DOC. NO. PDRP0456-8110-PD-101-0002 REV.

O1
HDO DOC. NO. A4-2100866-101-BEP-Vol I-002
PROCESS DESCRIPTION
PARADIP REFINERY PROJECT DEMINERALISED WATER SYSTEM
FOR
INDIAN OIL CORPORATION LIMITED
CONSULTANT: -
FOSTER WHEELER (INDIA)
SUBMITTED
BY

DORR-OLIVER HOUSE,
CHAKALA, ANDHERI (EAST), MUMBAI 400099
INDIA
TEL. NO. :-022 28359400
FAX NO. :- 022 28365659

R1 10.06.2010 ISSUED FOR APPROVAL PRB VGV RK

PREPARED CHECKED APPROVED
REV. DATE REVISIONS
BY BY BY
HINDUSTAN DORR OLIVER LTD.

PROCESS DESCRIPTION

The DM Plant comprises of two packages:

1) Ultrafiltration Package
2) Demin polishing Package
Ultrafiltration Package is designed to remove colloidal silica from the treated raw water and the Demin
Polishing Package is design to demineralise RO permeate and/or ultrafiltered water.

Ultrafiltration package (101-A-003):

The basic functionalities of this package are :1)Storage of treated Raw Water 2)Ultrafiltration of treated
raw water to remove colloidal silica producing ultrafiltered water of suitable specification to supply to
the Demin package 3)Transfer of ultrafiltered water to the Demin Feed tank 4)Transfer of Ultrafiltration
reject to UF Reject storage Tank.

The Ultrafiltration package is to be designed to produce 1170 TPH of ultrafiltered water with a feed
supply not exceeding 1300 TPH of treated raw water for full Refinery and 870 TPH of ultrafiltered
water with a feed supply not exceeding 967 TPH of treated raw water for the fuels refinery. 25% spare
membrane capacity in addition to the design capacity shall be provided. Treated raw water from the
RWTP (Unit 100) is pumped into the Ultrafiltration feed Tank at a pressure of 2.5 kg/cm2g at Demin
Battery limit. Ultrafiltration feed tank should have four hours of hold up capacity (net capacity of 5200
m3). Ultrafiltered water is used as the supplementary of RO permeate water. During startup, when no
RO permeate water is generated in the Water Recovery plant, ultrafiltered water is used as the only
source of feed for Demin Polishing Package.

Treated raw water from Ultrafiltration feed tank is pumped by Ultrafiltration feed Pump to the filter
units of the Ultrafiltration system and the ultrafiltered water is stored in to the DM Feed Storage tank.

The backwash and reject water from the Ultrafiltration package is stored in UF Reject Tank of capacity
640 M3 and is transfered to Unit 100 where it is reused for make-up to cooling towers. The battery limit
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pressure of the reject transfer pump shall be 3.5 kg/cm2g.

Demin polishing Package (101-A-002):
The basic functionality in the scope of the Demin Polishing package is broadly categorised as - 1)
Storage of demin feed water, 2) Polishing of demin feed water in ion exchanger trains, 3) Transfer of
DM water to DM tank, 4) Regeneration and chemical storage and 5)Neutralization and waste disposal.

Ultrafiltered water from the Ultrafiltration package and RO permeate water from the Effluent Treatment
Plant ETP (Unit 235) are stored in the Demin feed tank. RO permeate water is supplied to Demin
battery limit at 2.5 kg/cm2g. Demin feed tank is to be designed for four hours of net to service hold up
capacity (net capacity of 7648 m3). From the Demin feed tank, demin feed water is pumped by DM
Feed Pump to the ion exchanger trains and finally the DM water is transferred to the DM Water Storage
Tank (101-TK-001 and 101-TK-002).

During regeneration, chemicals (acid and caustic) are transferred from the chemical storage tanks using
the Regeneration pumps. Regeneration wastes are diverted into the Neutralization pit and the reject
water is stored in the DM Reject Tank. Disposal of the reject water is done in ETP using the DM
Reject pumps.

Strong Acid Cation Exchanger (SAC)

Ultrafiltered Water / RO Permeate water stored in DM Feed Storage tank (101-TK-005) is pumped
using DM Feed Pumps (101-P-005A/B/C/D) to Strong Acid Cation Exchanger (SAC) (101-V-
001A/B/C/D/E) to remove cations from Water.

Strong Acidic Cation exchanger consists of strong acidic cation resin charged with mobile replaceable
hydrogen ions. Water is fed to cation exchanger, which in turn passes through a column of cation
exchange resin. Thus cations in the raw water which are mainly Ca, Mg, and Na gets adsorbed on the
resin surface. The resin in turn releases hydrogen ions in the water. Hence, the water coming out of
cation exchanger will contain acidic salts such as Hydrochloric acid, Sulfuric acid, Carbonic acid.
Hence, the pH of Decationised water will be about 3 to 3.5

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The reaction-taking place during Normal Operation are as under : -

Cation resin salts in raw water Acid
R-H + CaCO3 HCO3 + R-Ca
R-H + CaSO4 H2SO4 + R-Ca
R-H + MgCO3 HCO3 + R-Mg
R-H + MgSO4 H2SO4 + R-Mg
R-H + CaCl2 HCl + R-Ca
R-H + MgCl2 HCl + R-Mg
R-H + Na2CO3 HCO3 + R-Na
(Note: - R represents resin)
After constant usage the hydrogen charge on the cation resin gets exhausted, a solution of hydrochloric
acid is passed through the cation resin bed for regeneration. During this regeneration process cation
resin is restored for hydrogen charge. To wash away traces of chemicals used for regeneration entire
system is flushed with purified water, which is rejected. After this operation the cation exchanger will
be ready for the next cycle of operation.
Reaction taking place during Regeneration are as under : -
R-Ca + HCl CaCl2 + R-H
R-Mg + HCl MgCl2 + R-H
R-Na + HCl NaCl + R-H
(Exhausted resin) (Regenerant) (Effluent) (Regenerated resin)

Degasser System:
Outlet coming out from Strong Acid Cation Exchanger (SAC)(101-V-001A/B/C/D/E) is fed to Degasser
Tower (101-C-001A/B/C/D/E).

The contents of water split the carbonic acid (H2CO3) into carbon dioxide CO2 and water H2O. The
CO2 is driven out with air through the air vent provided at the top of degasser.

2R-H + Ca (HCO3) 2---------> R2-Ca + 2CO2 +H2O

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The water is introduced into degasser top via spraying nozzle. This nozzle distributes the water over the
entire surface of tower packing. An air stream is led under these packing into the degasser with the help
of Degasser Air Blower (101-K-001A/B/C/D/E/F/G). The downward trickling water comes into contact
with the updraft flowing air forming a Degassed Water. Degassed water is then stored in Degassed
Water Tank (101-TK-006A/B). From Degassed Water tank (101-TK-006A/B) water is fed to (SAC)
Regeneration with Degassed Water Pumps for (SAC) (101-P-009A/B) and to Weak Base Anion
Exchanger (WBA) (101-V-002A/B/C/D/E) and Strong Base Anion Exchanger (SBA) (101-V-
003A/B/C/D/E) with Degassed Water Pumps (WBA Feed) (101-P-008A/B/C/D).

Weak Base Anion Exchanger (WBA) & Strong Base Anion Exchanger (SBA)
Strong Base Anion Exchanger (101-V-003A/B/C/D/E) consists of strong base anion resin charged with
mobile replaceable hydroxyl ions. Water is fed to Weak base Anion Exchanger (101-V-002A/B/C/D/E)
followed by Strong Base Anion Exchanger, which in turn passes through a column of anion resin. Thus,
Equivalent Mineral Acid load comprising of Sulphates, Nitrates, Chlorides, etc. is adsorbed by Weak
Anion Unit while the remaining anions such as Silica, CO2 slipped from Degasser, Carbonates, etc. get
adsorbed on the Strong Base anion resin surface. The resin in turn releases hydroxyl ions in the water.

The absence of cations and anions in the water at the outlet of anion exchanger will be indicated by low
electrical conductivity of D.M water.

Reaction taking place during the Normal Operation are as under : -

Anion resin acidic Decationised water
R-OH + HCO3 H-OH + R-CO3
R-OH + H2SO4 H-OH + R-SO4
R-OH + HCl H-OH + R-Cl
(Note: - R represents resin)

After the constant usage hydroxyl charge on the anion resin gets exhausted as indicated by disturbances
in conductivity, a solution of Sodium Hydroxide (Caustic Soda) is passed through the anion resin bed.
During this regeneration process anion resin is restored for hydroxyl charge. To wash away traces of

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chemicals used for regeneration entire system is flushed with purified water, which is rejected. After this
operation the anion exchanger will be ready for the next cycle of operation.
Reaction taking place during Regeneration are as under: -
R-CO3 + NaOH Na2CO3 + R-OH
R-SO4 + NaOH Na2SO4 + R-OH
R-Cl + NaOH NaCl + R-OH
(Exhausted resin) (Regenerant) (Effluent) (Regenerated resin)

Mixed Bed Unit (MB):

Normally, the cation and anion exchanger columns will allow a small slippage of both cations and
anions through the respective beds. Hence the conductivity of Deionised (DI) water at the outlet of
anion exchanger will be upto 10 s/cm, which is equivalent to approximately upto 10 ppm of dissolved
solids in Deionised water.

Passing through a Mixed Bed Polisher Unit(101-V-004A/B/C/D/E), in which the remaining Cations and
anions are removed to get DI water, further polishes this DI water. The mixed bed unit consists of a
mixture of both cation and anion exchange resins, which remove the traces of remaining cations and
anions from the DI water. After constant usage when the ionic charges on these resins get exhausted, the
cation and anion resins are separated by back washing the unit for few minutes. Due to difference in
densities, they get separated forming two distinct layers, with the anion resin on the top and cation resin
at the bottom. Passing a solution of Sodium Hydroxide (Caustic Soda) then regenerates the anion resin
and passing a solution of Hydrochloric Acid regenerates the cation resin. The resin columns are rinsed
individually and finally remixed again, by passing air of 5 psi from MB Air blowers (101-K-002A/B)
Thus the unit becomes ready for another cycle of operation to produce pure deionised water of electrical
conductivity less than 0.5 s/cm equivalent to approximately 0.8 ppm of dissolved solids in DI water.
Reactions taking place in a Mixed Bed Unit are similar to that of taking place in Cation & Anion
Exchangers.
Hence the final composition of water after mixed bed unit is -
H + OH H2O
General reaction taking place in cation exchanger is :-
R-H + CaCO3 HCO3 + R-Ca
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General reaction taking place during regeneration of cation exchanger is :-

R-Ca + HCl CaCl2 + R-H

General reaction taking place in anion exchanger is :-

R-OH + HCO3 H-OH + R-CO3
General reaction taking place during regeneration of anion exchanger is :-
R-CO3 + NaOH Na2CO3 + R-OH
Hence the final composition of water after Mixed Bed Unit is -
H + OH H2O (De- Mineralized water)

The effluent waste water during regeneration from DM polishing unit will be collected in the
neutralization pit(101-SU-001). From the neutralization pit (101-SU-001) the waste will be transferred
to DM Reject Tank (101-TK-017) and from there to ETP.
The treated DM water is collected in DM Water Storage Tank (101-TK-001 & 101-TK-002).
Morpholine dosing is done using Morpholine solution Dosing Pumps (101-P-014 A/B/C) to correct the
pH in DM water.

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