DMPLANT LECTURE ON WATER TREATMENT PROCESSES AND ION EXCHANGE RESINS

DMPLANT LECTURE
OPERATION, RESIN
MAINTENCE & TROUBLE
SHOOTING

SOURCE
RAIN.
 SURFACE
 UNDERGROUND
 SEA

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,soil or industrial
effluents.
Major impurities
Ionic-Dissolved
Non-Ionic-Suspended
Dissolved Gases.

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

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

INDUSTRIAL WATER
TREATMENT
Water is the most important raw
material used in industry.
It has good heat capacity.
It is a universal solvent.

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

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

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

ANALYSIS
3.Suspended Deposits in the water Gravimetric
solids line, heat exchanger etc analysis
4. Alkalinity Combines with divalent Types : p & m
cations to form scales. alkalinity.
Analysed after
titration with std.
acid.
expressed in
ppm as CaCO3
PARAMETERS

PARAMETERS
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.

PARAMETERS
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 phosphate Colorimetric
levels in cooling water. Analysis on
Classified as ortho, poly spectrophotometer.
and total phosphates

PARAMETERS
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.

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 & biocidal Titration with FAS
activity. or with chlorotex
reagent.
PARAMETERS

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

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 02.5 TO 04.5 02.85
7 INSOLUBLE % BY MASS 0.50 0.024

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 cl2 mg/L as cl2 0 0.2 0.1
3Turbidity NTU 5.4 1.0 1.0
4
Conductivity micro
mho/cm 211 222 219
5M Alkalinity as CaCO3 104 100 102
6
Total Hardness as
CaCO3 94 96 94
7Ca Hardness as CaCO3 54 56 54
8Mg Hardness as CaCO3 40 40 40
9Silica mg/L as SiO2 11.5 11.4 11.3
10EMA mg/L as CaCO3 16 22 20
11
Chloride mg/L as
CaCO3 12 16 16
12
Sulphate mg/L as
CaCO3 4 6 4
13
KMnO4 Value mg/L as
O 2.7 1.6 1.6

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 Water Pump
Capacity-230M3/Hr
Filter Water Pump
Cap:-280M3/Hr Each.
Degassed WatePump
Capacity - 240M3/Hr.
Output-1680M3.
Max.Pr. - 7.0Kg/Cm2.
Output-10080M3.
Max.Pr. - 8.0Kg/cm
SAC-
2AB
C
Output-10080M3.
Max.Pr.- 8.0Kg/Cm2.
MB-
2AB
Process &
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
WaterPump
Cap.230M3/Hr.

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

DETAILED SPECIFICATION
FOR ACTIVATED CARBON
• 1. Grade : Dechlorination
• 2. Appearance : Black granular
• 3. Iodine absorption: : 850 mg/gm, Min.
• 4. Bulk density : 500 Kg/M3 +/- 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)

CONTINUE
• 8. Operating pressure : 8.0-9.0 Kg/cm2g
• 9. Flow normal/Max. : 150/180 M3/Hr.
10. Packaging 50 Kg. HDPE bags

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 " -

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

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

Ion Exchange
•What is Ion Exchange
Dictionary definition of ion exchange resin is a polymer
made up of monomer having at least one benzene ring

Ion Exchange
•Insoluble Solid material which carries
exchangeable ions.
•A reversible stoichiometric process.
• Every ion which is removed from the
solution is replaced by equivalent amount of
another ion of same charge.
•After the ion exchange, the exchanger
material can be brought back to original
form by process called regeneration.

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

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 -

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

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

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

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

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

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

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

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

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

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%

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.

Resin Strong acid Cation:
• Type Gel
• Volume change H+ to Na+, Approx. ~6%
• Voids Approx. 40%

SAC(Chemical)
• Ionic Form H+
• Effective Operative Ph 0-14
Agents Good
• Exchange Capacity 2.0 meq./ml.(Na+form)
& 1.8 meq./ml.(H+form)

Resin Weak Base Anion(PHY:
• Type Macro porous
• Osmotic Strength Excellent
• Mechanical Strength Excellent
• Moisture Content 47-55 % (Cl-)
• Vol.change Free Base to ClApprox.+20%
• Voids . 40%

WEAK BASE ANION(Chemical)
• Ionic Form Free Base
Agents Good

Strong Base Anion(Phy):
• Type Gel (Iso porous)
• Vol.change OH - to Cl -, Approx. 7 to17%
• Voids . 40%

SBA CHEMICAL PROPERTIES
• Ionic Form Cl -
Agents Good

Ion Exchangers
Insoluble solid material carrying exchangeable
cations or anions
WAC SAC
Cation Exchange
WBA
Type I Type II
SBA
Anion Exchange
Ion Exchange Resins

Ion Exchange Resins
• Properties of ion exchange resin.

Properties of Ion Exchange Resins
• Particle Size :
Purely hydraulic and kinetic influence on the ion exchange process.
0.3 - 1.2 mm size is satisfactory for industrial applications
• Effective size = Sieve (mm) on which 90% of beads are
retened.
• Uniform Coefficient = ratio of 40% and 90%.
• Moisture Content :
It is bound water related to cross linking. About 45 - 55 ° depending
on type of resin. Gives valuable information. on resin under use.

• 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.

(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

(Contd...)
• Total Exchange Capacity :
It is the capacity obtained from the total
quantity of counter ions that is capable of
exchange per unit weight or volume of either
dry or swollen resin
• Operating Capacity :
The capacity that could be realized in a
column under a set of selected conditions.

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

Properties of Ion Exchange
Resins (Contd...)
 Total Exchange Capacity :
it indicates he total number of exchange sites available. It can
be expressed as meq/gm of dry resins, meq/gm of wet resins or
meq/ml of wet resins. Another method is in terms of Gms of
CaCo3 instead of meq.
consider a cation exchange having a capacity 5.2 meq/gm
of dry resins having water regain 1.10 gms/gm and bulk
density 0.84gms/ml.
Total exchange cap. On wet basis=5.2/1+1.1=2.47meq/gm of
wet resins. OR
2.47x0.84x1000 =2080 meq/lit of wet resins
Since 1meq of Caco3=50gm than it can be expressed as
2080x50/1000 =104gm of Caco3/liter of wet resins.
.

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

WAC AND WBA RESIN
EXCHANGE CAPACITY VS PH

– HOW DOES ION EXCHANGE
RESIN WORKS.

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.

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 silica not 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.

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

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

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
By back washing, more uniform distribution of
fluid is obtained in subsequent down-flow
operation.

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

Regeneration Process
The process to bring back the exhausted
resin to original or usable form is
regeneration.
The reaction is opposite to service
reaction.
There are two methods for regeneration
co-current and counter current method.

Regeneration (Injection)
According to the resin by HCl, H2SO4 or NaOH,
the major factors affecting the degree of
regeneration are :
 Composition of the exhausted bed
 Flow rate
 Contact time
 Temperature
 Purity of regenerant
 Conc. of regenerant
 Amount of regenerant applied (Reg. level)

Counter Current Regeneration
# To minimise leakage and get better
quality effluent
No back wash given
Provisions made to avoid fluidizing of
the bed and then regenerant is passed
in opposite direction of service
Back wash is given only when
necessary but followed by double
regeneration

Co - Current regeneration.
Service inlet
Regeneration
inlet.

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

Slow Rinse
It is extended regeneration. Hence at
regeneration flow rate generally by 2 BV of
water
Fast Rinse :
To remove traces of regenerant. Done at
service flow rate.

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

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

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

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

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

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

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

DMPLANT LECTURE ON WATER TREATMENT PROCESSES AND ION EXCHANGE RESINS

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DMPLANT LECTURE ON WATER TREATMENT PROCESSES AND ION EXCHANGE RESINS