<p>Purolite Ion Contents of help:</p><p>Exchange</p><p>Design</p><p>Calculation</p><p>Program</p><p>20 21 22 23 24 25 26 29 51 55 56 57 58 59 61 IX Treated</p><p>Water</p><p>Treatment 63 Design Calculation Mixed Beds Softening 64 Dealkalisation 65 Demineralization 66 Extra RAW Cycle WATER Time Choice Plant Treated Pressure Operating Conditions Design Operating Water Drop Working Conditions Mixed Mixed Water Analytical origin and of and Flow Beds Analysis Data pretreatment Rate Resin Regeneration Design Quality Calculation Beds Polishing Objectives</p><p>Working Polishing Nitrate Program Influent Design</p><p>Mixed Mixed</p><p>Beds 67 Beds 68 Removal 69 Difficulty 70</p><p>Water Process Water of Bed</p><p>Data 71 Calculation 72 Options 73 Specifications 74 regenerants 75 Options 76 Options 77 Overrun</p><p>Neutralization Dealkalisation Mixed</p><p>62 Nitrate Removal 20 Water Treatment Select the type of process to be carried out in your plant. SOFTENING: Exchange of hardness ions for sodium ions. DEALKALISATION: Removal of hardness associated with bicarbonates (alkalinity) using a weak acid resin. The program also includes permanent hardness removal by use of a strong acid cation resin, in the softening mode which is sometimes used in breweries. DEMINERALISATION: Water can be demineralised by means of cation and anion resins in separate vessels. Weakly functional resins can achieve partial demineralization with economical use of regenerants. More complete demineralization requires the use of strongly functional resins and higher regeneration levels. MIXED BEDS: Water can be purified to higher standards using a Working Mixed Bed or further purified after standard demineralization using Polishing Mixed Bed to remove any leakage remaining. Where the inlet load is negligible, this process is termed 'polishing'. If the ion exchange load is high enough to utilize a substantial proportion of the available operating capacity, such as water treatment directly after demineralization, this is termed a working mixed bed.</p><p>NITRATE REMOVAL: There is a recommended limit for nitrate in potable water published by the World Health Organization. Consequently many countries have placed their own limits to cover the quality of the potable water available. Nitrate is removed by strong base anion resins. Where the water to be treated contains sulfate, this is removed preferentially, and nitrate capacity is reduced because the resin is loaded with sulfate. Purolite 520E is selective for nitrate over sulfate and all other common anions, thus all the capacity is available for nitrate removal. 21 Softening 1) The standard choice is 1 Purolite C-100 or C-100E. Only a change to very special conditions, (high osmotic shock, very high TDS, presence of oxidizing agents etc.) would create a need to select another resin. The Purofine grade offers advantages of a smaller plant and use of less regenerants. 2) Select one of the options shown in scroll box. Option 1 (Co-flow), used by default, is simpler to construct and operate. However salt utilization and hardness leakage are both high. Option 2 (Counterflow) offers the lowest leakage. 3) Input the Regeneration level grams per liter of resin: Co-flow (Option 1): Counter-flow: 90300 g/l 40150 g/l</p><p>4) Standard concentration is 10% . Other concentrations will reduce operating capacity especially for Coflow operation. 5) Bed depth is important for counter-flow operation. Deeper beds above 0.7 m give higher capacity and lower leakage. 6) The design program calculates capacity and leakage. If results are unsatisfactory, changes in regenerant dosage, mode, and flow rate can offer improvements. 22 Dealkalisation Purolite weak acid cation resins are capable of removing cations associated with bicarbonate anions (or carbonates/hydroxides) to reduce total solids, and especially temporary hardness. Its main advantage is that regeneration can be achieved with practically a stoichiometric quantity of regenerant. The capacity for temporary hardness ions is particularly high, especially at low flow rates. (Removal of temporary hardness can reduce precipitates and scale which normally occur on the boiling of water.) Where bicarbonates are associated with sodium rather than hardness ions the operating capacity is significantly reduced. It should also be noted that lower feed water temperatures reduce operating capacity significantly. Also low regeneration temperatures increase the risk of calcium sulfate precipitation. Flow rates should be maintained to ensure regenerant is removed from the resin before precipitation commences. Dealkalisation can also form part of a demineralization process, the salts of mineral acids are treated on the strong acid cation filter which follows the weak acid cation filter. Depending on the proportional load on each filter it can also be advantageous to allow some or all of the sodium alkalinity to over-run to the strong acid filter. The redistribution of load can produce a better balance in the size of filters and can have the added advantage that the operating capacity of the weakly functional resin improves if the hardness to alkalinity ratio being treated approaches 1.</p><p>23 Demineralization Demineralization works by exchanging all cations of salts present in the water to be treated to hydrogen, thus converting the salts to acids. Passing the water through a following strong base resin in the hydroxide form will exchange the anions for hydroxide by acid neutralization to produce demineralised water of reasonably good quality. To obtain purer water a polishing stage should be added. This will form part of a separate design program. Unfortunately it is quite difficult to regenerate resins with strongly functional active groups, especially strong base anion resins which have high selectivity for the mineral anions, sulfate, nitrate, and chloride. A large excess of sodium hydroxide is therefore necessary to achieve a good regeneration. The Type-I strong base anion resins Purolite A-400, A-600, A-500, A-505, are more thermally stable than Type-II resins, Purolite A-200, A-300, A-510 and they are also more selective for weak acids. However they are the most difficult to regenerate. Acrylic Type-I resin Purolite A-850 can offer good silica removal and reasonable regenerability, however this type is also less thermally stable. Type-II resins are also easily regenerated, but silica leakage is often significantly higher. Of the resins mentioned, Purolite A-500, A-505, and A-510 are macroporous. This more open structure also offers significant improvement in terms of resistance to organic fouling compared with the gel counterparts. However the acrylic resins Purolite A-850 and A-870 offer an even more effective solution to this particular problem. These resins also have superior resistance to osmotic shock compared to gel-type polystyrenic resins. Substantial savings can be made to regeneration costs by introduction of resins with weak functionality before their strong resin counterparts. Weak base resins are frequently used in front of strong base resins. These effectively remove mineral acids which can be regenerated with alkali using only an excess of 20% over theory in many cases. On the other hand strong base resins often require over 50% stoichiometric excess alkali for effective regeneration. The strong base resins may then be used to remove the weak acids such as silica and carbon dioxide. Hence there are a large number of process options to choose from. Purolite technical sales staffs are knowledgeable in making the required choices. Purofine variations of these resins may be chosen. They may be used at higher flow rates, in shallower beds, at lower levels of regeneration, offering considerable savings in running costs and producing better treated water quality. These differences necessitate different operating conditions from those used for standard resins so default values for standard resins are not appropriate. If the Purofine option is chosen at the Design Option stage the correct default values may be applied making for a more rapid solution. Of course only Purofine Grades may be used here.</p><p>24 Working Mixed Beds For operation, please obtain the separate disc from Purolite. Working mixed beds are used to directly ionize a feed water, typically with low total dissolved solids. They may also be considered when the residual leakage after conventional 24 stage [demineralization] processes is high. The section on Water Treatment explains their use in more detail. Influent Water Data describes the water to be treated and explains the impact of the water analysis on the process. Ionic loads are lower than those treated by demineralization, so specific flow rates and linear velocities may be higher than those used for demineralization. Beds should be sized to optimize flow rates. However constraints to meet ionic loads and resin operating capacity can apply.</p><p>25 Polishing Mixed Beds For operation, please obtain the separate disc from Purolite. Polishing is the term applied to the removal of the last traces of ionic impurities in treated water. For further information see Influent Water Data. Efficient polishing is normally achieved using highly regenerated mixed beds of strong acid cation resins and strong base anion resins. Because the ionic loads are very low, the flow rates used are usually much higher than those used for demineralization. The bed size is designed to optimize flow rate. The choice of IX process options enables selection of three polishing systems, preferred resin ratio, internal or external regeneration, use of Trilite, and, if chosen the volume of inert resin required. The Design Calculation enables sizes of the anion and cation resin components to be calculated. 26 Nitrate Removal Nitrate removal works similarly to water softening. The resin is used in the chloride form, and the nitrate ion is exchanged for chloride. The regeneration is made with sodium chloride (usually at a concentration of 10%). Counter flow regeneration is generally recommended. This gives a lower nitrate leakage. If a higher leakage is acceptable it is generally more economic to blend back raw water than to use Co-flow regeneration. If co-flow regeneration has to be used for any reason, it is often advisable to give the resin a mix after the regeneration rinse. This will disperse the bank of nitrate form resin left at the bottom of the bed and produce a lower nitrate leakage initially and a more consistent leakage through the run. In order to further improve the quality of the treated water up to 25% of the sodium chloride, may be replaced with a sodium carbonate wash at a concentration of 510%. For each reduction of 10g/L of sodium chloride a replacement with at least 20 g/L of the sodium carbonate is needed. In any case significant losses in performance can often be expected if the sodium chloride level falls below 90g of NaCl/Litre of resin. The choice of resin will depend upon the feed water. In particular the ratio of nitrate/nitrate + sulfate will determine the choice of a conventional resin or a nitrate selective resin, Purolite A520E. If in doubt, the latter is recommended. In any case Purolite A520E is recommended when the above ratio is less than 0.6. In fact advantages in operating capacity are not usually noticed unless the ratio is less than 0.5, however there are other advantages obtained from using Purolite A520E. Firstly, if there are sulfates in the water, over-run of the cycle, can produce water which is higher in nitrate than the original feed solution. This is because the sulfate displaces and concentrates the nitrate in the ion exchange resin. When the Purolite A520E is used the worst scenario is that the water remains as if there were no nitrate removal treatment. Thus when using a standard resin more careful and expensive monitoring is recommended. Secondly the nitrate selective resin does not, on average, substantially remove the sulfate from the feed water by exchange of this ion for chloride. Hence there is less risk to exceed the limits of chloride in potable water. (WHO limit is 450 mg/L). The problem of exceeding the WHO limits on chloride and sulfate (250 mg/L) can be lessened by the use of a bicarbonate wash after the regeneration. This means that during a portion of the run, chloride is exchanged for bicarbonate, while sulfate is also retained in the resin. Thus the average leakage of the anions of mineral acids is reduced. Where the waters to be treated are high in hardness ions there is a possibility of precipitation of these ions in the resin. The use of a small softener to treat the water used to dilute the sodium chloride regenerant and for the water used for the displacement rinse is required to avoid this problem. The Puredesign softening program can be used if necessary. It is also possible to combine nitrate removal and softening. The SAC and SBA resins may be combined as layers in one vessel with the SAC resin as the lower layer. The Puredesign programs for nitrate removal and softening are used to find the solution for each layer in the vessel. When working out the vessel geometry enough room should be left to accommodate the partner</p><p>resin. The recommended aspect ratio (height/diameter) for each layer should be less than 1 and the bed depth of each layer greater than 750 mm. When conventional resins are chosen, the choice will depend on a number of factors. Type I resin will in general maintain a slightly higher capacity than the Type II resin, and give a slightly lower leakage in counter-flow operation. This is so small, it is not shown in the program. If there is any risk of high pH in any part of the cycle, Type-II resins are preferred. When operating at higher flow rates, or in vessels of higher aspect ratios (near or above 2) macroporous resins are preferred. The nitrate removal process is rarely if ever affected by organic fouling. The need for quite high levels of sodium chloride for regeneration to displace the nitrate avoids this problem. Like all resins, high levels of iron in the feed water should be avoided, see the warning on water analysis. When ion exchange resins are used for potable applications, the control of bacteria is of great importance. This is particularly true of nitrate removal. Nitrate is a nutrient, and if allowed to remain on exhausted resin is can support the rapid growth of bacteria throughout the ion exchange plant. Once this happens, it can be difficult to remove. For more information on resin storage and disinfection, please refer to the Purolite bulletins 'The storage and transportation of ion exchange resins' and 'The fouling of ion exchange resins and methods of cleaning'. Briefly if the plant has to be shut down, the resin should be backwashed, treated preferably with alkaline brine or regenerated, and stored in salt solution. 29 Program Difficulty Was the complete water analysis entered? If not, please obtain more data. Otherwise please c..</p>
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Purolite Ion Exchange Design Calculation. Help Purolite Ion Exchange Design Calculation Program Contents of help: 20 Water Treatment 63 Design Calculation - Mixed Beds 21 Softening 64 Mixed Beds 22 Dealkalisation 65 Water Analysis 23 Demineralisation 66 Extra Analytical Data 24 Working Mixed Beds 67 RAW WATER origin and pretreatment 25. Ion Exchange Design Hand calculation Brian Windsor (Purolite International Ltd) Introduction Before design programmes were introduced, every engineer had to calculate the design by hand using resin manufacturers.
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1 Ion Exchange Design Hand calculation Brian Windsor (Purolite International Ltd)
2 Introduction Before design programmes were introduced, every engineer had to calculate the design by hand using resin manufacturers data. Each engineer had their own way to carry out in their calculation. Before starting the design ideally you need to know some basic information: 1. Maximum / Average / Minimum flow rate and roughly how many hours per day the maximum flow rate is required (m 3 /h). 2. Daily requirement (m 3 /day) over how many hours. 3. Design water analysis 4. Cation regenerant (sulphuric or hydrochloric acid)
3 Flow rate 1. If the maximum demand is for a short period, or if there is a wide range of operating flow rates, then you can design the plant on the average demand and include a larger treated water storage to cater for the maximum flow rate or variations in demand. 2. It is always to keep the plant in operation rather than operating on an on-off basis with lots of stopping and starting. 3. Resins can operate over a range of flow rates, but the design of ion exchange columns is often very basic and many cannot accommodate very low flow rates. Poor distribution / collection is often encountered at low flow rates leading to channelling and poor performance.
4 Cycle Time / No of Streams The cycle time for each cation anion pairing is determined by the water analysis, flow rate and number of streams. Where demineralised water is critical to the sites operation then normally the client will require a standby stream to cover for regeneration time of the other stream(s) and allow some basic maintenance. Most commonly encountered plants are therefore 2 x 100% or 3 x 50% duty, but where very high flow rates are encountered 4 x 33% duty and 5 x 25% duty streams have been supplied. A cation anion pair can be regenerated in under 2 hours if simultaneous regeneration is employed and with short cycle plant it is even quicker. Mixed beds are more complicated, but are regenerated less frequently and usually take 2 to 3 hours.
5 Cycle Time / No of Streams Ignoring short cycle plants, then classical designs are often base on 8 or 12 hours on line between regenerations depending on the water analysis used for the design. Longer cycle times are encountered when the raw water TDS is low. Such thin waters often see plants designed on 24 hours on line or even longer. We will now select the basis for our design calculations.
6 Design Analysis 1. Knowledge of the maximum and typical analysis is critical when choosing the cycle time. No point choosing short cycle time on the design analysis if the worst water has a much higher TDS. This will mean the time between regenerations is too short. 2. The analysis should balance i.e. The cations and anions expressed as mg/l CaCO 3 or in meq/l should be very similar (within 5%) 3. You have to design the plant to cope with the worst water, but if that water is very infrequently seen then all design operating costs and design decisions need to be based on the typical water analysis.
7 Maximum Water Analysis (Worst Water) If designed on the worst water analysis presented by the end user the water may not balance as the client may have cherry picked the highest recorded level for each ion. These highest level for all ions will not occur on the same day and hence it will not balance. Then you can round down the highest category to give the balanced analysis as naturally occurring waters must balance. In our calculation the end user has given us the analysis of his anticipated worst water.
8 Design Basis for this Calculation Flow Rate 60 m3/h (for 24 hours per day) Important application so standby stream required 2 x 100% duty. Hydrochloric acid for cation regeneration. Water temp 10 centigrade. Worst Water Analysis from client (all expressed in mg/l as CaCO 3.) Cations Anions Calcium (Ca) 110 Bicarbonate (HCO 3 ) 100 Magnesium (Mg) 55 Sulphate (SO 4 ) 50 Sodium (Na) 100 Chloride (Cl) 75 Potassium (K) 11 Nitrate (NO 3 ) 25 TOTAL CATIONS 276 TOTAL ANIONS 250 Greater than 10% difference!
9 Design Basis Corrected Analysis Corrected Worst Water Analysis to balance (all expressed in mg/l as CaCO 3) ) Cations Anions Calcium (Ca) 100 Bicarbonate (HCO 3 ) 100 Magnesium (Mg) 50 Sulphate (SO 4 ) 50 Sodium (Na) 90 Chloride (Cl) 75 Potassium (K) 10 Nitrate (NO 3 ) 25 TOTAL CATIONS 250 TOTAL ANIONS 250 Design analysis to go forward In addition we will assume a Reactive Silica of 5 mg/l as CaCO 3. It is a ground water and contains negligible dissolved organics.
10 Degassing tower The inclusion of a degassing tower to remove the bicarbonate after the cation, when it is converted to carbonic acid, has to be decided before the design is commenced. If the bicarbonate level is above 40 mg/l as CaCO 3 then it is normally cost effective to include a degasser, this is particularly the case on engineered design where a neutral effluent is often required from the waste water produced and plant costs are greater. However, on small, low flow rate, standard plants many companies do not supply a degasser as the capital cost associated with the tower, degassed water pumps (stainless steel) makes the pay back period less attractive and here all the bicarbonate load is often removed by the anion stage. On this design with 150 mg/l bicarbonate we will have a degasser tower.
11 Design Approach In all cases however you have to design from the back of the plant. If you have a cation anion mixed bed system then you start with mixed bed calculation, then anion and then the cation. This way you can calculate or estimate the waste water required which must pass through the preceding unit during the design. For this example I will assume a simple co-flow regenerated system of cation anion followed by a polishing mixed bed. Counter flow regeneration is a little more complicated as you have to estimate the additional treated water required for regenerant injection and slow rinses on the cation and anion beds.
Purolite Ion Exchange Design Calculation Program
12 Polishing Mixed Bed - Design basis After SAC / SBA resins the loading on to polishing mixed beds is very low and so these units are sized on flow rate which makes it very simple. The basis I use is: Vessel sizing based on specific velocity of 60 m 3 /m 2 /h. 600 mm minimum bed depth for cation / anion components. Anion regeneration level 65 g/l with cation regen level designed to give substantially self neutralising effluent. Depending on cation load, approx. 62 g/l for HCl and 80 g/l for sulphuric acid gives a neutral effluent. If not worried about neutral effluent then regen levels as low as 60 g/l NaOH and 48 g/l HCl or H 2 SO 4 have been used.
13 Polishing Mixed Bed - Sizing Applying these parameters to 60 m 3 /h flow rate then: 60 m 3 /h divided by 60 m/h = Minimum area 1 m 2 required. Hence based on UK vessel sizing = 1219 mm diameter (1.16 m 2 ) Resin volume per unit = 0.6 m x 1.16 m 2 = m3 (696 litres) Rounded up to the nearest 25 litres = 700 litres of each component. Caustic applied at 65g/l regen level = 65g/l x 700 / 1000 = 45.5 Kg (as 100% NaOH). HCl applied at 63 g/l regen level = 63 g/l x 700 / 1000 = 44.1 Kg (as 100% HCl). (Metric Sizing 1200 mm diameter with 675 litres of each resin)
14 Polishing Mixed Bed - Operation Mixed beds should never be run near to exhaustion due to the long run length this has little effect on plant operating costs. Historically I tend to use the following guide capacities to determine run length of a polishing mixed bed based on the cation / anion leakage. Anion reactive silica loading should not exceed 9 g/l (6 g/l used by some) Cation sodium loading should not exceed 15 g/l. These are highly conservative. Hence good quality obtained at all times!
15 Anion Design Anion analysis after Degasser Tower After the degassing tower the bicarbonate anion loading will be reduced typically to < 5 mg/l CO 2 as CaCO 3 Therefore the anion load based on the original raw water will now be: Anions Sulphate (SO 4 ) 50 Chloride (Cl) 75 Nitrate (NO 3 ) 25 Reactive Silica 5 Carbon Dioxide 5 Anion Load = 160 mg/l as CaCO 3
16 Anion Design Gross water production per cycle Early we chose 8 hour on line for the worst water. Therefore volume of water treated per cycle would be: (8 hours x 60 m) + MB regen water (Note MB normally uses between 12 and 20 BV of water per regen.) We will use 15 BV for the calculation, so with 1400 litres of resin per mixed bed it needs 15 x 1400 = litres (21 m 3 ) Therefore anion volume of treated water = (8 x 60) + 21 m 3 = 501 m 3
17 Anion Design Anion load per cycle Therefore anion volume of treated water = (8 x 60) + 21 m 3 = 501 m 3 The anion ionic load per cycle is therefore 501 m 3 x 160 mg/l / 1000 = Kg as CaCO 3 Now we have the load per cycle to calculate the resin volume we need to now calculate from the resin manufacturers data the working capacity of the resin. For the basis of this calculation, with a low organics content I am basing on a gel, polystyrenic, anion resin with a high capacity. This type of product is available from all the leading suppliers.
18 Anion Design Capacity Correction Factors For a type 2, gel, polystyrenic, anion resin the working capacity is determined by a base capacity dependent on regen level (amount of caustic applied. This capacity then has various correction factors applied and each manufacturers graphs presented differently. The percentage sulphate in the anion load. The percentage CO2 in the anion load. The silica endpoint for regeneration. The bed depth (if shallow below 0.7 m). We can ignore this with our design as with the size of plant our bed depth will be between 1 and 1.5 m. The percentage silica in the anion load and regenerant temperature. Co-flow plant regen levels tend to be between 55 and 80 g/l. However, regen levels are sometimes encountered outside this range.
19 Anion Design Base Resin Capacity For this co-flow regenerated design I have chosen a regeneration level of 60 g/l NaOH. From the resin engineering bulletin this gives a base working capacity of 0.75 eq/l. This is 37.5 g/l as CaCO 3 (0.75 x 50)
20 Anion Design Anion Capacity Adjustment Sulphate percentage in anion load 50 mg/l / 160 mg/l x 100 = 31.25%. From graph correction factor = 0.95 Carbon Dioxide percentage in anion load 5 mg/l / 160 mg/l x 100 = 3.125%. From graph correction factor = 1.00 (no effect)
21 Anion Design Anion Capacity Adjustment We can operate to a 200 ppb endpoint. From graph correction factor = 1.00 (No effect) We will have a bed depth above 0.7 m. From graph correction factor = 1.00 (No effect)
22 Anion Design Capacity (Theoretical) Silica percentage equates to 3.1% of Anion load. If we assume regenerant temperature of 10 C then from graph correction factor = If we now apply all these correction factors to the base capacity we will obtain the theoretical working capacity (Ignoring those which are 1.0 as they have no effect). Theoretical Working capacity = 37.5 g/l x 0.95 x = g/l as CaCO 3
23 Anion Design Rinse Correction Now I need to correct the capacity for the loading on to the bed caused when the resin is rinsed after regeneration with decationised water. For a co-flow regenerated anion resin I would use 6 BV final rinse (when new). Therefore the rinse correction in g/l as CaCO 3 is: 6 (bed volumes) x 160 (mg/l anion load) / 1000 = 0.96 g/l Therefore revised working capacity is now = g/l Depending on the design / actual knowledge of the water, and the engineering system being used, a smart engineer will now apply a design margin to ensure the resin manufacturers performance can be guaranteed for an operating plant for the warranty period.
24 Anion Design Design Margin / Working Capacity The selection of and the amount of design margin is critical to a well designed reliable plant. When I am doing these calculations I favour taking a larger design margin on the anion resin over the cation resin. This is because I want the plant to be cation limiting making conductivity control of the plant on exhaustion easier and also because anion resin performance usually falls off at a quicker rate than cation performance. I therefore tend to take a 10 to 15% design margin on the anion capacity and correspondingly lower 5 to 10% on the cation resin. Many engineers just take 10% design margin on both to make the plant more competitively priced etc. On this example I will apply 10% to both. Therefore anion working capacity = x 0.9 = g/l.
25 Anion Design Resin Volume If you recall we calculated back on slide 17 we calculated the anion load as Kg as CaCO 3 The resin volume required (in litres) is therefore the ionic load / the working capacity of the resin x 1000: ( / 30.07) / 1000 = 2665 litres We normally round up to nearest 25 litre bag quantity hence: 2675 litres required Anion regen level was 60 g/l. Therefore caustic applied per regen is 60 x 2675 / 1000 = Kg as 100% NaOH.
26 Cation Design Design Analysis and Water Production The cation load based on the original raw water will now be: Cations Calcium (Ca) 100 Magnesium (Mg) 50 Sodium (Na) 90 Potassium (K) 10 Cation Load = 250 mg/l as CaCO 3 The volume of water treated per cycle would be: (8 hours x 60 m) + Anion regen water + MB regen water (21 m 3 ) (Note: a co-flow anion normally uses between 10 and 12 BV of water per regen.) We will use 12 BV for the calculation, so with 2675 litres of resin per anion unit, it needs 12 x 2700 litres = litres (32.1 m 3 )
Ion Exchange Design Calculation
27 Cation Design - Cationic Load Therefore cation volume of treated water = (8 x 60) + 32 m m 3 = 533 m 3 The cation load per cycle is therefore 533 m 3 x 250 mg/l / 1000 = Kg as CaCO 3 Now we have the load per cycle to calculate the resin volume we need to now calculate from the resin manufacturers data the working capacity of the resin. For the basis of this calculation, I am basing on an 8% DVB cross linked, gel, polystyrenic, standard grade strong acid cation resin with a high capacity. Similar product available from all the leading suppliers.
28 Cation Design - Capacity Correction Factors For this type of resin the working capacity is determined from a base capacity dependent on regen level (amount of acid applied). This capacity then has various correction factors applied dependent on the following: The percentage bicarbonate present in influent water. The temperature of the water treated. The percentage sodium in the cation load. The kinetic loading. This will not apply as this is mainly linked to high TDS waters or high BV/h flow rates.
29 Cation Design Base Resin Capacity For this co-flow regenerated design I have chosen a regeneration level of 66 g/l HCl. This corresponds from the cation engineering bulletin to a base working capacity of 1.14 eq/l. This is 57 g/l as CaCO 3 (1.14 x 50)
30 Cation Design Cation Capacity Adjustment Bicarbonate percentage in Cation load 100 mg/l / 250 mg/l x 100 = 40%. From graph correction factor = 0.97 Design water temperature 10 C (minimum water temp) From graph correction factor = 0.96
31 Cation Design- Cation Capacity Adjustment Sodium percentage in cation load 100 mg/l / 250 mg/l x 100 = 40%. From graph correction factor = This graph applies to high TDS or high BV/h flow rates. In this design it does not apply as we are to the LHS of the graph where the factor is 1.0 (No effect).
32 Cation Design Working Capacity If we now apply all these correction factors to the base capacity we will obtain the theoretical working capacity (Ignoring those which are 1.0 as they have no effect). Theoretical Working capacity = 57 g/l x 0.97 x 0.96 x = If we now apply rinse correction for co-flow cation. I tend to use 5 BV for this calculation for a co-flow regenerated cation. = 5 BV x 250 mg/l cation load / 1000 = 1.25 g/l as CaCO 3 This gives a theoretical capacity of = g/l as CaCO 3 If we then apply 10% design margin we have a working capacity of: x 0.9 = g/l as CaCO 3
33 Cation Design Resin Volume If you recall we calculated back on slide 27 we calculated the cation load as Kg as CaCO 3 The resin volume required (in litres) is therefore the ionic load / the working capacity of the resin x 1000: ( / 47.83) / 1000 = 2785 litres We normally round up to nearest 25 litre bag quantity hence: 2800 litres required Cation regen level was 66 g/l. Therefore acid applied per regen is 66 x 2800 / 1000 = Kg as 100% HCl.
34 Checking for Neutral Effluent (Taken from earlier slides) Cation load = Kg as CaCO 3 Anion load = Kg as CaCO 3 Cation acid applied = Kg as 100% HCl Caustic applied = Kg as 100% NaOH If we convert the chemicals applied to as CaCO 3 we can establish the excess acid and caustic generated from a regeneration (Conversion factor for HCl is x 1.37 and for NaOH it is x 1.25). Acid applied = x 1.37 = Kg. Therefore excess acid is the = Kg as CaCO 3 Caustic applied = x 1.25 = Kg. Therefore excess acid is the = Kg as CaCO 3 The two excesses are similar therefore neutral effluent!
35 Checking for Neutral Effluent I CHEATED I did the calculation first before preparing the slides and this is why I selected a cation regen level of 66 g/l. I knew it gave me a neutral effluent for the calculation/presentation Otherwise this part of the hand calculation takes some time to resolve. You have to draw a graph on which you plot regeneration level against excess regenerant generated and regeneration level against resin volume. Based on this graph it is then possible to interpret the results to reach a neutral effluent but it takes some time! Probably the subject of a another presentation. THIS IS WHERE DESIGN PROGRAMMES HELP SO MUCH
36 Vessel Sizing Design Parameters Fortunately in this example co-flow cation and anion have very similar resin volumes so the sizing will be almost identical (2.675 m 3 in the anion and m 3 in the cation. For insitu regenerated co-flow regenerated plant I use the following parameters for my vessel sizing: Maximum service velocity. 50m 3 /m 2 /h (m/h) Minimum service velocity. 12m 3 /m 2 /h (m/h) Guide to maximum pressure drop at minimum temperature for a fully classified bed to allow for some compaction/fouling. 100 to 122 Kpa. Maximise bed depth within pressure drop guide but rarely would the bed depth exceed 1.75 m and preferably more than 1.0 m and never below 0.6 m. 50 to 60% freeboard above resin for co-flow backwash.
37 Vessel Sizing Using these parameters and the pressure drop curves for each resin the vessel size I would have selected the same vessel size for both columns: Metric 1600 mm diameter x 2250 mm i/s. This corresponds to 1.40 m cation and 1.34 m anion bed depth (installed) and a service velocity of 30 m 3 /m 2 /h (m/h) UK 5 feet diameter x 8.25 feet i/s This corresponds to 1.54 m cation and 1.47 m anion bed depth (installed) and a service velocity of 33 m 3 /m 2 /h (m/h)
38 Pressure Drop Across Resin Beds We know the bed depths 1.4 m (cation) and 1.34 m (anion) and because the vessels are the same diameter the velocity of the water through each bed is the same (30 m 3 /m 2 /h (m/h)). If we assume the minimum water temperature is 10 C in the winter, we can now calculate the pressure drop from a single graph for each resin which is based on the. Velocity Water Temperature Bed Depth
39 Pressure Drop Across Resin Beds Anion Resin Example Different graph for cation resin At a velocity of 30 m/h and temperature of 10 C (green line) we can read of the pressure drop. In this case the answer is 46 kpa/m. Our bed depth is 1.34 m so pressure drop across a clean, fully classified, not compacted bed is 46 x 1.34 = Kpa. For my pump calculations I add a safety margin between 10 and 20% depending on how free of solids the water is, cycle length (compaction), resin ageing etc. Therefore pressure loss for pump is around 70 Kpa within limit.
40 Leakage from Resin Beds Cation Resin Example From the cation regen level selected, and the raw water analysis we can calculate the sodium leakage from the cation resin which allows us to establish the conductivity exit the anion. Reactive silica leakage from anion makes no contribution to the anion outlet conductivity. Similar to the capacity calculation the leakage starts with the base leakage based on the regeneration level. Then we apply factors. In this case the factors are: 1. The EMA present in the feed in meq/l. (EMA = Sulphate + Nitrate + Chloride) 2. The % Sodium in the feed as CaCO3.
41 Leakage from Resin Beds Cation Resin Example Regen level selected 66g/l. From slide 9: Sodium % in feed 90/250 = 36% EMA level in meq/l 150 mg/l / 50 = 3.0 Sodium Leakage 7 mg/l x 0.35 x 0.75 = 1.83 mg/l Therefore average leakage 2 mg/l as Na
42 Leakage from Resin Beds Anion Resin From the anion regen level selected, and the raw water analysis we can calculate the reactive silica leakage from the anion resin. Similar to the cation calculation the leakage starts with the base leakage based on the regeneration level. Then we apply factors. In this case there are five factors which are: 1. The % Reactive Silica to Total Anions. 2. Feed Water Temperature (Highest temp gives highest leakage correction). 3. Regenerant Temperature (Highest temp gives lowest leakage correction). 4. Sodium leakage from cation in mg/l Na. 5. Silica end point.
43
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