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MODULE 1 DEIONIZED (DI) WATER SYSTEM

MODULE CONTENT 1.0 Introduction 1.1 1.2 Water Deionization Process Explained Deionization Systems 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 2.0 System Design 2.1 2.2 3.0 3.1 3.2 3.3 Feed Water Analysis Product Water Specifications Raw Water Tank Raw Water Pumps Cartridge Filters 3.3.1 3.3.2 3.4 3.4.1 3.4.2 3.5 Initial Start Up Operation And Maintenance Initial Start Up Operation And Maintenance What is Deionization? Continuous or batch? Counter current regeneration Power Purge regeneration Sophisticated PLC Automation Ion Exchange Reaction Ion Exchange Chemistry, Chelated Resins Chelated Resins

Process Description

Carbon Filters

Portable Mixed Bed Ion Exchangers 1

Chemical Plant Utilities Lab 3.5.1 3.5.2 3.6 Final Filters 3.6.1 3.6.2 4.0 5.0 6.0 Initial Start Up Operation And Maintenance Initial Start-Up Operation And Maintenance

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Equipment Specification Drawings Conclusion

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1.0
1.1

INTRODUCTION
WATER DEIONIZATION PROCESS EXPLAINED

The process used for removal of all dissolved salts from water is referred to as deionization. Deionization requires the flow of water through two ion exchange materials in order to effect the removal of all salt content. Deionization. The terms demineralization and deionization are used somewhat interchangeably by the industry. While the term demineralization is generally better understood, deionization is especially apt. The passage of water through the first exchange material removes the calcium and magnesium ions just as in the normal softening process. Unlike home equipment, deionization units also remove all other positive metallic ions process and replace them with hydrogen ions instead of sodium ions. As the metallic ions in the water affix themselves to the exchange material, the latter releases its hydrogen ions on a chemically equivalent basis. A sodium ion (Na+) displaces one hydrogen ion (H+) from the exchanger; a calcium ion (Ca++) displaces two hydrogen ions; a ferric ion (Fe+++) displaces three hydrogen ions, etc. (Recall that home softeners also release two sodium ions for every calcium or magnesium ion they attract.) This exchange of the hydrogen ions for metallic ions on an equivalent basis is chemical necessity that permits the exchange material to maintain a balance of electrical charges. Now because of the relatively high concentration of hydrogen ions, the solution is very acid. At this point the deionization process is just half complete. While the positive metallic ions have been removed, the water now contains positive hydrogen ions, and the anions 3

Chemical Plant Utilities Lab originally in the raw water.

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The partially treated water now flows through a second unit, this time an anion exchange material normally consist of replaceable hydroxyl anions and fixed irreplaceable cations. Now the negative ions in solution (the anions) are absorbed into the anion exchange material. Released in their place are hydroxyl anions.

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WATER CONTAINING VARIOUS MINERAL CONTAMINANTS ENTERING HERE

All that emerges from such a two unit system is ion-free water. It still contains the positive hydrogen ions released in the initial exchange plus the negative hydroxyl ions released in the second exchange. 5

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What has become of these two ions? Through the magic of chemistry they have combined (positive to negative) to produce water molecules which are in no way different from the water in which they were produced. The result of this two-stage ion exchange process is water that is mineral-free. Equipment for use in the deionization process may be of several types. Available are both multiple bed and single bed units. Multiple bed units have pairs of tanks, one the cation exchanger, the other for the anion exchangers, mixed in a single tank. Deionized water has a wide range of uses in industry. Chemical production, pharmaceuticals, electroplating, television tube production and leather goods processing are among the many diversified applications for deionized water. Efforts to produce mineral-free water through multiple distillations have proved to be extremely complex and require elaborate and costly equipment.

1.2 1.2.1

DEIONIZATION SYSTEMS What is Deionization?

The deionization process removes all ions from a solution. Cation exchangers remove all cations (positively charged ions such as Sodium, Calcium, and Magnesium) and anion exchanger remove all anions (negatively charged ions such as sulphate, bicarbonate, and chloride). The cation exchanger is operated in front of the anion exchanger and converts the salts to acids. CaSO4 + 2R-H CaR2 + H2SO4 NaCl + R-H R-Na + HCl The anion exchanger removes the acid from solution: H2SO4 + 2R-OH R2SO4 + H2O 6

Chemical Plant Utilities Lab HCl + R-OH RCl + H2O

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The result is water ions. Some Sodium will leak from the Cation exchange and this whar determines the purity of the water leaving the system. One ppm Sodium is equal to 5 micromhos conductance (or 0.2 megohms resistance). 1.2.2 Continuous or batch?

Deionization systems can be either continuous or batch mode operations. In a continuous system, there are duplicate sets of columns when one set has expired, the system switches to the other set and regenerates the first. In a batch system, there is only one column pair and the system is off-line for several hours when regenerating. Batch mode systems are less expensive but require larger tanks for storage if you plan to continue supplying deionized water while regenerating. A batch system is sized larger to make up for the time lost during regeneration. 1.2.3 Counter current regeneration -

Counter current regeneration maximizes regenerant contact efficiency and results in high water quality. Older style, less sophisticated systems use co-current regeneration where the regenerant flow is in the same direction as the normal water flow. This results in overall low water quality because the bottom part of the bed is only partially regenerated. Countercurrent systems pass the regenerant in the direction opposite the normal water flow, fully regenerating the bottom of the beds which minimizes leakage resulting in very high water quality. 1.2.4 Power Purge regeneration 1. Rinse, to remove sediment, undersize resin particles, and reclassify the bed; 2. Regenerate with acid or caustic (depending on resin type); 3. Rinse again to remove excess regerant. Traditional systems run all three cycles sequentially, using the second to push out the first and the third to push out the second. If you think about it, you will see that you will get 7

Regeneration is a 3 step process for Deionizing systems:

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dilution of the regenerant and no clear break between the regenerant and this rinse water. Our Power Purge ion exchange regeneration system isolates the regenerant by removing all (over 98%) of the water from the column before adding the regenerant to the system. After regeneration, we purge the remaining regenerant from the system before adding any rinse water. This reduces the overall rinse water requirements dramatically. Final rinsing is a rinse-leach-purge step rinse operation that efficiently uses the minimal amount of water. Each time the column fills with rinse water, the system waits until the water and resin reach an equilibrium condition (concentration inside the bead = concentration in the water) then we purge the water and refill. This allows us extensive control over the process and, in some cases, even allows us to mix anion and cation bed rinse water to achieve mutual neutralization. 1.2.5 Sophisticated PLC Automation

Remco Engineering sells fullly automated systems using microprocessor based programmable logic controllers to control the regeneration process. We find that manual deionization system are very uneconomical to operate when viewed from both your costs to operate and the costs to support continous personnel training and retaining. We put our expertise in a box inside the control panel so you don't have to call us every time you regenerate to figure out which valves to open and close. Because we sell automated systems that are computer ready, we can integrate pump and level controls alarms, conductivity and other process sensors, and remote interfaces. We offer the most sophisticated deionization systems available. Sizing a system based on water use. Two requirements determine the size of a system : 1. 2. Maximum demand (gpm peak), Average demand (gpm average per day).

The first governs the amount of storage you will need, the second sizes the flow rate.

Chemical Plant Utilities Lab For example:

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1. If you need 200 gallons to fill a tank 3 times per day and 2 gpm continously for rinsing, then over an 8 hour day, you would need a total of 1560 gallons (8 x 120 gal/hr + 600) or about 3.25 gallons per minute. A 5 gpm system would be large enough with a 300 gallon storage tank for fills. If the tank fills were all at once, you wolud need enough storage to cover all of them. 2. Ten(10) gpm required continously with tank fills of 85 gallons each every hour. The total requirement would be about 11.5 gpm. We would recommend a 12-15 gpm system with about 200 gallons of storage as a minimum. Column Sizing a 5 gpm system. (calculations) The actual pysical size of system you will need will vary depending on the quality of the water you eish to deionize. Deionization systems use a resin that has a certain capacity given as kilograins of calcium carbonate per cubic foot. A grain is 17.1 ppm. The actual operating capacity is less than 100% and is based on the amount of regenerant (acid or caustic) added during regeneration. Doing a complete regeneration wastes a lot of regenerant so systems are regerated to an economical range of 60-70 percent of theoretical capacity. There are a lot of alculation to determine actual capacity of a specific resin with a specific water chemistry so we have a quick formula to do a rough 80% estimate of capacity. Cation columns 1. 2. 3. 4. Take your water TDS (total dissolved solid) analysis. Look at Calcium, Magnesium and Sodium concentration in ppm. Add up the total ppm and divide by 17.1 (i.e., 250 ppm/17.1 = 14.6 grains/gal). Assuming a conservative 16 kilograin/cu. ft. capacity with an economical regeneration, now divide 16,000 by 14.6 (16000/14.6 = 1095). You will get over a thousand gallons of decationized water per cubic foot of resin.

Chemical Plant Utilities Lab Anion columns 1. 2. 3. 4. 5.

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Next add up the anions, they should be equal to the cations plus silica (SiO2) and dissolved CO2. Add up the anions plus silica and carbon dioxide in ppm. Lets say total carbonate and silica is 20 ppm. Take the total anion ppm and divide by 17.1 (270(250+20)ppm/17.1 = 15.8 gr/gal..). Divide 14 kilogram/cu.ft by you answer (14,000/15.8=886 gallons per cubic foot). A 5 gpm system would require about 2.5 cu.ft. of cation resin and about 3 cubic feet of anion resin, resulting in about 2500 gallons of DI water between regenerations.

If you need more than 2500 gallons between regenerations such as 5 gpm for hours then regenerate at night, you would have to double the resin capacity of the system to 5000 gallons. Factors effecting the capacity of the system are the relative amount of Sodium, Chloride, and weak acids in the water. These can change the capacity by 20 to 30% as can the regenerant laoding used.

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Chemical Plant Utilities Lab 1.2.6 Ion Exchange Reaction

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Ion exchange is a reversible chemical reaction where in anion (an atom or molecule that has lost or gained an electron and thus acquired an electrical charge) from solution is exchanged for a similarly charged ion attached to an immobile solid particle. These solid ion exchange particles are either naturally occurring inorganic zeolities or synthetically produced organic resins. The synthetic organic resins are the predominant type used today because their characteristics can be tailored to specific applications. An organic ion exchange resin is composed of high-molecular-weight polyelectrolytes that can exchange their mobile ions for ions of similar charge from the surrounding medium. Each resin has a distinct number of mobile ion sites that set the maximum quantity of exchanges per unit of resin. Most plating process water is used to cleanse the surface of the parts after each process bath. To maintain quality standards, the level of dissolved solids in the rinse water must be regulated. Fresh water added to the rinse tank accomplishes this purpose, and the overflow water is treated to removed pollutants and then discharged. As the metal salts, acids, and bases used in metal finishing are primarily inorganic compounds, they are ionized in water and could be removed by contact with ion exchange resins. In a water deionization process, the resins exchange hydrogen ions (H+) for the positively charged ions (such as nickel, copper, and sodium), and hydroxyl ions (OH-) for the negatively charged sulphates, chromates and chlorides. Because the quantity of H+ and OH ions is balanced, the results of the ion exchange treatment is relatively pure, neutral water. Ion exchange reactions are stoichiometric and reversible, and in that way they are similar to other solution phase reactions. For example: NiSO4 + Ca(OH)2 = Ni(OH)2 + CaSO4 In this reaction, the nickel ions of the nickel sulphate (NiSO4)mare exchanged for the calcium ions of the calcium hydroxide [Ca(OH)2] molecule. Similarly, a resin with 11

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hydrogen ions available for exchange will exchange those ions for nickel ions from solution. The reaction canbe written as follows: 2(R-SO3H) + NiSO4 = (R-SO3)2Ni + H2SO4(2) R indicates the organic portion of the resin and SO3 is the immobile portion of the ion active group. Two resin sites are needed for nickel ions with a plus 2 valence (Ni+2). Trivalent ferric ions would require three resin sites.

As shown, the ion exchange reaction is reversible. The degree the reaction proceeds to the right will depend on the resins preference or selectivity, for nickel ions compared with its preference for hydrogen ions. The selectivity of a resin for a given ion is measured by the selectivity coefficient. K. which in its simplest form for the reaction R-A++B+=RB++A+ (3)

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Is expressed as: K = (concentration of B+ in resin/concentration of A+ in resin) X (concentration of A+ in solution/concentration of B+ in solution). The selectivity coefficient express the relative distribution of the ions when a resin in the A+ form is placed in a solution containing B+ ions. Table 1 gives the selectivity of strong acid and strong base ion exchange resins for various ionic compounds. It should be pointed out that the selectivity coefficient is not constant but varies with changes in solution conditions. It does provide a means of determining what to expect when various ions are involved. As indicated in Table 1, strong acid have a preference for nickel over hydrogen. Despite, this preference, the resin can be converted back to the hydrogen form by contact with a concentrated solution of sulfuric acid (H2SO4): (RSO4)2Ni + H2SO4 -> 2(R-SO3H) + NiSO4 This step is known as regeneration. In general terms, the higher the preference a resin exhibits for a particular ion, the greater the exchange efficiency in terms of resin capacity for removal of that ion from solution. Greater preference for a particular ion, however, will result in increased consumption of chemicals for regeneration. Resins current available exhibit a range of selectivitys and thus have broad application. As an example, for a strong acid resin, the relative preference for divalent calcium ions (Ca+2) over divalent copper ions (Cu+2) is approximately 1.5 to 1. for a heavy-metal-selective resin, the preference is reserved and favors copper by a ratio of 2.300 to 1.

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Chemical Plant Utilities Lab Table 1. Selectivity of ion Exchange Resins. In Order of Decreasing Preference Strong acid cation exchanger Barium Lead Calcium Nickel Cadmium Copper Zinc Magnesium Potassium Ammonium Sodium Hydrogen Strong base anion exchanger Iodide Nitrate Bisulfite Chloride Cyanide Bicarbonate Hydroxide Fluoride Sulphate

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Ion Exchange System

1.2.7

Ion Exchange Chemistry, Chelated Resins

Ion exchange is a simple process where an organic molecule has been substituted with acid or base exchange sites. As a solution with exchangeable ions passes through the resin, the ions are captured and exchanged for the ions on the resin. For example, some weak acid ion exchange resins can use the carboxylic acid radical, in the sodium form, R-COO-Na as the exchange site. As solutions of metal ions such as Magnesium (Mg), Calcium (Ca), or Copper (Cu) pass through the resin, they are exchanged for the Na (Sodium) at that site. The molecule would now appear like this R-COO-Ca, for a Calcium exchange. R-COO-Na + Ca+2 = R-COO-Ca + 2 Na+

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These resins are used in water softeners where the alkaline earth metals such as Calcium and Magnesium are exchanged for Sodium. In a water softener Sodium Chloride (salt, NaCl), is used to regenerated the resin. The salt solution is passed through the resin in very high concentrations and the sodium displaces the metals attached to the active sites. When the concentration of sodium is low, the sites prefer the alkaline metals again and the resin can be used to softener water again. 1.2.8 Chelated Resins

The same principals apply in industrial ion exchangers except that usually a strong acid or base is used to regenerate the resins (except in industrial water softeners). To remove a metal from your waste stream at low pH using ion exchange, the most cost effective method is to use a weak acid chelating resin. An iminodiacetic acid resin is useful to remove a metal when a chelate such as ammonia or EDTE is present. The pH is adjusted to the correct range remove the metal, but kept under 6 to prevent the formation and precipitation of hydroxides and oxides of metals. This resin has a hierarchy of preferences, i.e., it prefers Copper more than Zinc. This requires their use mainly in compatible metal systems. If only one metal is being passed through the column, there is no competition for sites and the progress of the system is easier to monitor. Reclaiming the metal is also easier as multiple metal systems are difficult to plate. The ion exchange resin used in most metal recovery systems is what is called a weak acid resin. This system allows low chemical usage, usually about 1.25 times the 16

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theoretical amount to regenerate the column. This resin is used in the sodium form. This allows us to regenerate with an acid and recover the metals in a useful form. The resin is then conditioned so that the pH does not drop to low when we start up the column. The basic chemistry of this system is as follows: 1. The solution is adjusted to a pH which is optimum for the resin but low enough to prevent hydroxides from forming and high enough to ensure the capture of the metals. 2. The solution is passed through s media filter to remove any solids and then through the lead/lag columns where the a metal is exchanged for sodium ions. The capacity of the columns is about 1.8 pounds of metal per cubic foot of resin depending on the competing ion passing through with the metal. 3. When a column is saturated with a metal, breakthrough occurs. This results in a greatly increased passage or metal ions to the lag column. This is when you will regenerate the first column. 4. The regeneration chemistry is in 5 steps, they are: a. Water backwash to remove any broken beads. This recycles to the main holding tank. b. Acid backwash to remove the metal. A recirculating acid tank ensures full metal removal. c. Water backwash to remove residual metal and acid from the column. A timing cycle ensures the backwash goes to the acid tank until the steam is acid free. d. An caustic soda backwash which removes the acid (recycles to the holding tank for pH adjust before passing throuth the column), and replaces the H+ with Na+ ions. This prevents the pH from dropping when the column goes on line. e. A final water backwash to restratify the resin and remove the remaining caustic from the system. The main things to remember when setting up a system is to not let organic solvents, oil, or 17

Chemical Plant Utilities Lab grease in the system as these will foul the column.

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Feed line segregation is very important for successful utilization of ion exchange. Call for a segregation scheme for your facility.

2.0

SYSTEM DESIGN

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Chemical Plant Utilities Lab 2.1 FEED WATER ANALYSIS

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The following water analysis is expressed as the ion mg/l unless otherwise indicated, represents the anticipated water to be treated by the water purification Parameter pH Turbidity Conductivity Suspended Solids Temperature system specified by this manual. Value 6-8 < 1.0 NTU 135 micro-mhos Trace 24 ~ 32 deg C

2.2

PRODUCT WATER SPECIFICATIONS Resistivity (at 25 Deg C) Design Capacity > 10 Megaohm.cm 20 USgpm

3.0

PROCESS DESCRIPTION

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Chemical Plant Utilities Lab Essentially, this 20gpm (4.5m3/h) water treatment plant comprises of:1) 2) 3) 4) 5) 6) 3.1 1 no. of Raw Water Tank 2 nos. of Water Feed Pump (100% standby) 2 nos. of 5 micron Cartridge Filter 2 nos. of Carbon Cartridge Filter 2 nos. of Portable Mixed Bed Ion Exchanger, and 2 nos. of Final Filters

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RAW WATER TANK The Raw Water Tank is supplied in 5.0m3 capacity. It is important as a storage tank to ensure continuous water supply of 4.5m3/h for approximately one (1) hour failure. A manual float switch is installed to ensure level at all time. in the case of water supply

automatic fill up of water to maintain high 3.2 RAW WATER PUMPS

Two (2) units of Raw Water Pumps (one duty, one standby) are installed to deliver 4.5m3/h of raw water to the treatment system. The pumps are protected with prevent run dry condition. a low water level cut off switch to 3.3 CARTRIDGE FILTERS Two (2) units of cartridge filter (5 micron rating) are installed in parallel to remove particulate matter greater than size of 5 micron.

Influent enters the housing under pressure and must pass through the filter elements in order to exit the housing. In the same time, majorities of particles larger than the filters size rating (5 m) are blocked and retained at the filter elements.

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Chemical Plant Utilities Lab 3.3.1 Initial Start Up

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Flow into the filtration module is controlled by inlet and outlet isolation valves. During start-up, the inlet valve is opened to allow water in. The outlet valve and air flow out, either to drain or to the into service. shall also be opened to allow water

down manufacturing detergents before they can be put 3.3.2 Operation And Maintenance

When the filter elements become clogged with impurities, pressure will drop across the cartridge filter system. To avoid insufficient pressure at the downstream, the filter elements shall be replaced. A 15psi clean differential pressure drop is the usual specification indicating the needs to change new filter elements.

3.4

CARBON FILTERS Two (2) units of carbon cartridge filter are installed in parallel to remove free chlorine and some organic matter in the feed water. Elimination of free chorine is very importance because it can attack and damage resins. Although the filter also accomplishes some filtering or turbidity, it is incidental to the prime purpose of the filter. Greater amount of turbidity in the inlet water can decrease the effectiveness of the carbon, shortening its useful life.

3.4.1

Initial Start Up Flow into the filtration module is controlled by inlet and outlet isolation valves. During start-up, the inlet valve is opened to allow water in. The outlet valve shall 21

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also be opened to allow water and air to flow out, either to drain or to the down stream equipment. New filter elements must be rinsed to remove loose particles, carbon fines and manufacturing detergents before they can be put into service.

3.4.2

Operation And Maintanance Carbon media does not have an unlimited life. Eventually the carbon will no longer have the capacity to adsorb organic and chlorine to a useful degree. When this occurs, carbon filter elements must be replaced. High levels of chlorine and organic can reduce the media life while low levels can increase the life. The best way to determine the condition of the carbon bed is to periodically check the filter effluent for excessive signs of chlorine and organic. Based on the city water quality, we estimated a life span of 5 to 6 months for the carbon filters.

3.5

PORTABLE MIXED BED ION EXCHANGERS Ion Exchange Theory Ion Exchange may be defined as the reversible interchange of ions between a solid and a liquid phase in which there is no permanent change in the structure of the solid. The solid is the ion exchange material. Reversible and No Permanent Change are key points in this definition and in ion exchange. Ion exchange has important applications in water conditioning such as softening and deionization. With few exceptions, the great utility of ion exchange rests with the ability to use and re-use the ion exchange material. For example, in water softening: 2R Na+ + Ca2+ R2Ca2+ + 2Na+

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The exchange R in the sodium ion form is able to exchange for calcium and thus remove calcium from hard water and replace it with and equivalent quantity of sodium. Subsequently, the calcium-loaded resin may be treated with sodium chloride solution, bringing it back to the sodium form, ready for another cycle of operation. This conversion step is commonly called regeneration. The reaction is reversed, the ion exchange is not permanently changed. Millions of gallons of water may be treated per cubic foot of resin during an operating period of many years. Demineralization is the process of removing dissolved ionic impurities from water. These positively charged cations and negatively charged anions allow conductance of electricity and are called electrolytes. Electrical conductivity is thus a measure of water purity, with low conductivity corresponding to high. Weakly ionized contaminants such as silica contribute only slightly to the conductivity of water. Ion exchange demineralization is basically a two-step process involving treatment with both cation and anion exchange resins. This treatment can be a series operation or in a common bed depending on process conditions and requirements. In most demineralization systems, the water is first passed through the cation exchanger. Here Ca2+, Mg2+, and Na+ are exchanged for H+. R-H+ 2R-H+ 2R-H+ + + + Na+ Mg2+ Ca2+ R2 Mg R2 Ca + R-Na+ + + 2H+ H+ 2H+

The degree of removal of these ions depends on the cation resin selectivity. Cation resins exhibit a much greater selectivity for divalent calcium and magnesium ions than for monovalent sodium ions (also potassium if present). Thus any leakage (non-removal) from the cation exchanger tends to be sodium rather than calcium or 23

Chemical Plant Utilities Lab magnesium.

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The demineralization process is completed by anion resin treatment, with the feed being the acids of the anions in the raw water feed. These anions are exchanged for hydroxide. The hydroxide neutralizes the acid as the water proceeds through the column. The choice of the anion exchange resin(s) is most critical to the water quality achievable and economics of the system. When high quality water is required, a strong base anion exchange resin is used. R+OH2R+OH R+OH+ + + ClSO42HCO3R+Cl- + R2SO4 + R HCO3 OH2OH+ OH-

Since the OH- released is neutralized by the acids, a favorable acid-base equilibrium exists and there is no acid leakage. Even the silica and the carbon dioxide are reduced to very low levels. Regeneration is accomplished by a strong base solution such as caustic.

Theory of Operation Mixed Bed Concept

INLET

C A C

A C A

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A
OUTLET

SCHEMATIC MIXED BED EXCHANGER

In the mixed bed unit, strong acid cation and strong base anion resins are thoroughly mixed to form a homogeneous bed. A series of many cation/anion beds are formed in this one unit allowing for the removal of the small quantities of impurities not removed in the cation or anion units. When the unit is exhausted, it is regenerated with hydrochloric acid and sodium hydroxide. Chemical reactions in the mixed bed unit are the same as in the individual cation and anion exchange units. Indications of Resin exhaustion are: Increase in sodium leakage Increase in silica leakage Decrease in resistivity Increase in pressure drop across bed (maximum permissible pressure drop = 35 psi) There are two common types of resin used in a portable mixed bed unit:1. 2. Regenerable type resin Non-regenerable type resin

As the name implies, regenerable resin can be regenerate and re-use after exhaustion, while non-regenerable resin have to be upon exhaustion because separation of cation and anion

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resin is impossible in this type of resin. Generally quality of product water from nonregenerable resin is much higher and stable compared to regenerable type. 3.5.1 Initial Start-Up The Portable Mixed Bed Unit is normally come in regenerated form and is ready to be put in service:1.) Connect the service Inlet, Service Outlet and the rinse/drain valve to the columns. 2.) Perform Air mixing if necessary. 3.) Open Service Inlet and rinse/drain valve. 4.) Rinse the resin with post-filtered water until achieved the desired quality. Note: Product water quality may differ depending on the feed water quality. 5.) Close the rinse/drain valve and open Service Outlet valve to allow the unit to service. 3.5.2 Operation And Maintanance Over time, the resin will become exhausted with ionic impurities. When the resin is exhausted, the ionic impurities will start to leach into product water, typically sodium (Na+) will be the first ion to leach out from cation resin and silica (SiO2) is the first from anion resin. Water resistivity will started to drop when the time comes and the resin is required to be regenerated. In system using regenerable resin in their portable mixed bed, it is a common practice to send the exhausted columns to regeneration plant to perform external regeneration.

3.6

FINAL FILTERS

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The Final Filters are used to prevent resin loss in unlikely event of an underdrain failure. When resin from the Mixed Bed Deionizer passed through the filter, all resin shall be trapped at the filter, this will cause increasing of pressure drop across the filter. When this is detected, nozzles of the upstream Deionizers shall be thoroughly checked. The Final Filters have smaller pore size (1 micron), which can give a finer filtration for the production water. Besides act as a resin trap, particulates larger than the filters pore size in the process water shall be also trapped on the filter while the clean water is pass through.

3.6.1

Initial Start Up Flow into the filtration module is controlled by inlet and outlet isolation valves. During start-up, the inlet valve is opened to allow water in. the outlet valve shall also be opened to allow water flows out to the downstream equipment or directed to drain. New filter elements must be rinsed to remove loose particles, carbon fines and manufacturing detergents before they can be put into service.

3.6.2

Operation And Maintanance Increase pressure drop across the filter is due o filter elements have been clogged with impurities. To avoid insufficient pressure at the downstream, the filter elements shall be replaced. A 10psi clean differential pressure drop is the usual specification indicating the needs to change new filter elements.

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4.0

EQUIPMENT SPECIFICATIONS
A. Raw Water Tank * * * B. Quantity Material Capacity : : : 1 FRP 5 m3 no.s

DI Water Transfer Pump 28

Chemical Plant Utilities Lab * * * * * C. Pre-Filter * * * * * * D. Carbon Filter * * * * * E. Quantity Brand Material Cartridge Length Capacity : : : : : 2 PE 20 20 Inch USgpm no.s Cuno USA Quantity Brand Material Cartridge Length Filter Rating Capacity : : : : : : 2 PE 20 5 20 Inch no.s Cuno USA Quantity Maker Type Capacity Power supply : : : : :

BKC 3761 2 no.s (1 no. standby) Grundfos CHI 4-50 AWG BQQV 4.5 M 3 @ 35 M

415V/3P/50Hz

Micron Nominal USgpm

Portable Mixed Bed (Regenable Resin) * * Quantity Capacity : : 2 10 Sets USgpm/unit

F.

Final Filter * * * * Quantity Brand Material Cartridge Length : : : : 2 PE 20 Inch 29 no.s Cuno USA

Chemical Plant Utilities Lab * * G. Filter Rating Capacity : : 1 20

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Resistivity Meter * * * * Quantity Brand Type Power : : : : : 1 1 no.s 8225 24 VDC set BurkertGerman

H.

Control Panel

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5.0 DRAWINGS

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6.0

CONCLUSION 35

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Water quality from deionizers varies with the type of resins used, feed water quality, flow, efficiency of regeneration, remaining capacity, etc. Because of these variables, it is critical in many DI water application to know the precise quality. Resistivity /conductivity is the most convenient method for testing DI water quality. Deionized pure water is a poor electrical conductor, having a resistivity of 18.2 million ohm-cm (18.2 megaohm) and conductivity of 0.055 microsiemens. It is the amount of ionized substances (or salts) dissolved in the water which determines waters ability to conduct electricity. Therefore, resistivity and its inverse, conductivity, are good general purpose quality parameters.

7.0

EXPERIMENTAL WORK 36

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WATER ANALYSIS

Purpose of Analysis - to ensure the quality of water under the operation specificarion.

Parameter of Analysis pH, Conductivity (25C, 35C, 45C, 55C), Tubidity, Chlorine, Teperature and Total Dissolved Solid (TDS)

Sampling Points Water inlet (JBA Water) Water Outlet (DI Water) Distilled Water

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