefficient=ratioof40%and90%.
•Moisture Content :
Itisboundwaterrelatedtocrosslinking.About45-55°depending
ontypeofresin.Givesvaluableinformation.onresinunderuse.

49. Properties of Ion Exchange Resins
•Density :
Ion exchange resins are sold on volume basis, hence density
measurement is necessary. Density difference of cation and
anion exchange resins is used for MB operations.
•Porosity :
Related to degree of cross linking, influences capacity &
selectivity. Functional groups are present throughout the
resin body. Pores provide path for exchanging & exchanged
ions. Pores can be micro or macro in size.

50. Properties of Ion Exchange Resins
(Contd...)
Swelling :
–It is volume change due to change in surrounding
medium.
–Depends upon medium, resin matrix.
–Ionic group present and type of counter ions

51. Properties of Ion Exchange Resins
(Contd...)
•Total Exchange Capacity :
Itisthecapacityobtainedfromthetotal
quantityofcounterionsthatiscapableof
exchangeperunitweightorvolumeofeither
dryorswollenresin
•OperatingCapacity:
Thecapacitythatcouldberealizedina
columnunderasetofselectedconditions.

52. Properties of Ion Exchange
Resins (Contd...)
•Kinetics (speed of exchange reaction) :
It is influenced by cross linking, functional groups, particle size,
properties of the influent(ionic load) and temperature.
•Stability :
During service and regeneration resin is subjected to expansion
and contraction. Oxidizing agents attack the resin. There is
mechanical attrition. All these influence resin life and
economics of operation

53. Properties of Ion Exchange
Resins (Contd...)
Total Exchange Capacity :
itindicateshetotalnumberofexchangesitesavailable.Itcan
beexpressedasmeq/gmofdryresins,meq/gmofwetresinsor
meq/mlofwetresins.AnothermethodisintermsofGmsof
CaCo3insteadofmeq.
consideracationexchangehavingacapacity5.2meq/gm
ofdryresinshavingwaterregain1.10gms/gmandbulk
density0.84gms/ml.
Totalexchangecap.Onwetbasis=5.2/1+1.1=2.47meq/gmof
wetresins. OR
2.47x0.84x1000=2080meq/litofwetresins
Since1meqofCaco3=50gmthanitcanbeexpressedas
2080x50/1000=104gmofCaco3/literofwetresins.
.

54. continue
•Exchange capacity (gm caco3) * resin
volume (l) = out put between two
regeneration * total ionic load (ppm caco3)
•Indian 225 sac resin
•104 gm caco3 / lit * resin vol (l) = 2400
M3 * 356 ppm caco3
•Resin vol = 8015 (L) = 40 drum

55. WAC AND WBA RESIN
EXCHANGE CAPACITY VS PH

56. –HOW DOES ION EXCHANGE
RESIN WORKS.

57. Water treatment by Ion
exchange technique.
–Softening.
–Dealkalization / Partial
Demineralization.
–Demineralization.
•With Or Without Silica removal.
–Mixed bed.
–Condensate Polishing.
–Nitrate, Fluoride, Heavy metal
removal.
Color and Organic matter removal

58. DIFFERENT SCHEMES OF DEMINERALIZATION
3.SAC-DGT-SBA
This system produces water having total dissolved solids of not more
than 2-3 mg/lt and residual silicanot more than 0.2mg/l. The
degasser is interposed between the cation and anion exchangers to
obtain saving in NaOH consumption during regeneration and to reduce
the quantity of anion exchange resin required. This is the standard
system for most raw waters where an acceptable degree of purity is
achieved.

59. Demineralization
•Strong Acid Cation Exchanger :
Ca ) HCO3 Ca) (HCO3
Mg) Cl+ R -H Mg) R+H(Cl
Na ) SO4 Na) (SO4
•Anion Exchanger :
(HCO3 (HCO3
H(Cl + R -OH R -(Cl +H2O
(SO4 (SO4

60. Advantages of Ion -Exchange
Technique
Ambient temperature operation
Instantaneous treated water
Take care of fluctuation of load
Easy waste disposal
Cheaper to operate

61. Back Washing
Back washing is done for :
Loosening the bed
Re-classifying the bed
To remove dirt and filtered matter
To separate resin in MB
Bybackwashing,moreuniformdistributionof
fluidisobtainedinsubsequentdown-flow
operation.

62. Back Washing
Pressing water (*) in upward direction to
expand the bed to about 50%.
(*)Raw water for SAC.
Decationised (and degassed) water
for SBA.
SBA outlet for MB

63. Regeneration Process
Theprocesstobringbacktheexhausted
resintooriginalorusableformis
regeneration.
Thereactionisoppositetoservice
reaction.
Therearetwomethodsforregeneration
co-currentandcountercurrentmethod.

64. Regeneration (Injection)
AccordingtotheresinbyHCl,H2SO4orNaOH,
themajorfactorsaffectingthedegreeof
regenerationare:
Compositionoftheexhaustedbed
Flowrate
Contacttime
Temperature
Purityofregenerant
Conc.ofregenerant
Amountofregenerantapplied(Reg.level)

65. Counter Current Regeneration
#Tominimiseleakageandgetbetter
qualityeffluent
Nobackwashgiven
Provisionsmadetoavoidfluidizingof
thebedandthenregenerantispassed
inoppositedirectionofservice
Backwashisgivenonlywhen
necessarybutfollowedbydouble
regeneration

66. Co -Current regeneration.
Service inlet
Regeneration
inlet.

67. Counter -Current
regeneration.
Service inlet
Regeneration
inlet.
Regeneration
Outlet.

68. Slow Rinse
Itisextendedregeneration.Henceat
regenerationflowrategenerallyby2BVof
water
Fast Rinse :
Toremovetracesofregenerant.Doneat
serviceflowrate.

69. Fouling of Ion Exchange
Resins
It is covering of exchange sites and / or obstructing ion exchange
process.
•Major Foulants:
·Turbidity and mud
·Oil
·Iron
·Calcium
·Organics
•Many a times fouled resin cannot be completely cured.
•Fouling of resin can be treated by different methods according to
the
nature of foulants

70. Troubleshooting
•Ion exchange units may experience problems during
operation
•For effective troubleshooting consideration should be
given to the following areas:-
–Flow rates
–Pressure drop
–Resin
–Backwash :-Pressure drop
–Regeneration:-Concentration, Quality
–Water quality:-Ion concentration
–Design criteria:-Original design and operating condition

71. Troubleshooting
•Problems generally encountered
–High pressure drop
–Decrease in pressure drop
–Reduction in capacity
–Poor Quality of treated water

72. Trouble Shooting
Major causes in general for less OBR :
Insufficient regeneration
Increased load
Over running in previous run
Fouling
Resin loss (quantity & quality)
Malfunctioning of up-stream unit/s
Excessive rinsing

73. Trouble Shooting
Major causes in general for poor quality :
Mechanical problem
Chemical precipitation, silica precipitation.
Improper separation and improper mixing
(MB)
Wrong or misleading analysis hence
apparent poor quality

74. MB O/L QUALITY
DESIGN ACTUAL
Ph…………….. 7.0+_0.2 6.2 to 6.9
Cond…………. <0.2 micro mho/cm 0.05
Silica as sio2 <0.015 0.006 ppm
Chloride as caco3<.015 <.01 “
Na as caco3 <0.015 <0.02 “
Cu as cu <.003 NT “
Fe as fe <0.01
K as k <0.01 <0.007 “
Cl & So4 30 ppb

75. Condensate analysis
FEED COND PROCESS MIXED(
TURBINE)
HARDNESS TRACES
AMM AS
NH3
<10.0 PPM 10.0 11.42
CO2AS CO2<10.0 “ 15.0 NIL
ELECTROLY
TES AS
CACO3
<1.0 “ 1.15 1.15
OIL “ <1.0 “ NIL 5.0
SIO2AS
SIO2
<0.10“ 0.5 0.5
Fe AS Fe <0.05 1.0 0.2
PH
CH3 oH
8.0 TO 9.58.0 ~9.5
20.0 PPM
8.5 TO 9.5
NIL

76. Thanks