Design for Reliable CEDI

Operation

©2014 Evoqua Water Technologies Pty Ltd

www.IONPURE.com
LX / VNX Module Layout

S 4 pipings for module

(1) Dilute Inlet Dilute (2) Dilute Outlet or Product

Conc (4) Conc Outlet or Reject

(3) Conc Inlet

S No separate electrode stream

Ø Electrode compartment is a concentrate spacer
Ø Ion-exchange resins at electrodes

Page 2
CDI Pretreatment Requirements

S CDI pretreatment similar to IX systems

S Good pretreatment avoids chemical cleaning

Chemical attack
(Chlorine & Oxidants)

Fouling
S Prevents (Organics & Metals)

Plugging
(Particulates & Colloids)

Scaling
(Calcium carbonate)

Page 3
The Process CDI Design

S Based on feed water quality

Ø RO projection or RO permeate analysis

S Use IP-Pro v2.10 CDI projection program

Ø Determine number and type of modules required
Ø Estimate performance and fine-tune adjustments

S Other concerns
Ø Pretreatment
Ø Mechanical Design
Ø Commissioning
Prevent scaling, fouling, oxidation etc
Instrumentation design on skid
Ensure no hydraulic shock, setting of recovery
and pressure balancing

Page 4
Feed Water Specification

Parameters Standard Ionpure Modules

FCE < 40 uS/cm
Source 2-Pass RO
Inlet PSIG (Bar) 20-100 (1.4 – 7)
Temp Range 5 – 45 oC
Recovery 90 – 95 % (90% recommended generally)
Total Cl2 < 0.02 ppm
Fe, Mn, S- < 0.01 ppm
pH 4-11
Total Hardness < 1 ppm as CaCO3
(Recommended to be < 0.5 ppm as CaCO3)
Dissolved Organics < 0.5 ppm
Silica (SiO2) < 1 ppm

Page 5
Feed Water Hardness

S All CDI devices are sensitive to hardness

Ø Most tolerate maximum 1 ppm as CaCO3 (> 0.5 ppm = periodic cleaning required)
Ø Higher end Ionpure modules required 0.1 ppm as CaCO3
Ø General recovery for CDI is 90% or below

S Two (2) Requisites for 95% recovery

1. At least softer + 1-Pass RO, 2-Pass RO
2. Feed hardness of < 0.2 ppm as CaCO3

S Note: 95% recovery = 20x concentration factor = higher chance

scaling

Page 6
How to Identify Hardness Scaling

S High module resistance (ohms)

Formula R(ohms) = V / I
Conc dP

10 psi
S Increasing concentrate pressure drop Time
Conc Flow

S Decreasing concentrate inlet flow

Time

Page 7
Design to prevent CDI Scaling

S Use a softener before RO

Ø Lower hardness load for RO, membranes last longer

S 2-pass RO
Ø Often the most desired situation. 2nd pass RO polishes up the 1st pass permeate

S Softener + 2-pass RO
Ø Typical semiconductor pretreatment

S Antiscalent + 1-pass RO
Ø Not recommended for long term operation. Only for very low hardness water
Ø Watch out for start/stop systems….

Page 8
Feed Conductivity Equivalent (FCE)

S Measured RO permeate conductivity is misleading

S CO2 and SiO2 not fully included (low ionic conductance)

FCE = Measure conductivity + [ ppm as CO2 x 2.79 ] + ppm as SiO2 x

1.94]

Example:
Measured conductivity (from analyzer) = 1uS/cm
Measured CO2 (using test kit) = 5 ppm as CO2
Measured SiO2 (using test kit) = 0.5 ppm as SiO2

FCE = 15.92 uS/cm

Page 9
Function of Voltage and Ampere

S Voltage (potential) causes current to flow

S Current causes transfer of salt, regeneration of resins
S Without power supplies, the CDI simply behaves like any IX resin
columns (mixed-bed). Module (or resins inside) will be exhausted
after some time
S Ionpure power components design is based on constant current
control mode, which means the voltage “floats” around based on the
resistance of the module

Page 10
Ohm’s Law

S Ohm’s Law

V = IR
Voltage, Volts Current, Amps Resistance, Ohms

S Factors determining resistance

Ø Feed water temperature
Ø Conductivity (feed, product, reject)
Ø CDI recovery (affects reject conductivity)
Ø Ionic composition of feed water
Ø Degree of scaling or fouling
Ø Resistance of CDI components (membrane, resins)
Page 11
Calculating Amps required

S Faraday’s Law
- I = 1.31 (Q)(FCE)/(# cells)(eff)
- I = DC current, amps (per module)
- Q = product flow rate, liters/min/module
- FCE = feed conductivity equivalent, µS/cm
- eff = current efficiency, %
- (assume 10% current efficiency)

Page 12
Ionpure Softwares

S Note: This guide only serves as a shortcut for users whom are new to Ionpure
programs. Please read the user manuals in each of the program for detail
information on how to use them

Current available Ionpure programs

IP-Pro v3.0 – Performs CEDI projections based on feed water input,

similar to Dow’s ROSA software and Rohm & Hass IXCalc software

https://ippro.evoqua.com/

Page 13
IP-Pro v3.0

Login if registered

Register if new user

Page 14
IP-Pro v3.0

Four (4) sections needed to

be completed in order.

Enter job name

Page 15
IP-Pro v3.0

Key in feed
parameters

Select
application type

Click NEXT Select units

once done preference
Page 16
IP-Pro v3.0

Enter in system
details

Page 17
IP-Pro v3.0

Print to PDF

Page 18
IP-Pro v3.0 Sizing Tips

S Always have a few iterations for comparison.

S If projection states “Periodic cleaning may be necessary”, then you

probably need a softener

S Try out different flowrates, CO2 and module types.

S Sometimes it may be better to split the product requirement into a

few portions so that it will be easier to schedule maintenance for the
modules.

Page 19
Important Notes for IP-Pro v3.0

S The RO projection results (e.g from ROSA) sometimes may not be

an exact representation of the CDI inlet feed. In the example below,
the RO permeate is contaminated by atmospheric air CO2 prior to the
CDI
Example:
2-pass RO Tank Cartridge Filter CDI

Projected CO2 (from ROSA): 0.1 ppm Actual CO2 entering CDI: 3 ppm

Page 20
Cont’…. Important Notes

S IP-Pro v3.0 is NOT able to depict long-term CDI performance,

cleaning frequency, lifespan. These depends on many factors:-

Ø Design of pretreatment (e.g 1-pass or 2-pass RO)

Ø Regularity of maintenance for the pretreatment
Ø Recording of daily information on parameters
Ø Knowledge of the service providers towards water process
Ø Etc…

Page 21
Module Instrument Layout

Display Instrumentation DC Power Controllers

1-Channel
8-Channel
are individual
16-Channel (2) Dilute
R
Outlet or
(1) Dilute Inlet PI PI Product
FI
Dilute
GRD SP SP GRD

PI PI
Conc
FI
SP
GRD
(3) Conc Inlet (4) Conc Outlet
or Reject

Multiple CEDI
modules in a skid
with common
instrumentation
Page 22
Determine the Flowrates for CDI system

S Determine % recovery, then set flowrates

Ø 90% recovery generally recommended

S How to calculate set 90% recovery for CEDI system

Ø Conc Inlet Flow = ((100 - R)/R) x product flow where R is the percent recovery

Example: Product Flow = 50 m3/h

Recovery = 90%

Conc Inlet Flow = [(100-90)/90] x 50 = 5.6 m3/hr

Shortcut : Conc Inlet flowrate = 11% of Product

RULE #1: The lower the hardness, the better the modules will perform!

Page 23
Pressure Balancing for CDI Systems

S Outlet differential pressure (product pressure minus conc outlet

pressure) must be be 2 - 5 psig
Example: If product pressure is 30 psi, conc outlet pressure should be ~25
psi. 30 psi

PI
Dilute Outlet or
Inlet Product (To Tank)
PI
Conc Outlet or
Reject (To Drain)
Zero
10
15
20
25
5 psi
psi
psi

Page 24
Overall System Setting

S The system is set by accomplishing 2 things:

1. Recovery % (example: 90%)
2. Outlet differential pressure

S To accomplish the above can be done by adjusting the conc inlet

and conc outlet valves

Multiple Modules

Page 25
Pressure Concerns

S > 100 psi can cause increased external leaking

S High product (D,out) >> Reject (C,out) pressure can cause poor
performance
Example: Product pressure: 50 psi
Reject pressure: 0 psi

S High reject (C,out) >> Product (D,out) can cause cross-leak

Example: Product pressure: 20 psi
Reject pressure: 50 psi
PSI

S Must avoid Water Hammer

DEAD END
Pipe FLOW!!!
Page 26
System Design Philosophy

SCEDI modules are usually designed in a system design, similar to

RO/UF systems.
Example: 4x VNX50 in a skid with common instrumentation

S Advantages of system design Multiple

Ø A lot cheaper in terms of instrumentation costs
modules
Ø Skid looks simple & tidy
Ø Easy to record data.
Ø End-users are not confused on how to operate

S Key idea is to create building blocks (skids) to meet the entire

flowrate demand.

Page 27
Other P&ID Design Notes

SGood to install individual sampling points on each of every

modules’ product line.

S For instruments, always have a single set of

instrumentation to monitor a couple of modules.
Not advisable to monitor certain parameters
individually.

S NOT advisable to install individual flowmeters for the modules in a

skid system. Why?
Page 28
Specific Issues - Important

1. RO permeate start-up
2. Reclaim of CEDI reject
3. Location of Pressure gauges
4. Electrode gas production
5. Hydraulic issues
6. Modules tightening
7. CDI system safeguards

Page 29
RO System Start-up

Level
Transmitter

Storage
Tank
Low level
detected!!
EDI will foul up
after some time
Page 30
Problems with RO Start/Stop

S What happens when RO pump shuts off?

Ø Salt equilibrates across membrane
Ø Average upstream salt concentration 2X feed

S RO restart: initial permeate worse than feed

Ø Affect on IX demineralizer: reduces capacity
Ø Affect on CEDI: can cause scaling

S Solutions:
Ø Flush permeate to drain before sending to CEDI

Page 31
High Conductivity upon RO start-up

S Insufficient flushing can cause scaling & organic fouling!

Page 32
Correct Method – RO pre-flush

Make sure one control

valve open first before
the other closes!!

Storage
Tank
Flushing based on:
1) RO conductivity setpoint
Water normally re-used
2) Timer (e.g 5 mins)
(e.g. To raw water tank)

Page 33
Reclaim of CDI Reject Water

S Advantages
Ø Low in conductivity
Ø Everyone desires 100% recovery

S What you need to take note of:

Ø CEDI reject contains electrode gases & CO2
Ø Reclaim of reject requires break tank to vent H2

S Returning reject to RO feed increases CEDI feed CO2 by up to 3X (if no

degasification or NaOH). May affect CEDI product water quality
Ø CO2 accumulates à FCE increases à Performance affected

Page 34
CO2 Accumulation

Page 35
CO2 Removal Methods

S Membrane contactor/degasser e.g. Liquid Cel.

Ø Located between Tank and CEDI – technically best option but pricey

Page 36
pH Adjustment Method

S pH Adjustment by NaOH chemical injection

Ø Least expensive but may increase overall

conductivity and also depends on system
design:

Ø Pre 1st stage RO – may cause hardness

precipitation

Ø Pre 2nd stage RO – limited contact time

to convert CO2 to bicarbonate especially at
low temperatures.

Page 37
Pressure Gauge

S Pressure gauges are installed to indicate any form of restriction for

a CEDI module (same for RO systems). Hence they must be position
right before and after the module.

S Correct pressure drops @ nominal flowrate & ~90% recovery

Ø Dilute: 20 – 30 psi (< 2 bar)
Ø Conc: ~ < 10 psi (<0.7 bar) Dilute Inlet
Dilute Product
Conc Reject
S If you don’t see the above Conc
Inlet ??? Pressure
pressures, this means
These gauges will indicate similar pressures
somewhere is wrong
Page 38
Pressure Readings Rule of Thumb

Example
S Feed pressure always < 100 psi
S Dilute pressure drop (nominal flowrate) ~ 20 – 30 psi
S Conc pressure drop ~ < 10 psi
S Dilute ∆P >>> Conc ∆P (Always the case)
S Dilute IN Pressure >> Conc IN Pressure.
S Outlet differential pressure (Product MINUS Reject) = 2 – 5 psi
Note: The commissioning data is your baseline!

Page 39
Electrode Gas Production

S In Ionpure modules, electrode compartments act like concentrate

compartments.

S No separate electrode stream

S Water that flushes the electrodes mixes with the concentrate

stream and exits together.

S CEDI reject is required to be discharged into an open ventilated

area (example – open tank/drain)

Page 40
Cont’… Electrode Gas Production

S The amount of chemical reaction is proportional to electricity passed

S Anode (accepts electrons - oxidation)
½ H2O ® ¼ O2 + H+ + e- [1]

Cl- ® ½ Cl2 + e- [2]

Chlorine gas is rarely produced because Ionpure modules do not require brine
injection, and uses resin fillers in the electrode compartments instead.

S Cathode (donates electrons - reduction)

H2O+ e- ® ½ H2 + OH- [3]

Page 41
Hydraulic Issues

S Water hammer
Ø Simultaneous operation of product and divert valves
Ø Must open one before closing other

S Pressure differential between compartments

Ø Keep pressure slightly higher on product side

Note: The conc out pressure

is always fixed, so to meet the
2-5 psi difference, the product
pressure should be somewhat
consistent wherever it flows.

Page 42
Sequence of Valves Changeover

Product Mainstream
(To DI Tank) PSI

Divert
(To RO Tank)
Dilute Out
DEAD END Pressure Gauge
FLOW!!!

Product Mainstream PSI

(To DI Tank)

Divert
(To RO Tank) Dilute Out
Pressure Gauge
3-5 seconds delay

S Must open one before the other first

S Recommended to have a timer delay (3-5 seconds) in between
valve changes
Page 43
Solution Downstream

S If using 3-way valves, make sure use Double-L port to prevent

dead-ending

Use control valves, e.g air actuated

Page 44
Module Tightening

S Only LX modules need to be tightened

S VNX modules do NOT need to be tightened

S Refer to LX modules manual for tightening

procedure
S Only need to do it once before commissioning
S Only use a torque range for tightening
S Do NOT over-tighten
S De-pressurize module first before
tightening
Page 45
CDI System Safeguards

S Low flow alarm - Product and reject flow

Note: Recommend to have a timer delay (e.g 5 seconds ) before the
power cuts off.

S RO (or CEDI feed pump) interlock - CEDI “runs”

only when RO or feed pump is in operation
S Low product quality - Control product divert valve
S Low feed quality alarm - Protects CEDI from high
hardness or chlorine/ORP

Rotameter with Flowswitch

Page 46
Tank to CDI Configuration

Highly
Cartridge filter
Recommended!!

RO
Break CDI Demin
Tank Tank

S Interlock CDI to CDI feed pump

Close up view of spacers at
S Install a cartridge filter between tank & CDI the inlet port

Page 47
Direct Feed of RO to CDI

RO service pre-flush See Slide 34

required!!

RO CDI
Tank

S Interlock CDI safety to RO pump

S Pressure relief between RO & CEDI
S Controls to initial RO permeate flushing during startup

Page 48
Ionpure System Design Approach

S Design in small building blocks

S Multiply them to meet the designed flowrate
Ø Example: 120 m3/hr divided into 4 building blocks of 3 modules each

Page 49
Any Questions?

JS Pan
Technical Manager
Asia Pacific
E-mail:
jiasheng.pan@evoqua.com

www.IONPURE.com
www.CEDIUniversity.com

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