Ion Exchange Dmw2019

Operational Manuals For Demineralisation Water Plant Supplied By
ION EXCHANGE (INDIA) LTD

Retyped for various corrections in chemical formulas and revival of damaged pages
By
Arun Kumar Bakshi
Junior Engineer Special Grade (Prod), U-1, PACL Naya Nangal
E. No. 250-3-786-0
OPERATION & MAINTENANCE
MANUAL FOR
DEMINERLISATION PLANT
SUPPLIED TO
PUNJAB ALKALIES & CHEMICALS LTD. NAYA NANGAL
BY
ION EXCHANGE (INDIA) LTD. 2nd FLOOR, NEETA TOWERS DAPODI,

PUNE - 411012.
CONSULTANT: UHDE (INDIA) LTD.
By Harcharan.S.Mann,
Section Incharge (Special Grade) (Production), U-1,
Punjab Alkalies & Chemicals Ltd; Naya Nangal,
Distt. Ropar. PB- 140126
THE POWER BEHIND WATER Page 1

By
Arun Kumar Bakshi
E. No. 250-3-786-0
CONTENTS
1. INTRODUCTION
2. TREATMENT SCHEME
3. TECHNICAL DATA
4. DESCRIPTION
5. OPERATION
6. CHEMICAL CONTROL

By
Arun Kumar Bakshi
E. No. 250-3-786-0
INTRODUCTION
This manual provides guidelines for operation and maintenance of Demineralisation plant at Punjab
Alkalies & Chemicals Ltd; Naya Nangal, site. This manual has been presented as a guideline to
plant personnel responsible for starting operation and maintenance of equipments supplied to you as
per the contract. Do read through the guidelines in this manual prior to actual start of the plant.
The plant should be operated by trained and qualified personnel. In case you have any further
clarification as regards operation and maintenance of the plant. Please do contact us. We will be
pleased to offer our services & advice to you.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
WATER
Water, which is required for industrial or process use, is available from two sources. Surface supplies such as from
rivers, lakes and surface wells – and under ground supplies such as tube-wells.
Natural water contains dissolved salts. The water dissolves these salts in flowing over limestone, gypsum, dolomite
and other minerals deposits containing them. Natural water is likely to contain different concentrations of: ==>
Alkaline salts such as the Bi-carbonates and (rarely carbonates of Calcium, Magnesium and Sodium.
Other dissolved impurities such as Silica, dissolves Carbon Dioxide and metals – Iron, Manganese and organic
matters may also be present to a lesser extent. The range of minerals contained in most natural water is quite limited.
The CATIONS present are normally Calcium, Magnesium and Sodium while ANIONS are mainly Chlorides,
Sulphate and Bicarbonates with lower concentration of Nitrate and Silica. Thus the most waters, analysis of the
ions mentioned above will give the TDS (Total Dissolved Solids).
The range of uses of water in industry is very wide. Where water is to be heated within a process such as in boilers,
heating and cooling systems, laundries, bottle washing, scale formation is the most immediate hazard but for high
pressure boilers, for laboratory purposes, electronic, metal finishing and membrane cell technology for Chlor-
Alkalies industries any dissolved impurities in the water may contaminate the product and the complete removal of
all dissolved ions DIMENRALISATION OR DEIONISING becomes necessary.
ION EXCHANGE PROCESS: -
Ion exchange resins are porous materials which contains an inert base attached to which, are free ions. These ions are
Free to move about within the resin structure and can be replaced by other ions of the same type from a surrounding
solution. The modern ion exchange resins are made of cross-linked Polystyrene: this ensures a physically robust
structure and chemically an insoluble, inert base. Cation resins are made of Sulphonated Polystyrene. The
Sulphonic Acid group is the strong acid SO3H – contributes the free Hydrogen ion H+ available for exchange and
can be represented in an equation as HR.
The Anion exchange is similarly made but it is Chloro-methylated and then Ammoniated. The final product is a
quaternary Ammonium Compound – a strong base similar to Sodium or Potassium Hydroxide and this can be
represented in an equation as ROH
CATION EXCHANGE
In demineralisation, the Cation exchange resin is used in the Hydrogen form (HR). the ions in the water are actually
freely moving but for purpose of simplicity they may be identified as definite pairs.
Passages of water containing Sodium Chloride, Magnesium Sulphate and Calcium Bicarbonate, through the
cation exchange resin results in the removal of the Cation by the resin and in their place Hydrogen ions are released
into the solution.
Na+ Cl- + H+R- ----------- > Na R

+ -
+ H+ Cl- (1)
(Sodium Chloride) (Hydrogen Resin) < ----------- (Sodium Resin) (Hydrochloric Acid)
Mg+2SO4 -2 + 2H+R- ------------

+2
> Mg R2 -2 + H2 +2SO4 -2 (2)
(Magnesium Sulphate) (Hydrogen Resin) < ------------ (Magnesium Resin) (Sulphuric Acid)
Ca+2(HCO3)-2 + 2H+R- > Ca+2R2 -2 + 2CO2+2H2O (3)

(Calcium Bicarbonate) (Hydrogen Resin) <------------- ------------ (Calcium Resin) (Carbonic Acid)

By
Arun Kumar Bakshi
E. No. 250-3-786-0
It will be seen from the equation that the Alkaline Salt Calcium Bicarbonate has been split into Carbonic Acid
which being weakly ionized can also be represented as free Carbon-Dioxide and water.
The natural salt has been converted into their respective mineral acids. The treated water is therefore acidic and has a
low pH.
ANION REGENERATION
There are several types of Anion exchange resins which differ in BASICITY. Commonly used are the STRONG
BASE ANION exchange resins such as INDION FF (IP) or INDION N (IP).
The Strong Base resins are completely ionised throughout the complete pH range and can remove all acids- strong
acids such as Hydrochloric acid and Sulphuric acid and weak acids such as Carbonic acid and silica.
Weak Base resins are ionised only at a low pH and can therefore remove only the strong Acids. Weak acids pass
through the resin unaffected.
INDION H (IP) is a MEDIUM BASE resin as it contains both and weak base groups.
In Demineralisation, the Anion exchange resin is used in the BASIC or HYDROXIDE form. If the treated water from
the cation exchange resin is passed through the ANION exchange resin, the acids are removed.
HCl + ROH------------ > R Cl + H2O (4)

(Hydrochloric Acid) (Hydroxide Resin) < ------------ (Chloride Resin) (Water)
H2SO4 + 2ROH------------- > R2SO4 + 2H2O (5)

(Sulphuric Acid) Hydroxide Resin< ------------- (Sulphuric Resin) (Water)
The Carbonic Acid (Free Carbon Dioxide in water) can also be removed in the similar manner but in some cases it is
more economical to remove the carbon dioxide by passing the water downwards through a packed column of
Rasching/Pall rings through which air is blown upwards. The unit is called a DEGASSER.
For weak base anion exchange resins, the reactions are similar but the process is more correctly represented as acid
addition rather than ion exchange.
HCl + R -------------- > R HCl (6)

Hydrochloric Acid Basic Resin < ------------- Hydrochloride Resin
Weak acids such as Silica and Carbon Dioxide are not removed.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Regeneration
When the supply of the exchangeable ions within the resin is exhausted the treated water from the resin deteriorates
and the resin requires regeneration-reconversion of the resin into the operating form.
For cation exchange resin a mineral acid such as Hydrochloric acid or Sulphuric acid is used.
For Anion exchange resins, Sodium Hydroxide (Caustic Soda) can be used, for all types of resins but for weak basic
resins Sodium Carbonate (Soda Ash) can be used. The process is as follows: -
Na R + HCl -------------- > HR + NaCl (7)

Sodium Resin Hydrochloric Acid <-------------- Hydrogen Resin Sodium Chloride
MgR2 + H2SO4 <--------------- > 2 HR + MgSO4 (8)

Magnesium Resin Sulphuric Acid --------------- Hydrogen Resin Magnesium Sulphate
R Cl + NaOH --------------- > ROH + NaCl (9)

Chloride resin Sodium Hydroxide < --------------- Hydroxide Resin Sodium Chloride
R HCL + NaOH ---------------- > R + NaCl + H2O (10)

Hydrochloride Sodium Basic resin Sodium Chloride Water
Resin Hydroxide
Inlet water quality: -
Because an ion exchange resin must be kept clear to function efficiently. The inlet water or Raw Water must be cold,
clean and colourless.
The water should be free of suspended matter, organic matter, oil, algae, slime and heavy metals such as iron,
aluminum. These impurities would collect on or within the resin particles and reduce their capacity for removal of the
ions. Hence some water may require coagulation and filtration prior to being fed into the Deioniser.
The ion exchange resin particles can act as filters but their deionising ability and capacity will suffer and the resin
bed may then require frequent cleaning or replacement.
Capacity between regenerations: -
The capacity of the Deioniser between regenerations depends on the type and quantity of ion exchange resin used in
the column, the quantity of the acid and alkali used per regeneration of each respective column and the dissolved
ionic content of the raw water. An economical quantity of regeneration chemical has been specified in the Technical
Data.
The capacity between regenerations, if specified, has been based on the design raw water analysis. The concentration
of ions in the raw water is referred to as the ionic load.
The CATION LOAD is the sum of Calcium, Magnesium and Sodium ionic content.
The ANION LOAD is the sum of the Chloride, Sulphate, Nitrate, Silica and free Carbon Dioxide contents of the
water from the Cation column.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
The concentration of the individual ions are normally measured in milligram/liter as Calcium Carbonate (mg/ltr as
CaCO3 or parts per million as Calcium Carbonate i.e. ppm as CaCO3).
Apart from SILICA, the other ions present may be considered as existing in two forms
1 Alkaline Salts
2 Neutral Salts
The concentration of Alkaline Salts may be obtained by measuring the TOTAL ALKALINITY of METHYL
ORANGE (M.Alk.). the Neutral Salts contents is conveniently obtained by measuring the EQUIVALENT
MINERAL ACIDITY (E.M.A). This gives the sum of the Anions Chloride, Sulphate, Nitrate, (Phosphate if present).
When the concentration of the ions are expressed in equivalents per liter or mg/ltr as CaCO3 the total Cation content
is numerically equal to the total Anion content if Silica and free Carbon Dioxide are ignored.
It follows that the sum of the Alkaline Salts and Neutral Salts content gives either the Cationic or Anionic
content. CATIONIC LOAD = M.Alk. + EMA
ANIONIC LOAD = M.Alk. + EMA + Silica + Free CO2 NB: - All
concentrations must be measured as mg/liter or ppm CaCO3.
If a Degasser is included in the system, the free Carbon Dioxide present is the water as well as that produced by the
splitting up of the alkaline salts is almost all removed by it. The concentration of CO 2 remaining after DEGASSING
is that which is soluble in water at the particular ambient temperature. For an approximation this may be taken as 6
ppm CaCO3.
Therefore, if a DEGASSER is included
ANIONIC LOAD = EMA + Silica + 6ppm CO2 as CaCO3.
The capacity of DEIONISER is based on the individual ionic loads for both the Cation and Anion exchange resin
column.
If there is an increase in either of the ionic loads there will be a corresponding decrease in the capacity between
regeneration.
Treated water quality: -
The purity of demineralised water is most conveniently assessed by measurement of its electrical conductivity. The
electrical conductivity which is conventionally expressed in µS/cm or micro mhos/cm is influenced by ionisable
substances such as Sodium Chloride, Sodium Hydroxide and Carbonic Acid, but not by silica.
Units using strong base anion resins
Deionisers which use Strong Base Anion exchange resins such as INDION FF (IP) or INDION N (IP) produce
treated water virtually free from Carbon Dioxide, Silica and other dissolved solids. At this stage the pH will be
around 8.5 to 9.5 and the electrical conductivity between 5-20 µS/cm. this quality will be maintained until the point at
which Carbon Dioxide and Silica (both weak acids) are no longer removed. There will then be a sharp drop in pH to a
new level around 5 and a rise in conductivity of about 10-20 µS/cm. at this point the treated water will sill be free of
Sulphates and Chlorides but will contain Carbon Dioxide and Silica. If their presence is objectionable, the unit must
be regenerated but if not the unit may be further run until the conductivity further rises and Chloride break through
occurs.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Although the treated water is very low in dissolved solids, has a low conductivity and is substantially more pure than
distilled water the pH is likely to be higher than 7.0. The actual quality is greatly dependent on the raw water quality,
particularly its Sodium Ion content.
Sodium being monovalent is less efficiently removed by the cation exchange resin. There is therefore a very slight
LEAKAGE of Sodium ions into the treated water from the Cation exchange resin. This treated water will therefore
contain mineral acidity and a trace of neutral salts such as Sodium Chloride.
This trace of Sodium Chloride is converted into Sodium Hydroxide on passage of the treated water through the anion
exchange resin.
NaCl + ROH ------------ > R Cl + NaOH

Sodium Hydroxide < ------------ Chloride Sodium Hydroxide
Chloride Resin Resin
The presence of NaOH has a very marked effort on both the pH and conductivity of treated water.
1 ppm of Sodium Hydroxide results is a conductivity of 6µS/cm. 0.4 ppm of NaOH results in a pH of 9.0
The actual leakage of Sodium is dependent on the Sodium content of the raw water and is not uniform throughout a
run. It begins high, gradually reduces to a minimum and then increases steadily. The pattern of conductivity and pH
of the treated water is also similar.
The CHEMICALS CONTROL section should be referred to for further details.
Units using weakly basic resins: -
The use of a weakly basic resin presupposes that the presence of Carbon Dioxide and Silica is not objectionable. The
treated water pH will normally be around 5-6 due to the presence of CO2 and the conductivity will be below 35
µS/cm. leakage of Sodium ions will not affect the conductivity or pH markedly as the Neutral salt Sodium Chloride
will pass through the Anion exchange resin unchanged. 1ppm NaCl results in a conductivity of 1.8µS/cm.
Note: - INDION 850 is a weak base anion exchange resin. Because it contains both strong and weak base groups the
treated water quality will initially be as described for units using Strong Base resins that is pH 8.5 to 9.5, conductivity
5-20 µS/cm and after about 10-20 % of the service output it will be as described for a weak base resin.
Regeneration
For either exchange unit, regeneration is carried out in three stages.
1 Back wash
2 Injection
3 Rinse
Back wash: - The resin requires be flushing and regarded with an up flow of water. This is an important part of the
operation as it prevents the accumulation of suspended matter within the bed, which may also cause channeling of
the resin in side the columns.
Injection: - A predetermined quantity of the regeneration Chemicals e.g. Acid for the Cation exchange unit and
Alkali for Anion exchange unit is introduced into the resin in a given time maintaining a given density with water.
Rinse: - the ion exchange resin is rinsed down flow with water to flush out the salts formed during regeneration and
also to flush out the excess regeneration chemicals. Raw water is used for the Cation exchange unit but for the
Anion exchange unit, the inlet water must come from the regenerated Cation exchange unit.
By
Arun Kumar Bakshi
E. No. 250-3-786-0
The treated water is checked for purity and if found satisfactory, taken to service.
Important notes
1 The preceding notes are general in nature, the DESCRIPTION sheet should be seen for a more
detailed description of the unit
2 The actual regeneration Chemicals are specified in the TECHNICAL DATA.
3 The estimated treated water quality is specified in the TECHNICAL DATA.
4 The following sections especially OPERATION, CHEMICAL CONTROL and MAINTENANCE must
be studied carefully before attempting to operate the plant.
Treatment scheme
Raw water is first passed through a Multigrade Filter (MGF) where the suspended impurities are filtered off.
Filtered water is then passed through an Activated Carbon Filter (ACF) unit. The ACF removes free Chlorides
present in the filtered water. Presence of free Chlorides is harmful to the ion exchange resins and hence should
be removed before entering the Demineralisation section.
Filtered water from the ACF is then passed through a Strong Acid Cation (SAC) unit. This SAC unit removes all
the Cations present in the raw water like Calcium, Magnesium and Sodium and replaces it with hydrogen ions
forming respective free mineral acids.
This Decationised water then passes through a Degasser tower where free CO2 from the water is removed by
passing low pressure air counter current to the down flowing water. The degassed water is then stored in a Degassed
water storage tank.
This Degassed water is then pumped through a Strong Base Anion (SBA) unit. The SBA unit exchanges the
free mineral acidity with hydroxyl ions.
The SBA unit exchanges the Anions present in the entering unit with hydroxyl ions to give treated water nearly
free of Cation and Anions.
The water coming out from the SBA is passed through the column having either Cation and Anion resin in mixed form so
is the name MIXED BED (MB), which is responsible for checking out for Cationic and Anionic traces if any.
The water coming out of the MB is virtually free of ionic impurities. It will have a pH in the range of 6.5 to 7.5 and
conductivity less than 0.2µS/cm.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
TREATMENT SCHEME
Refer P & I Diagram No. A1-VD0002-01-01/C
==== > Service Raw Water < ============Regeneration (Backwash)

: !
V !
------------------- !
: MGF : < -------------- !
------------------- !
: !
V !
------------------- !
: ACF : < -------------- !
:
V
----------------
: SAC : (Counter Current Regeneration)
---------------- HCL ACID ------------------
: < ---------------------------------------- : AMT-1 :
v ------------------
----------------
: DGT :
B1 A/B Air :
---------------- > :
V
------------------
: DGWT :
------------------
:
:
V
--------------------------------------
: :
V V
--------------- ----------------
: P2 A : : P2 B:
---------------- ---------------
: :
----------------------------
:
V
-----------
: SBA : (Counter Current Regeneration)
------------ NaOH ________
: < --------------------------------- : CDT-1 :
V : ________ :
----------- : NaOH _________
: MB : < --------------------------------- : CDT-2 :
: : : : _________:
: ACID (HCL)
: ----------- : < --------------------------------- :_________:
: AMT-2 :
: :________ :
V
Treated Water (DMW)
Flow Chart Of DM Water Plant

By
Arun Kumar Bakshi
E. No. 250-3-786-0
MGF ACF SAC SBA
T
O Mix Bed
W
E
R
Degassed Tank
AMT-2 CDT-2 CDT-1 AMT-1
FLOW CHART OF DM.WATER PLANT

Page 11
By
Arun Kumar Bakshi
E. No. 250-3-786-0
TECHNICAL DATA
Reference P & I diagram No A1-VD0002-01-01/C.
Water Analysis
S.No. Design Parameters Units Raw Water Treated Water
1 Iron ppm as Fe Not Detectable <0.005

2 Total Alkalinity ppm as CaCO3 100 --
3 Chlorides --do-- 16.5 --
4 Sulphates --do-- Traces --
5 Phosphates --do-- 8.0 --
6 Total Hardness --do-- 80 Not Detectable
7 Mg Hardness --do-- 20 --
8 Silica as SiCO2 8 <0.02
9 Conductivity at 200C µS/cm. or µ mhos - <0.2
10 pH - 7~8 6.5 ~ 7.5
11 T.D.S. mg/ liter. 100 --
12 Copper ppm Not Detectable <0.003
13 Appearance Oil free/ Colourless Oil free/ Colourless
14 Odour Odourless Odourless
Pressure Vessels
Multigrade Sand Filter (MGF)
Tag -- 734U1F01
Number Offered -- Nos One
Diameter -- mm 1800
Height on Straight -- mm 2300
Material of Construction -- Carbon Steel
Internal Lining -- Epoxy
Working Pressure -- Kg/cm2 9.48
Design Pressure -- --do-- 6.32
Maximum Flow Rate -- m3/hr 48
Distribution/ Collection System
Top -- Inlet Bell mouth

Bottom -- Header Lateral
Header Size -- NB 150
Lateral Size -- NB 40
Laterals Quantity -- Nos 32

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Internals
Description Size Quantity per Unit (Kg)
Pebbles 1.5‖~ 1‖ 500

-- do -- 1‖~ ¾‖ 450
-- do -- ¾‖~ ½‖ 350
-- do -- ½‖~ ¼‖ 350
Gravel ¼‖~ 1/16‖ 350
Sand 4000
Regeneration/ Backwash Of MGF: - When pressure drop exceeds 0.5 Kg/cm2 or once in a
day. Activated Carbon Filter (ACF)
Tag -- 73U1F02
Diameter -- mm 1400
Internal Lining -- Epoxy
Distribution/ Collection System
Top -- Inlet Bell mouth

Bottom -- Header Lateral
Header Size -- NB 100
Lateral Size -- NB 40
Laterals Quantity -- Nos 24
Internals
Description Size Quantity per Unit (Kg)
Pebbles 1.½‖ ~ 1‖ 300

-- do -- ½‖~ ¼‖ 250
-- do -- 3/8‖~1/8‖ 250
-- do -- ¼‖~1/10‖ 250
Activated Carbon (m3) 1.3
Regeneration/ Backwash of ACF: - Once in a day.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Strong Acid Cation (SAC)
Tag -- 73U01C01
Diameter -- mm 1000
Internal Lining -- Rubber Lined 4.5mm thick
Resin Type -- INDION 225 H
Resin Quantity -- Liters 926
Type of Regeneration -- Counter Current
Capacity per Regeneration -- m3 280.5
Period between Regeneration -- hrs 10
Time per Regeneration -- minuets 90
Waster Water per regeneration (Effluent) -- m3 12.6

Regenerant
Chemicals HCl (Hydrochloric Acid)

Chemical Quantity (Kg 100%) 32
Distribution /Collecting System per Unit
Top -- Baffle
Bottom Collector -- Strainer on Rubber lined Plate
Strainer Type -- MK79
Quantity -- Nos 90
Middle Collector
Header -- Material SS 316
Strainers -- Type MK801
Quantity -- Nos 58
Strong Base Anion (SBA)
Tag -- 73U01C02
Diameter -- mm 1000
Resin Type -- INDION N (IP)

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Resin Quantity -- Liters 785

Type of Regeneration -- Counter Current
Capacity per Regeneration -- m3 268
Regenerant
Chemicals NaOH (Sodium Hydroxide)

Chemical Quantity (Kg 100%) 27
Top -- Baffle
Quantity -- Nos 91
Middle Collector
Quantity -- Nos 58
Mixed Bed unit (m.b.)
Tag -- 73U01C03
Diameter -- mm 1000
Resin Type -- INDION 225H/
INDION FFIP
Resin Quantity -- Liters 540/540
Type of Regeneration -- Top & Bottom
Counter Current at Middle
Capacity per Regeneration -- m3 6816

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Regenerant
Chemicals HCl (Hydrochloric Acid)/

NaOH (Sodium Hydroxide)
Chemical Quantity (Kg 100%) 32.5/23.5
Top -- Strainer Assembled with SS 316 mesh

Quantity -- Nos 91
Middle Collector
Strainer Quantity -- Nos 58
Tanks & Vessels
Degasser Tower (DG)
Tag -- 73U01V01
Diameter -- mm 800
Internal Lining -- mm Rubber Lined 3.0mm thick
Working Pressure -- Kg/cm2 Atmospheric
Max. Working Pressure -- --do-- Atmospheric
Packing -- Pall Rings
Size -- mm 50 Dia X 50 lg
Quantity -- Liters 1.1 m3
Degassed Water Tank (DGWT)
Tag -- 73U01D01
Diameter -- mm 2000
Internal Lining -- mm Rubber Lined 4.5 mm thick
Working Pressure -- Kg/cm2 Atmospheric
Max. Working Pressure -- --do-- Atmospheric

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Acid Measuring Tank (AMT-1 & 2)
Tag -- 73U01D02A & 73U01D02B

Number Offered -- Nos One One
Diameter -- mm 600 600
Height on Straight -- mm 900 900
Material of Construction -- Carbon Steel Carbon Steel
Internal Lining -- mm Rubber Lined Rubber Lined

4.5mm thick 4.5mm thick
Working Pressure -- Kg/cm2 Atmospheric Atmospheric

Design Working Pressure -- --do-- --do-- --do--
Caustic Dilution Tank (CDT-1 & 2)

Tag -- 73U01D03A & 73U01D03B
Number Offered -- Nos One One
Diameter -- mm 600 600
Height on Straight -- mm 800 800

Working Pressure -- Kg/cm2 Atmospheric Atmospheric

Design Working Pressure -- --do-- --do-- --do—
Fumes Absorber
Tag -- 73U01D04A & B

Number Offered -- Nos Two
Diameter -- mm 200
Depth -- mm 300

Location -- Overflow of AMT-1 & 2

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Instruments
Level Switches
Tag LA 7327-8
SL No 171-172
Type Side Mounted
Quantity 2 Nos
Material of Construction
Wetted Parts AISI. SS316.

Non-Wetted Parts AISI SS304
Process Connection Flanged
OD 120.5
PCD 92
No. of Holes 04
Enclosure Weather Proof
Electrical Cable Entry ¾‖ ET (F)
Switches Employed Entry 2 Nos. SPDT micro switch type (2Nos. + 2 NC)
Repeatability ± 1.5 mm
Contact Rating 60W/VA
230 VAC 5AMP Surge
Make Revathi Electronics
Level Switches
Tag LA 7322
7336
7330
7333
SL. No 167-170
Type Top Mounted
Quantity 4 Nos
Material of Construction
Flange CS PP Lined
Float Polypropylene
Stem Polypropylene
End Stopper Polypropylene
Process Connection Flanged
OD 9‖
PCD 7.5‖
No. of Holes 08
Enclosure Weather Proof
Electrical Cable Entry ¾‖ ET (F)

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Switches Employed Entry 1 Nos. SPDT (1Nos. + 1 NC)

Repeatability ± 1.5 mm
Contact Rating 60W/VA
230 VAC 5AMP Surge
Make Revathi Electronics
Details of Actuation Point
SL No Stem Length from Actuation Point From

Bottom of Flange Bottom of Flange
H1 H2
167 1000 300 900

168 900 300 800
169 900 300 800
170 900 300 800
Data Sheet: pH Sensor & Transmitter

Project: PACL Naya Nangal
pH Sensor
Tag No. AE 7322

Type Flow Through
Sample Temperature 4 to 500C
Wetted Material Glass Filled Kynar (PVOF), Glass Ceramic & Viton
Process Connection 1‖ Main Point
Make Rose Mount
Model 399pH-01-11-16
Quantity One
Fluid Water (de-mineralised)
Temperature Compensation Automatic 0-850C
pH Transmitter
Tag No. AT 7322

Range 0---14pH
Output Isolated 4-20mA.D.C.into 570 OHMS at 24 VDC
Ambient Temperature -30 to 700C
Accuracy 0.1 % Reading ± 1 count
******************************************************************************************

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Data sheet: conductivity meter

Project: - PACL NAYA NANGAL
Tag No. AE 7321 AE 7323

Location SBA Outlet MB Outlet
Range 0-100µS/cm. 0-5µS/cm
CONDUCTIVITY SENSOR
Cell Constant 0.1 0.1

Electrode Material SS 316 SS 316
Temperature Compensation 0-1000C 0-1000C
Max Temperature 500C 500C
Junction Box ----------Weather Proof-----------
Make -----------Rosemount --------------
Model -----------150-03-16-19-----------
Quantity 01 No 01 No
CONDUCTIVITY TRANSMETER
Tag No. AT 7321 A3 7323
Power Supply ---------------VDC----------------
Output Isolated 4 0 20 MA into 700 Ohms at 24 VDC Digital
Accuracy 1% of full Scale.
Ambient Temperature -30 to 700C -30 to 700C
Repeatability ------------± 0.5% of Full Range----------
Temperature Compensation ------------Automatic (5 to850C) ---------
Housing ------------ Cast Aluminium --------------
Enclosure ------------ Nema ---- 4 --------------------
Cable ------------ Two wire shielded Transmitter to Power supply.
Mounting (Field) ------------ Pipe Mounted with U Clamps-
Local Indication ------------ Not Required -------------------
Quantity 1 No 1 No
Make ------------ Rosemount ----------------------
Model ------------- 1101C—02—10—07—11----
******************************************************************************************
Data sheet: panel mounted indicator Project: - PACL NAYA NANGAL
Tag No. A1A 7321(C) A1A 7322 (pH) A1A 7323(C) Combined
Range 0-100µS/cm. On field 0-14 (pH)
Type Channel & 0-5µS/cm. On Second Channel
Input 4-20 mA DC from Transmitter
Power Supply 230V AC ± 10%, 50Hz
Supply to Transmitter 24V DC
Display 50 Segment Bar Graph & 8 Digit Seven Segment Numeric Characters
Accuracy ± 0.5 % of Span
Display Resolution Numeric 0.1% of upper Range Value Bar Graph 2% of Upper Range Value
Temperature 5 - 500C
By
Arun Kumar Bakshi
E. No. 250-3-786-0
Alarms High & Low On Each Channel Can Be Set Over Entire Range.
(Alarm Indicator Flashing)
Relay Contacts Potential Free, No or NC Switch Selectable (Two Per Channel, One
High One Low)
Mounting Panel Mounted
Overall Size 69W x 165.5 H x 501D in mm
Output 66.5W x 149.5 ± 0.5 H in mm
Model BDE 4300 BPA 1
Make Bells Control
******************************************************************************************
Data sheet: level transmitter

Tag No. LT 7324

Type Electronic 2 Wires
Principle Variable Capacitance Type
Power Supply 24V DC – 2Wire into 600 Ohms
Input Water Column
Output 4-20mA DC Linear
Accuracy ± 0.2 % of Calibrated Span
Process Connection ½‖ NPT (F)
Output Internal O/P Meter Reqd – 0 to 100%
Conduit Connection ½‖ NPT (F)
Material Of Construction
Sensing Element SS 316 Diaphragm
Body & Other Wetted Parts SS 316
Mounting On 2‖ O.D. Pipe With Stand Bracket
Enclosure IP 65
Ambient Temperature 0 - 500c
Fluid Temperature 5 - 500c
Span Range 0 – 6400 mm wc
Calibration Range 0 – 2000 mm wc
Model FFC 34 WB2 – 900V
Location Near Degassed Water tank, In Epoxy Painted Enclosure
Make Instrumentation Ltd;
Quantity 1 No
Accessories 1) Mounting Bracket With Necessary Hardware
2) SS 316 3 Way Manifold
*****************************************************************************************

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Data sheet: level indicating controller

Tag No. LICA 7324

Type Single Station Micro Controller
Input 4-20 mA DC from Level Transmitter
Power Supply 110V ± 10%, 50Hz ± 2%
Supply to Transmitter 24V DC
Display 50 Segment Bar Graph & 8 Digit Seven Segment Numeric Characters
Accuracy ± 0.5 % of Span
Display Bar Graph 50 Segments & 8Digit Numeric
Operating Temperature 5 - 500C
Humidity 5 – 95% at 400c
Accuracy Display
A) Display 0.1%
B) Bar Graph 0.5%
Tank Dia Height 2000 mm
Alarms High & Low On Indication & Contact) 2 Separate Potential Free Contacts
Required
Output Isolated 4 – 20 MA To Control Opening/Closing of Pneumatic
Glove valves
Mounting Panel Mounted
Model BCE 761 CSA AP – 0 - 1
Make Bells Control
*******************************************************************************************
Data sheet: control valve
Tag No. LV 7324

Service Flow Control
Location Inlet of Degasser Tower
Fluid Degassed Water
DP Max/Sizing 1500mm WC
Normal Service Flow 28m3/hr
Working Pressure 3.5 Kgs/cm2
Working Temperature 500c
Specific Gravity 1.0
Up Stream Pressure Max 3.5 Kgs/cm2
Normal 1.5 Kgs/cm2
Downstream Pressure Atmospheric
Pipeline Material C.S. R/L
Size 80 NB (IS 1239 CL.C.-3THKR/L
Flanged STD ASA 150 # FF off Centers
Type Of Valve Butterfly
Body/Port Size 3‖ Dia
Body Material CI to IS 210 GI FG 200 EPOM Lined

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Packing /Seal Teflon

No. of Ports 01
Disc Material SS 316
Failure Position Open
Input Signals 4 – 20 mA
Accessories E/P Positioner, Hand wheel, Limit Switches, Filter Regulator, Valve
Positioner, Inbuilt Stem Travel Indicator
Bonnet Tightness As Per ANSI B 16.104 C4
Air Supply Connection ¼‖ NPT (F)
***************************************************************************************************
Data sheet: pressure gauge
Tag No. / Range/Location/Qty See Table Blow

Dial Size 100mm
Type Bourdon Tube Type
Bourdon SS 316
Movement SS 304
Snubber Pulsation Dampener Reqd
Base Cast Aluminum (Weather Proof)
Accuracy ± 1 % of F.S.D
Process Connection ½‖ NPT (M), Bottom Entry
Scale Marking Black Letters On White Dial
Blow OF Disc Required as a Safety Vent
Make Bells/Precision/General
Requirement As Following table
Tag No Line Pressure Range Location
PI 7321 3.5 Kgs/cm2 (G) 0 - 6 Kgs/cm2 MGF Inlet

2 (G) 2
PI 7322 3.5 Kgs/cm 0 - 6 Kgs/cm MGF Outlet
2 (G) 2
PI 7323 3.5 Kgs/cm 0 - 6 Kgs/cm ACF Inlet
2 (G) 2
PI 7324 3.5 Kgs/cm 0 - 6 Kgs/cm ACF Outlet
2 (G) 2
PI 7325 3.5 Kgs/cm 0 - 6 Kgs/cm SAC Inlet
2 (G) 2
PI 7326 3.5 Kgs/cm 0 - 6 Kgs/cm SAC Outlet
2 (G) 2
PI 7329 4.0 Kgs/cm 0 - 7 Kgs/cm PI A Discharge
2 (G) 2
PI 7330 4.0 Kgs/cm 0 - 7 Kgs/cm PI B Discharge
2 (G) 2
PI 7331 4.0 Kgs/cm 0 - 7 Kgs/cm SBA Inlet
2 (G) 2
PI 7332 4.0 Kgs/cm 0 - 7 Kgs/cm SBA Outlet
2 (G) 2
PI 7333 4.0 Kgs/cm 0 - 7 Kgs/cm MB Inlet
2 (G) 2
PI 7334 4.0 Kgs/cm 0 - 7 Kgs/cm MB Outlet
2 (G) 2
PI 7335 4.0 Kgs/cm 0 - 7 Kgs/cm B2 Discharge

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Data sheet: level gauge

Tag No. / Range/Location/Qty See Table Blow

Fluid Water/Acid/Alkali
Type Armored Relex Type
Glass Toughened Borosilicate
Wetted Parts PVC
Process Connection Flanged, 1‖ PVC, ASA 150#, Drilling F.F
Pressure Atmospheric
Drain Valve ½‖ NPT (F), PVC Plug
Packing PTFE
Requirement As Per Following Table

Tag No QTY Location C/C Distance
LG 7321 01 AMT-1 700mm

LG 7325 01 DGWT 1000mm
LG 7326 01 DGWT 1000mm
LG 7329 01 CDT-1 600mm
LG 7332 01 CDT-2 600mm
LG 7335 01 AMT-2 600mm
Data sheet: air operated diaphragm valve

Type WEIR Diaphragm, with Actuator

Service On – Off
Medium Handled Raw Water/Acid/ Alkali/DM Water
Operation Conditions
Line Pressure (Max) 7.0 Kgs/cm2 (G)
Temperature (Max) 500c
Air Pressure Available 4.5 Kgs/cm2 to 9 Kgs/cm2 Distributed to Actuator at 3.5 Kgs/cm2
Construction
A) Valve
Rating 125# (As Per Spec 66 – 0036 – 700/73U01/ANNEX.2
End Connections Flanged to ASA, 150 Dia FF off Centre CI To IS 210 GR FG 200
Manual Override Required (Top Mounted Hand Wheel) C.I
Body Bonnet CI to IS 210 GR FG 200
B) Actuator
Type Diaphragm, with Actuator
Air Connection ½‖ NPT (F)
Limit Switch Provided In Weather Proof Housing (IPGS)
Diaphragm Nylon Fabric
Stem AISI 410
Spring SPING Steel
Line Water Pressure For Actuator Size 4.0 Kgs/cm2 (G)

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Data sheet: rate of flow indicator

Tag No. FI 7321 & FI7323 FI 7322

Quantity 02 01
Type Bypass Rota Meter Online
Fluid Raw/Acidic Water Acidic Water
Specific Gravity 1.0 1.0
Location ACF/SBA Inlet AMT-1
Line Pressure 3.4 Kgs/cm2/4.0 Kgs/cm2 (G) 4.0 Kgs/cm2 (G)
Line Size 80NB 40NB
Pipe ID 78.8mm --
Normal Flow 28m3/hr 2650LPH
3
Scale Range 12 – 36m /hr 400 – 4000LPH
Frame Material Aluminum Aluminum
Measuring tube ------------------------------SS 316 ---------------------------
End Flanges 20NB, 150 #FF 40NB, 150 #FF
End Conn. Material -------------------------------Rubber Lined-------------------
Orifice Plate SS 316 --
Float Material -------------------------------SS 316 ---------------------------
Packing ------------------------------- Neoprene -----------------------
Test Pressure 20 Kgs/cm2(G) 7 Kgs/cm2
Scale Graduation m3/hr LPH
Accuracy -----------------------± 2% Of Full Flow ------------------------
Repeatability -----------------------± 0.5% of Full Flow ----------------------
Tube Rota Meter Angular/Having 900 Graduations
Make ----------------------- JNM/Blue Star ----------------------------
*******************************************************************************************
Data sheet: panel mounted indicator
Consultant: UDHE INDIA LTD; Bombay P&ID No.A1 – VD0002 – 01 - 01
Tag No. IND1, IND2, IND3, IND4

Input 4 – 20 mA
Power Supply To Transmitter 24V DC
Display Bar Graph 50 Segments & 8 Digit Seven Segments Numeric Character
Accuracy ± 0.5% of Full Scale
Operating Temperature 5 - 500c Ambient
Relay Contacts Potential Free No or NC Switch Selectable 1 For High & 1 For Low
Mounting Panel Mounting
Make Bells Control Ltd;
Model BDE 4300 APA – 1

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Quantity 4 No
Inspection ION Exchange (I) Ltd/UDHE INDIA LTD;
Documents Required Six Copies Of Each
- Performance & Guarantee Certificate
- Operation & Maintenance Manual
- Calibration Certificate
REV: A: B: C: D: E: Data Sheet
Date: 01-06-1994
Drwn By: DCK: No. A 4 – VD 0002 – 12 – 26
Approved By: SNS
*********************************************************************************************
Data sheet: panel mounted indication controller
Tag No. IND.CONT 1

Input 4 – 20 mA
Power Supply To Transmitter 24V DC
Display Bar Graph 50 Segments & 8 Digit Seven Segments Numeric Character
Accuracy ± 0.5% of Full Scale (Output)
Operating Temperature 5 - 500c Ambient
Humidity 5 – 95% at 400C
Relay Contacts Open Collector, No or NC Switch Selectable 1 For High & 1 For Low
Mounting Panel Mounting
Output Isolated 4 – 20 mA
Model BDE 761 CSA AP – 0 - 1
Quantity 1 No
Inspection ION Exchange (I) Ltd/UDHE INDIA LTD;
Documents Required Six Copies Of Each
- Calibration Certificate
Date: 01-06-1994
Drwn By: DCK: No. A 4 – VD 0002 – 12 – 27
Approved By: SNS

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Data sheet: distributor with o/p isolation

Tag No. D – 1, D – 2 & D - 3
Input 4 – 20 mA
Power Supply 110V AC, 50Hz
Operating Temperature 0 - 500c
Humidity 5 – 95% RH Max at 400C
Output 1 – 5VDC – 2 Nos
4 – 20mA – 01 No
Model BDE 4850 – C – 0 – A – S
Inspection ION Exchange (I) Ltd;
Documents Required Eight Copies Of Each of –
- Dimensional Drawing
- Material Test Certificate
Date: 24-05-1994
Drwn By: DCK: No. A 4 – VD 0002 – 12 – 28
Approved By: SNS
*******************************************************************************************
Data sheet: dual set point trip
Tag No. Ta – 1 to TA – 9
Quantity 9 Nos
Location To Be Mounted Inside The Panel
Input 1 – 5 VDC
Power Supply 110V AC, 50Hz
Operating Temperature 0 - 500c
Humidity 5 – 95% RH Max at 400C
Output 1 N/O + 1 N/C (1 for Low & 1 for High)
Model BDE 4992– A – A – 2 – 1
Contact Rating 10W/VA (DC/Peak AC) Within The Limits Of 0.5A Max. Switched
Current & 200 V Max. Switched Voltage
Inspection ION Exchange (I) Ltd;
Documents Required Eight Copies of Each of –
- Dimensional Drawing
- Material Test Certificate
Date: 21-05-1994
Drwn By: DCK: No. A 4 – VD 0002 – 12 – 29
Approved By: SNS

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Description
Please refer flow diagram No A1-VD0002-01-01/C
Multigrade Filter (MGF)
This is a carbon steel pressure vessel internally fitted with MS pipe work and diaphragm valves. The filtering media
sand is supported by crushed gravel and graded pebbles. Inlet distributor is a MS inverted bellmouth funnel. The
bottom collecting system consists of MS Header with perforated laterals fitted on it. Pressure gauge and sample
connection are given at the inlet and outlet to measure pressure drop across the bed. An orifice board is fixed in the
drain sump to measure the regeneration flow rates.
Activated Carbon Filter (ACF)
This is a carbon steel pressure vessel internally fitted with MS pipe work and diaphragm valves. The filtering media
Activated Carbon is supported by crushed gravel and graded pebbles and the main function of the activated carbon is
to remove unwanted chlorides. Inlet distributor is a MS inverted bell mouth funnel. The bottom collecting system
consists of MS Header with perforated laterals fitted on it. Pressure gauge and sample connection are given at the
inlet and outlet to measure pressure drop across the bed. An orifice board is fixed in the drain sump to measure the
regeneration flow rates.
Strong Acid Cation (SAC)
This is a mild steel rubber lined pressure vessel. It is externally fitted with rubber lined pipe works, diaphragm valves,
pressure gauges and sampling valves at the inlet and outlet. A calibrated orifice board in the drain sump is provided
for measuring various regenerations flows. There is an internally baffle distributor at the top and bottom collecting
system consists of strainer plate fitted with strainers.
Middle collector header is a SS316 header fitted with laterals. Polypropylene strainers are fitted to the laterals.
Complete assembly is supported with proper supporting members.
Regeneration is done by using hydrochloric acid. The reverse exchange action takes place during regeneration.
Hydrogen ions from regenerant are taken up by Cation resin and absorbed Ca, Mg, Na, and K ions are expelled.
While normal flow is from top to bottom, the flow of regenerant is from bottom to top. This ensures that bottom bed
is fully regenerated and helps in reducing the Sodium slip in service run. The acid consumption is also less in case of
counter current regeneration.
Degasser (DG)
This is a carbon steel rubber lined atmospheric tower packed with pall rings. Internally, it is fitted with a top
perforated tray which distributes water evenly over the packing and also provides an outlet for the carbon dioxide
enriched air. The bottom tray supports the bed of raschig rings and also acts as a distributor for low pressure air. A
vent for Carbon Dioxide and air is provided on the top of the Degasser Tower.
Degasser Blower Fans B1 (A/B)
These are motor driven blowers installed at the side of the Degasser and are provided to supply low pressure air for
degassing water rich in Carbon Dioxide. The blower is fitted with suction strainers and the delivery is connected to
the bottom of the Degasser by mean of mild steel ducting line.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Degassed Water Tank (DGWT)
This is a carbon steel rubber lined tank provided with an inlet for degassed water, an outlet leading to degassed water
pump, overflow and drain connection and two number of gauge glass type level indicator. High/Low level switches
are provided for alarm.
Strong Base Anion (SBA)
This is a mild steel rubber lined pressure vessel. It is externally fitted with rubber lined pipe work, diaphragm valves,
pressure gauges and sampling valves at the inlet and outlet. A calibrated orifice board in the drain sump is provided
for measuring various regeneration flows.
Internally the unit is provided with a baffled inlet water distributor, middle Alkali collector and a bottom collecting
system for collecting treated water and distributing Alkali during regeneration.
Middle collector header is a SS316 header fitted with laterals. Polypropylene strainers are fitted to the laterals.
Complete assembly is supported with proper supporting members.
Vessel is charged i.e. Regeneration is done by using Strong Basic Resin. The reverse exchange action takes place
during regeneration. The strong basic anion resin absorbs all SiO2 and CO2. Thus, demineralised water substantially
free from solids is produced. Regeneration is accomplished using a dilute solution of Caustic Soda which displaces
the Silica and Carbon Dioxide and other Anions. Regeneration is carried out in a direction opposite to that of the
normal service flow. While normal flow is from top to bottom, the flow of regenerant is from bottom to top. This
ensures that bottom bed is fully regenerated and helps in reducing the Silica slip in service run. The Alkali
consumption is also less in case of counter current regeneration.
Mixed Bed (MB)
This is a mild steel rubber lined pressure vessel. It is externally fitted with rubber lined pipe work, diaphragm valves,
pressure gauges and sampling valves at the inlet and outlet. A pH and Conductivity indicator is fitted at outlet. A
calibrated orifice board in the drain sump is provided for measuring various regeneration flows.
Internally the unit is provided with MS rubber lined and rubber covered inlet bend with SS strainer assembly. SS
middle collector for collecting spent caustic and distributing acid. The bottom collecting plate is strainer on plate
type. Middle Alkali collector and a bottom collecting system for collecting treated water and distributing Acid during
regeneration. Middle collector header is a SS316 header fitted with laterals. Polypropylene strainers are fitted to the
laterals. Complete assembly is supported with proper supporting members.
The vessels are provided with inspection windows, one at the interface of Caustic and Anion Resin and other at the
top to observe inside water level during drain down operation. SBA outlet water is passed through the MB to remove
the traces of impurities. MB contains a mixture of CATION and ANION resins thus presenting large number of
demineralisation pairs inside the unit. This results I treated water of high quality and purity.
The Cation and Anion Resins are regenerated with Acid and Caustic respectably after separating them before
regeneration with a particular back flow with water and they are remixed with air from air compressor before
returning to service.
Acid Measuring Tank (AMT-1 & 2)
This is a carbon steel atmospheric tank rubber lined internally. This is provided with inlet, outlet, drain overflow and
level indicator connections. A level indicator is provided to indicate the level of HCl in the tank during regeneration
of unit. A fume absorber is provided to absorb HCl fumes during transfer of Acid from bulk Acid Tank to AMT-1 &
2. A cast iron ebonite lined venture ejector of ration 1:5 is provided at the outlet of AMT-1 & 2 30% HCl stored in
these tanks is injected by means of this ejector into the SAC and MB.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Caustic Dilution Tank (CDT-1 & 2)
This is a carbon steel atmospheric tank rubber lined internally. This is provided with inlet, outlet, drain overflow and
level indicator connections. A level indicator is provided to indicate the level of HCl in the tank during regeneration
of unit. Tank to CDT-1 & 2 a cast iron ebonite lined venture ejector of ration 1:5 is provided at the outlet of CDT-1 &
2. The 30% NaOH stored in these tanks is injected by means of this ejector into the SBA and MB.
*******************************************************************************************
Operation
Control system description
Brief Description: -
The plant has following units in one stream: -
1. MGF: Multigrade Filter

2. ACF Activated Carbon Filter
3. SAC Strong Acid Cation
4. SBA Strong Base Anion
5. MB Mixed Bed
6. AMT – 1 & 2 Acid Measuring Tanks
7. CDT – 1 & 2 Caustic Dilution Tanks
8. DGF B1 A/B Degasser Fans (1 working & 1 Standby)
9. DGWP P1 A/B Degassed Water Pumps (1 working & 1 standby)
10. MB B2 Mix Bed Air Blower.
MGF, ACF, SAC, SBA and MB all these units are in continuous operation which consists of service and
regeneration. All the units automatically changeover in service mode, once regeneration operation of respective unit
is over.
Control panel will have main supply ON/OFF selector switch and PLC ON/OFF selector switch Indicator for auto
mode and manual mode. Also there will be three positions B/S for service/off/regeneration conditions of each unit.
The initiation of regeneration will be manual with the help of push button common for all units. Once the
regeneration initiated by operator, rest of the stages of each unit will proceed automatically as per sequence
mentioned below and regeneration stages will be controlled by means of programmable logic controller. One more
hold push button is given to hold the regeneration in between.
Please refer to BINGO chart drawing No.A2 – VD0002 -08 – 03 SHT No. 1 of 2 & 2 of 2.
1) Unit MGF Multigrade Filter

2) Unit ACF Activated Carbon Filter
Both the units undergo regeneration cycle which consists of following stages.
One common manual push button initiation will be provided for starting regeneration operation which is of 15
minutes. The time period between two regenerations is 24 hrs.
Stage Description Approximate Time Stage Term By Remarks
1 Backwash 10 min Timer Actually as these

are only filter
2 Fill 01 min - do - instead of any

By
Arun Kumar Bakshi
E. No. 250-3-786-0
regeneration
3 Rinse 04 min - do - Backwash, fill
& rinse are the
steps carried
out for cleaning
the filter.
*******************************************************************************************
3) Unit SAC
4) Unit SBA
Total regeneration time is about 108 minutes.
REGENERATION
Regeneration process will be initiated by pressing regeneration push button manually which will be provided
common for all units.
Backwash 20 min Timer this backwash

1 Flushing 5 min - do - operation will Be carried out
2 Fill 1 min - do - once in seven regeneration
3 Down-flow 1 min - do - Cycles. This will be carried
4 Pre-injection 1 min - do - out with separate selector
switch
5 Injection 20 min Low level
switch AMT-1
Low level switch
CDT-1
6 Up-rinse 55/65 min Timer
7 Final Rinse 10 min
Separate rinse selector switch - do -
is provided for SAC/SBA &
MB Units for carrying out
rinsing operation if required
*******************************************************************************************
5) Unit MB – Mixed Bed
1 Flushing 05 min Timer

2 Backwashing 10 min - do -
3 Fill 01 min - do –
4 Caustic Pre-injection 01 min - do –
5 Acid Pre-injection 01 min - do –

By
Arun Kumar Bakshi
E. No. 250-3-786-0
6 Caustic/Acid
Injection 15 min By Low Level This stage will be
Switches at terminated only after
AMT-2 & low level in both AMT-
CDT-2 2 & CDT-2
7 Caustic /Acid 02 min Timer
Flushing
8 Caustic/Acid
Rinse 30 min -do –
9 Drain Down 10 min - do –
10 Air Mix 10 min - do –
11 Rinse 3 min - do –
12 Refill 1 min - do –
13 Final Rinse 7 min - do –
These cycles of units are staggered in such a way that individual or simultaneous and continuous operation can
be achieved.
1. Seventh regeneration operation of SAC & SBA units will be carried out on two different dates and separated
by a day.
2. At every back wash of SAC & SBA acid and caustic injections to be prolonged to permit twice the quantity of
regeneration. Called double injection. This operation should be ensured manually by filling in both acid and
caustic tank with the help of separate switches provided in the system. During each of the operation stage,
certain valves will be opened. Please refer Bingo Chart. Each DOPO & DOPC valves is opened/closed
through a solenoid valve operated on 110 VAC through relays.
Following interlocks will be provided in PLC logic:

1. Regeneration operation for SAC will not start (Especially Acid pre-injection/injection stage) unless level in
AMT-1 is at high level and degasser water tank level is high.
2. Regeneration operation for SBA will not start (Especially Caustic pre-injection/injection stage) unless level in
CDT-1 is at high level and MGF, ACF and SAC units are in service and degasser water tank level is high.
3. During seventh regeneration of SAC & SBA regeneration will not start unless ensure backwash of unit.
4. Regeneration operation for MB (Mixed Bed) will not start (Especially Acid/Caustic pre-injection/injection
stage) unless level in AMT-2 & CDT-2, are at high.
5. Degasser water pump P1A/B will trip on low level of degasser water tank.
6. Stage No. 10 (Air Mixing) of MB will not start unless and until B2 is running.
7. Respective inlet valve for acid and caustic will close when respective tanks reach their high level.
8. During caustic pre-injection and injection stages, we have to ensure DM Water pump running (Client‘s scope)
feedback signal.
9. Raw water pump running.
Following modes of regeneration will be possible: -

1. Simultaneous regeneration of MGF, ACF, SAC & SBA.
2. Simultaneous regeneration of SAC & SBA.
3. Regeneration of any individual unit separately of each MGF/ ACF/ SAC / SBA/ MB. This could be carried
out by selecting respective selector switch in regeneration position and manually pressing regeneration P.B.
which is combined for all units.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
At the end of regeneration sequence the regenerated unit will be put back into service automatically. Solenoid valves
will be mounted in the field near respected units. From these solenoid valves, air signal will be taken to the individual
pneumatically operated control valves. Electrical cables from the conventional limit switches mounted on
pneumatically operated valves will be taken through multi-core electrical cables. Suitable pneumatic and electrical
FRP junction boxes [5 Nos.] will be provided for terminating air connections and multi-core electric cables. Four Nos
will be located near MGF, ACF, SAC, SBA and MB units. Balance 1 No will be located in AMT/CDT area. From the
junction boxes cables/PVC coated cupper tubes will be laid to individual limit switches/pneumatic valves. Alarm
enunciator of approved make will be provided with following alarm conditions: -
1 CIA-1 Conductivity high

2 CIA-2 Conductivity high
3 PHIA pH low
4 PHIA pH high
5 Degassed water tank level low.
6 Degassed water tank level high
7 Adequate quantity of water passed through MB outlet totaliser.
8 Regeneration over – six regenerations over ensure SAC backwash.
9 Regeneration over – six regenerations over ensure SBA backwash etc.
Mimic with 110 VCA will be provided on top portion of panel. Following will be indicated on mimic LED‘s.
a) Valve open/close position of all pneumatic valves.
b) ON/Trip indication of all motors.
Lamp test facility will be provided for mimic lamps.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Chemicals Control
Ion exchange demineralisation
A. Two-Stage Deminerlisation Using A Strong Base Anion Exchange Resin.
This is the most widely used system for de-minerlising water. The first stage consists of a Strong Acid Cation
Exchange resin such as INDION 225. This stage is referred to be the Cation Unit or SAC Unit.
This semi treated water is then passed through the second stage consisting of a strongly Basic Anion Exchange resin
such as INDION FF (IP) or INDION N (IP). This unit is referred to as the Anion Unit or SBA.
In some installations a Degasser may be included, normally placed between the SAC and SBA units. If the raw water
contains a high proportion of Bicarbonates (Alkalinity) the treated water contains an equivalent high concentration of
Free Carbon Dioxide. It may then be more economical to remove this by passing the water through a Degasser
wherein the gas is blown off rather than allowing the SBA Unit to remove it.
Nomenclature: -
Cation Unit or SAC Unit - The first unit containing the strongly Acidic Cation Exchange Resin
SAC Water - Water leaving SAC Unit
Degassed Water or Semi-treated Water - Water after Cation Exchange or Degassing
SBA Unit or Anion Unit - The second unit containing the Anion Exchange resin
Raw Water - Inlet water entering the SAC unit
DM Water or Treated Water - Water leaving the SBA unit after treatment
Wash effluent - The waste water obtained during backwashing
Rinse Effluent - The waste water leaving the unit during rinsing
Injection Effluent - The waste water leaving the unit during injection of regeneration chemicals
Total Alkalinity or M.Alk - Alkalinity to Screened Methyl Orange (SMO) indicator
P. Alk - Alkalinity to phenolphthalein indicator
EMA - The Equivalent mineral Acidity a measure of the neutral salt
(Chloride + Sulphate + Nitrate) content of the raw water
FMA - Free Mineral Acidity of water. The SAC water contains FMA due to
the conversion of the neutral salts in the raw water EMA into their
respective mineral acids
Conductivity - The electrical conductivity of the treated water. A measure of the
total dissolved solids it contains. It therefore gives an indication of
the quality of DM Water. The conductivity varies with the type of
dissolved solids present.
The following notes will explain the operation of the individual units, the types of analytical tests to be conducted for
the control of the unit and the possible variations in the quality and capacity of the units that can be expected. The
individual analytical test methods referred to are found at the end of this section.
THE SAC UNIT
This is the key unit in the system. The quality of the treated water is directly dependent on the operating efficiency of
the unit.
1. The water entering the unit will normally be alkaline to SMO indicator due to the presence of Bicarbonates.
2. The water leaving the unit will be acidic to SMO indicator. The FMA of the SAC water will be equal to or
just less than the EMA of the raw water.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
3. The numerical difference between the EMA and FMA is the LEAKAGE or SLIP of cation which have not
been removed. These ions are normally Sodium ions.
EMA-FMA = Sodium Slip

1. The slip is dependent on the quantity of acid used for regeneration and the percentage of Sodium ions to the
Total Cation (TC) contained in the raw water. For a given quantity of acid used, an increase in this ration will
lead to an increase in slip.
NB: SODIUM CONTENT = TOTAL CATIONS- HARDNESS (Na=ALK+EMA-HARDNESS)
1. The DM plant is designed to give a certain quantity of treated water. The quality especially
CONDUCTIVITY, pH and Dissolved Solids is directly dependent on the slip from the SAC Unit. The design
of the SAC Unit is therefore based on the quantity of slip that is tolerable and an economical quantity of acid
is prescribed for each regeneration.
2. The test for EMA gives a check on the operating action of the SAC unit. Measure the EMA of the raw water.
During rinsing the FMA gradually decreases as the excess acid is being washed out and becomes steady at
approximately the value of the EMA. Rinsing should be stopped when the FMA is 10% to 15% higher than
EMA.
3. When the SAC Unit exhausts, the slip increases and FMA decreases. But the pattern of slip during the run is
not linear, that is the slip is not constant. It starts high, gradually decreases to a minimum about 2/3 of the run,
then increases.
4. The raw water is liable to vary from time to time and the EMA is therefore likely to change and should be
checked regularly. To control rinsing, continue rinsing until two successive tests for FMA give the same
figures for FMA.
5. Regenerate SAC when the FMA begins to fall from its normal steady value.
6. If the sodium to Total Cation ratio increases, the sodium slip will increase. The treated water and pH will also
increase. In such instances an increased quantity of acid must be used for regeneration.
7. Sulphuric Acid: - The waste water during regeneration contains the Sulphates of Calcium, Magnesium and
Sodium. Calcium Sulphate has a low solubility, if the H2SO4 concentration exceeds the specified limit,
Calcium Sulphate precipitation may occur in the resin bed. This will block flow, lead to improper
regeneration, poor quality of treated water and hardness leakage and choking of distribution/collecting
systems. DON’T EXCEED THE ACID INJECTION CONCENTRATIONS SPECIFIED IN THE
TECHNICAL DATA. The concentration specified has been based on the Calcium contents of the raw water.
There is not precipitation when using Hydrochloric Acid and a slight variation is tolerable.
CAPACITY BETWEEN REGENERATIONS:
The capacity is proportional to the TOTAL CATION (TC) content of the raw water.
TC = M.ALKALINITY + EMA (OR ALK. + CHLORIDES, SULPHATES, NITRATES)

A regular comparison between actual TC and design TC will give an indication of the capacity that can be expected.
THE SBA UNIT: -
1. The water entering the SBA unit will be acidic to SMO indicator. It will also contain free carbon dioxide
about 6 ppm if a Degasser is installed prior to SBA unit or an amount equal to the free CO 2 content of the raw
water + the raw water alkalinity. The water also contains silica.
2. The water leaving the SBA unit will be alkaline to SMO indicator and initially free of chloride, silica, CO2.
The electrical conductivity of SBA water is a direct measure of its purity.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
3. The purity of DM Water is dependent on SAC water entering it. Any Sodium slip from the SAC Unit is
converted into Sodium Hydroxide in the SBA Unit.
NaCl + ROH -------- > R Cl + NaOH
Sodium Chloride Hydroxide Resin Chloride Resin Sodium Hydroxide
4. 01 ppm NaOH in the SBA treated water results in conductivity of 6 µ S/cm and pH of more than 8.3
5. A check on DM water should include tests for
Conductivity
pH
Chlorides
Silica
P. Alkalinity
M. Alkalinity
Note: - Conductivity and pH should be measured by on line instruments. The laboratory determination will introduce
error due to absorbing of atmospheric gases. Silica and Chlorides should be negligible (refer to actual specifications
where given)
The P-Alkalinity figure will give the Sodium slip and the corresponding conductivity and pH will also indicate the
concentration of Sodium Hydroxide in the DM Water.
1. However, the two main control checks are conductivity and Silica. Silica being a weak acid is less easily
removed than the mineral acids.
2. When the SBA Unit exhausts Silica appears first in the effluent. Silica does not affect the conductivity
reading. If conductivity is low, Silica high, the unit requires regeneration. When Silica breaks through into the
treated water, it is followed by Carbon Dioxide as well. There is therefore a fall in pH.
NB: - This must not be confused by a fall in pH and P-Alkalinity due to a reduction in Sodium slip.
3. If the pH is lower than the specified, check Silica and conductivity of DM Water. If both satisfactory then unit
is still operating efficiently.
4. If the conductivity and pH are consistently higher than specified, it is possible that this is due to an increase in
the Sodium content of raw water. Invariably, poor treated water from SBA unit is a function of the SAC unit,
not the SBA unit.
5. The concentration of Silica in the DM Water depends on the ration of Silica to TOTAL ANION (TA) of the
water to be treated. If the ratio increases the DM Water Silica increases.
6. A common problem with Anion exchange resin is that they are susceptible to fouling with organic matter.
Organic matter of vegetable origin (Leaves, plants, twigs are not to be confused with algae, bacteria and other
living organism) is a collection of a long chain, high molecular weight organic acids – anionic in nature,
which are absorbed by the resin and not so easily removed during regeneration. The use of INDION
ISOPOROUS resin has considerably reduced this problem but raw water containing organic matter will lead
to fouling problems. (Refer MAINTENABCE section).
7. Check end of RINSE by checking conductivity: and check exhaustion by both Silica and conductivity. When
the SBA Unit exhausts, Silica will emerge in the effluent, the pH will fall, there will be a decrease in
Alkalinity.
8. Capacity Between Regenerations: -
i. The capacity between the regenerations is dependent on the Total Anionic Load on the unit –
Total Anions (TA)
ii. TA= EMA + M.ALK + Silica + Free CO2 (ppm CaCO3 in Raw Water)
iii. If a degasser is used prior to the SBA unit TA = EMA + Silica +6 ppm CO2.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Summary for Operation.
1SAC Injection: -- For Sulphuric Acid, Don‘t use exceed specified dilution concentration.
- For Hydrochloric Acid a variation of ± 1 % in concentration is Tolerable.
- Don‘t exceed time specified especially for Sulphuric Acid. The time
shouldn‘t come to less than 15 minutes.
2 SBA Injection: -- Keep Injection time ± 5 minutes of that specified.
- A variation of ± 1 % in concentration of Alkalies is tolerable.
SAC Rinse: - - Check FMA after specified time if two successive readings at say 5 minutes
interval give the same reading of FMA, stop rinse. There should be no hardness in the
effluent.
4 For the medium basic resins such as INDION H (IP) there will be a combination of the two effects.
Initially the DM Unit will behave as per A - Using a strongly basic resin out after 10 – 20 % of the run, it will behave
as per B – At the juncture, there will be an increase in DM water Silica, increase in DM water Co2, decrease in DM
water pH. The conductivity variation is rather indefinite. 1 ppm of NaCl results in a conductivity of 1.8 µ S/cm.
Hence when the conversion to NaOH stops, there will be a decrease in conductivity but at the same there will be an
increase in conductivity due to non-removal of CO2.
Refer also the section on maintenance. The following analytical test methods are included in this section.
Alkalinity
EMA
Hardness
Silica (1 – 20 ppm)
Chloride
Free CO2 (Raw Water)
Free CO2 (SAC Water)
FMA
Silica (0 – 1 ppm)
Mixed Bed Unit

1. Capacity
a) For the first six months of operation, the mixed bed unit must be run to the rated capacity as stated in the
Technical Data Sheet and should then be regenerated. Thereafter the capacity may be gradually stopped up
until after a further three months the run may be terminated either on silica breakthrough or on conductivity
break through depending on the quality of treated water required.
b) As two types of ion exchange resins are used in the Mixed Bed Unit, two Ionic loads have to be considered
for capacity. Any increase in either will result in a decreased capacity.
TOTAL CATION (TC) = M.ALK + E.M.A (or Alkalinity + Chlorides + Sulphates + Nitrates)
TOTAL ANION (TA) = M.ALK + EMA + FREE Co2 + SILICA
If either the TC or TA increases, the capacity will decrease. If the Cation exchange resin exhausts first, the treated
water conductivity will rise. At exhaustion of the cation resin the treated water pH will increase. If the Anion resin
exhausts first, the treated water pH will decrease.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
2. Treated Water Quality

a) The quality of treated water from a Mixed Bed Unit is extremely pure. High purity water is an excellent
solvent and is therefore easily contaminated. If exposed to the air it will absorb free Carbon free Carbon
Dioxide and other gases from the atmosphere very rapidly.
Great care is therefore required when sampling and analyzing the water. The cleanliness of apparatus, purity
of reagents, and speed in analysis are critical items.
The best method for checking its purity is by measuring its specific conductance (conductivity) using an in-
line call assembly and an accurate measuring instrument. Error can arise if sample is taken and measured
elsewhere. The pH should also be checked using an in-line electrode assembly although it has been found that
readings may tend to be erratic because the liquid being measured is so close to being absolutely neutral.
b) The presence of Silica in the treated water does not appreciable affect its conductivity. If Silica free water is
required, silica tests should be conducted as a regular routine just before the end point of the treatment run and
the unit should be regenerated when the silica content of the treated water is no longer acceptable.
c) The treated water conductivity will generally be below 1.0 micro s/cm. the minimum be normally be in the
range of 0.2 – 0.5 micro s/cm. it is important to check the temperature of the water and make necessary
corrections to the reading. The pH will be in the region of 6.0 – 7.2 depending on the temperature.
d) An empirical relationship between the total dissolved solids (TDS) and conductivity may be considered. This
is generally accepted as follows.
1ppm TDS = 2 micro s/cm i.e. a ratio of 1:2.
3. Control Tests
To summarise, to check raw water ionic loads the following tests are required. –
Total Alkalinity
Equipment Mineral
Acidity Free Mineral
Acidity Silica
To check the quality of the treated water the tests required are as
follows: Conductivity
Silica
ALKALINITY (METHYL ORANGE AND PHENOLPHTHALEIN)
Reagents and Apparatus
Burette for standard acid

Nitric Acid 0.02N (N/50) or 0.02 HCl
100 ml. graduated measuring cylinder
Conical flask (150 ml)
Phenolphthalein indicator solution
10 ml. Graduated pipette
Sodium Thiosulphate 10% w/v solution
Method
If the alkalinity of the water is low, 100ml of sample should be measured using the graduated cylinder. Otherwise a
10 or 20 ml portion of sample should be taken with the pipette.
1. Transfer the appropriate amount of sample to the conical flask and add 5 drops of phenolphthalein indicator.
2. Run in 0.02N Nitric acid or 0.02N HCl from the burette until the pink colouration is just discharged.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
3. Note the volume of acid used, multiply by the appropriate factor (see table) and record as ―P‖
mls. Of sample taken Factor

100 10
20 50
10 100
4. If water is chlorinated, add 2 drops of Sodium Thiosulphate solution. Add 2 drops of screened Methyl Orange
indicator and continue the addition of acid until the solution just turns to smoky gray.
5. Read the burette again, note the total amount of acid used in both titrations and multiply by the approptate
factor (see the table above). Record result as ―M‖
INTERPRETATION OF SAMPLES
The relative quantities of Bicarbonates and Carbonates and Hydroxide alkalinity can then be obtained from the
following tables
Bicarbonates Carbonates Hydroxide
P=Nil M Nil Nil

P<1.2 M M-2P 2P Nil
P=1/2 M Nil 2P Nil
P>1/2 M Nil 2 (M-P) 2 (P-M)
P=M Nil Nil P
The above results are expressed in parts/million (ppm) as CaCO3
Note
1. Screened Methyl Orange Indicator Solution, Preparation of Indicator Solution – Dissolve 0.2 g of crystalline
Methyl Orange in a mixture of 25 ml. Methylated Spirit and 25 ml. Deionised water. Dissolve 0.28g x Xylene
Cyanol FF in a mixture of 25 ml. Methylated Spirit and 25 ml deionised water. Mix the two solutions
together.
2. For most RAW WATER samples, as also LIME SOFTENED water a 100 ml sample can be used. For
BOILER WATER samples use 10ml or 20 ml sample.
3. Use Sodium Thiosulphate solution before addition of Methyl Orange only if water has been chlorinated e.g.
from bottling precipitators.
HARDNESS
Reagents and Apparatus
1. N/50 E.D.T.A: - 4.0 grams of Ethylene Di-amino Tetra Acetic Acid are dissolved in 800 ml of water and
standardized and adjusted against a standard hardness solution until 1 ml = mg CaCO3
2. Ammonia Buffer: -
a) Dissolve 16.9 grams ammonium chloride, NH4Cl in 143 ml conc. Ammonium hydroxide NH4OH and 1.25
grams of magnesium salt of EDTA (this salt is available commercially) and dilute to 250 ml with distilled
water.
b) A buffer containing the magnesium salt of EDTA may also be made as follows:

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Dissolve 16.9 grams ammonium chloride, NH4Cl in 143 ml conc. Ammonium hydroxide NH4OH weight out 0.25
grams MgCl2.6H2O or MgSO4.7H2O, transfer quantitatively to a 100 ml volumetric flask, and make up to volume
with distilled water. Pipette out 50.0 ml. of this solution into a porcelain dish,
Add a few drops of the NH4Cl-NH4OH mixture and make up to 250 ml. with distilled water. Keep the solution (a or
b) in a plastic or resistant glass container, tightly Stoppard to prevent loss NH3 or pickup of CO2.
3. Indicator: - Mix 0.5 grams of Erichrome black T with 4.5 Hydroxylamine Hydrochloride. Dissolve the
mixture in 100 ml of 95 % Ethyl or Isopropyl alcohol.
4. Apparatus : -
i. Burette for N/50 EDTA
ii. 250 ml. beaker
iii. 50 ml. measuring cylinder
iv. Stirring rod
v. For soft water use 750 ml. evaporating dish and magnetic or electric stirrer
vi. 50 ml. measuring cylinder.
Method
A. For Raw Water
A 50 ml. quantity of the water is measured out in a measuring cylinder. 40 ml of this are placed in a 250 ml.
beaker, 01 ml. of buffer solution and a 6-8 drops indicator are added. The titration is then carried out by
adding EDTA solution from the burette, until the last tinge of red disappears. The last 10ml. of water ware
then added and the titration completed to the same end-point. The liquid in the beaker is illuminated from
underneath by a blue light.
B. For Soft Water :
a. Rinse the cylinder and the evaporating dish thoroughly with the water to be used.
b. Measuring 500 ml. of the sample into the evaporating dish and add 3 ml. of buffer solution followed
by 10-12 drops of indicator solution.
c. Run 0.5 ml of EDTA from the burette and stir the liquid in the dish thoroughly.
d. If a steel blue color is obtained with no tinge of red, the hardness is less than 1 ppm as CaCO3
e. If a red colour is observed add EDTA drop by drop with continuous stirring until a steel blue colour
with no tinge of red is obtained i.e. until the last tinge of red just disappears.
Calculation
A. For Raw Water: -

If titration reading is ‗T‘ ml
HARDNESS = T x 20 ppm CaCO3
B. For Soft Water: -
HARDNESS = T x 2 ppm CaCO3

Note
1. As the strength of the red tinge diminishes, the EDTA should be added carefully one drop at a time with
stirring between each addition.
2. If the end point has not been reached after adding total of 10 ml. of EDTA the test should be repeated using
250 ml. of sample with 2 ml. of buffer and 8-10 drops of indicator. Suitable allowance should then be made
when calculating the results.
3. The indicator solution should be kept in a cool place and out of the light as much as possible. It must be
replaced after two months.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
FREE MINERAL ACIDITY (F.M.A)
Reagent And Apparatus
Burette for Standard Sodium Hydroxide

Sodium Hydroxide 0.02N (N/50) Solution
100 ml. graduated measuring cylinder
Conical flask (150 ml)
Screened Methyl Orange Indicator
Preparation of Indicator Solution
Dissolve 0.2 grams of crystalline methyl orange in a mixture of 25 ml. Methylated spirit and 25 ml. deionised water.
Dissolve 0.20 grams Xylene Cyanol FF in a mixture of 25 ml. Methylated Spirit and 25 ml. deionised water. Mix the
two Solutions together.
Method
1. Measure out 50 ml. of the sample and pour into the flask.
2. Add three drops of screened Methyl Orange indicator. The sample should turn red.
3. Run in 0.02 N Sodium Hydroxide Solution a few drops at a time until the solution turns Smokey-grey. Mix
thoroughly while adding the solution.
Calculation
Free Mineral Acidity = Burette reading x 20 ppm as CaCO3
Note
This test is used to check water treated by a Cation Exchanger regenerated with acid.
Procedure
1. 100 ml. sample of cation treated water are measured in two 250 ml. flasks.
2. The first is carefully titrated with N/50 NaOH to S.M.O. end point and the reading (A) noted.
3. The second sample is now titrated with carbonate free N/50 NaOH to phenolphthalein end-point and the
reading (B) noted.
Calculation
(B-A-0.8) x 10 = ppm CO2 as CaCO3.
Note
The N/5 NaOH is rendered free from carbonate by passing the solution through a strongly basic Anion Exchanger
such as INDION FF – IP in the Hydroxide form during the titration.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
TREATMENT OF ORGANIC FOULING

Introduction
1. Some raw materials contain appreciable quantities of organic matter of vegetable origin. Most of this organic
matter is removed during the de-minerlising process and is removed from the ion-exchange resin during
regeneration, but some remains in the anion exchange resin. If unchecked this reduces the efficiency of the
Anion Exchange resin.
2. Organic fouling shows itself in one or more of the following ways:
a) Prolonged rinse time. The resin may have to be continued for more than the stipulated time to obtain
the required quality of demineralised water.
b) Unsatisfactory demineralised water quality.
i. Conductivity of demineralised water may not fall below the stipulated figure.
ii. Residual silica in demineralised water may increase slowly.
c) Reduced capacity. The conductivity of good demineralised water obtained per regeneration may fall
steadily.
3. These effects will occur slowly. A sudden drop in quality or capacity can usually be ascribed to some other
cause e.g. a change in raw water characteristics, or incorrect operation of the plant. Before assuming the
organic fouling is taking place, the raw water analysis should be checked and the plant regenerated carefully.
A resin sample should be sent to us (Ion Exchange India Ltd ;) for analysis.
(WE RECOMMEND THAT TREATMENT OF ORGANIC FOULING SHOULD BE DONE, AS A

ROUTINE, ONCE IN THREE MONTHS)
Equipment
4. (a) Tank to hold alkaline brine solution (see note 1 )

(b) Stirring arrangement in the tank.
(c) Pump or ejector with relevant pipe work and valves for alkaline brine injection.
Chemical Requirement
5. Two resin bed volumes of alkaline brine solution containing 10 % NaCl and 1% NaOH.
6. Prepare the required volumes of alkaline brine at the appropriate concentrations depending on the system on
the injection that will be used for the purpose. For e.g. if the solution is to be pumped directly into the unit
prepare 2 resin bed volumes of 10 % NaCl and 1 % NaOH for injection. If an ejector (1:1 ratio) with a pump
pressure and a mixing ―T‖ arrangement is used, prepare a lower volume but of higher concentration to
account for dilution water. In all cases ensure that you inject 2 resin bed volumes at a concentration of 10%
NaCl and 1% of NaOH.
Method
7. (a) Air scour and extended backwash

(b) Removal of organic fouling.
i. Open INLET VALVE and air release valve to fill up water in the vessel. When water flows out
through air release pipe, close air release and inlet valves.
ii. Next inject alkaline brine solution at the same flow rate as is done in normal alkali injection.
iii. After all the alkaline brine solution is injected into the unit close the valves.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
iv. Let the resin soak in the alkaline brine solution for eight hours or over night.
v. After the soak, open INLET valve and AIR RELEASE VALVE; when water comes out of air release
pipe, close AIR RELEASE VALVE.
vi. Open RINSE Valve and adjust the rate so that level in the sump reaches the rinse mark.
vii. Continue rinsing for 45 minutes or till effluent is clear, whichever is later.
viii. Regenerate the unit with double quantity of caustic than normally used for regeneration.
Note
i. The total volume of alkaline brine should be about twice the volume of resin i.e. if the resin is 100 liters then
the volume of alkaline brine solution will be 200 liters but care should be taken that concentration of NaCl in
the solution should be 10% and Caustic Soda NaOH 1%.
ii. In case with the existing injection system the injection strength is slightly more or slightly less than require,
the same system can be used.
iii. In case the ejector etc. is not incorporated with the unit then pump is necessary to inject brine into the vessel.
In this case the manhole should not be closed after removal of fines, and the brine injected into the vessel
from manhole.
iv. If tank already provided for regeneration is not sufficient to hole the entire quantity of alkaline brine, then the
injection of brine could be done in two installments. If such is the case the brine is injected once, the resin is
soaked and again the brine injection done.
DETERMINATION OF LOW SiO2 (0 – 0.25 ppm)
1. Reagents
a) Hydrochloric acid (1:1) To 100 ml. distilled water add 100 ml. hydrochloric acid (sp.gr. 1.19)
i.e. 33%.
b) Ammonium Molybdate (10%) – Dissolve 10 g. ammonium Molybdate Tetra-hydrate per 90
ml. distilled water.
c) Oxalic Acid (10%) – Dissolve 10 g. Oxalic acid per 90 ml. distilled water.
d) Amino Reducing Agent – Dissolve 0.5 g 1-amino-2-naphthol-4-sulphonic acid and 1 g.
Sodium Sulphate in 50 ml. distilled water and add to a solution of 30 g. Sodium Bi-Sulphate in
150 ml. distilled water (i.e. 27.4 g. Sodium Meta-bisulphate).
e) Sodium Silicate Standard Solution – Dissolve 4.74 g. of Sodium Silicate Nona-hydrate
(Na2SiO3.9H2O) in distilled water and dilute to 1 liter for approximately 1 mg/ml SiO2.
Determine exact silica concentration of the standard gravimetrically.
Sodium Silicofluoride may also be used as a standard without a gravimetric analysis. Dissolve 3.147 g. pure,
dry Na2SiF6 per liter distilled water = 1000 ppm SiO2 or 1 mg/ml SiO2.
Note The regent and distilled water used should be silica free. It is recommended that the use of glass be eliminated
wherever possible. Regent and standard solution should be stored in hard rubber or plastic bottles.
2. Procedure:
a) To an accurately measured 100 ml. sample in a 250 ml. Erlenmeyer flask add 1 ml Hydrochloric Acid
(1:1) and 2 ml. Ammonium Molybdate (10%) shake and let stand.
b) After five to ten minutes add 2 ml. Oxalic Acid (10%) and after shaking 15 – 20 seconds 1 ml. Amino
Reducing Agent. Shake and let stand.

By
Arun Kumar Bakshi
E. No. 250-3-786-0
c) After ten to fifteen minutes read % transmission using 100 ml. of the sample with distilled water
added in the same volume as the total regents as a reference standard for transmission at 815 mu or
use 608 filter 10 cm. cell.
d) Determine Silica concentration by referring to a calibration curve for the method. Wave length and
cell size used in the determination.
FREE CARBON DIOXIDE
1. Reagents And Apparatus

Burette for Sodium Carbonate solution
Sodium Carbonate solution 0.04 (N/25)
Phenolphthalein indicator (solution or
tablets) 100 ml. Nessler Cylinder
Glass stirring rod
2. Procedure
i. Fill the Nessler cylinder to the 100 ml. mark with the water to be tested avoiding splashing and 2
tablets or 20 drops of phenolphthalein indicator.
ii. Run in 0.04N Sodium Carbonate, a few drops at a time with gentle stirring until a pale pink colour is
produced which persists for one minute. Take the burette reading.
Interpretation of Result Free CARBON DIOXIDE concentration = Burette reading x 10 (ppm as CaCO3)
RESIDUAL CO2 IN CATION EXCHANGER TREATED WATER
Burette for Standard Alkali solution

Sodium Hydroxide solution 0.02 (N/50)
Screened Methyl Orange Indicator Solution
Phenolphthalein indicator (solution or tablets)
CO2 Flakes
100 ml. Graduated Cylinder
Glass stirring rod
2. Procedure
i. 100 ml. sample of cation treated water are measured in two 250 ml. CO2 flakes.
ii. The first is carefully titrated with N/50 NaOH to S.M.O. end point and the reading (A) is noted.
iii. The second sample is now titrated with carbonate free N/50 NaOH to phenolphthalein end point and
the reading (B) noted

By
Arun Kumar Bakshi
E. No. 250-3-786-0
3. Calculation
(B - A – 0.8) x 10 = ppm CO2 as CaCO3
Note: - The N/50 NaOH is rendered free from carbonate by passing the solution through a strongly basic
Anion Exchanger such as INDION- FF-IP in the Hydroxide form during the titration.
CHLORIDES
Mercuric Nitrate Method for determination of Chloride.
Burette for Mercuric Nitrate solution

Mercuric Nitrate Solution 0.02
(N/50) Concentrated Nitric Acid
Distilled water
0.02N Sodium Chloride Solution
0.1% w/v Solution Di-phenyl-Cabazon
Nickel Nitrate (Buffer Solution)
100 ml. Graduated Cylinders
10 ml. graduated pipettes
250 ml. conical flasks
2. Reagent Preparation
i.
To prepare 0.02 N Mercuric Nitrate Hg (NO3)2 : - dissolve 3.24 gms Hg (NO3)2 or 3.42 gms. Hg
(NO3)2 in approximately 500 ml. distilled water which contains 3 ml. of concentrated Nitric Acid.
When totally dissolved make up of 1 liter. Standaradise as under ‗Procedure‘ against standard Sodium
Chloride Solution.
ii. Standard Sodium Chloride Solution (0.02N) : - Dissolve 1.17 gms of pre-dried Analar Sodium
Chloride in 1 liter of distilled water (i.e. 1 ml. 0.02N NaCl = 1 mg Cl as CaCO3).
iii. 0.1% w/v solution of Di-phenyl-Cabazon is iso-propanol or Ethanol. This solution is unstable and
should be renewed monthly.
iv. Nickel Nitrate (Buffer Solution) : - 4 molar crystalline Nickel Nitrate solution containing 5 ml. of
concentrated Nitric Acid per 100 ml. of solution.
3. Procedure
Measure 100 ml. of sample into a 250 ml. flask; add 2 ml. Di-phenyl-Cabazon solution and mix again. The
resulting solution should be a pale green colour. If the solution had an orange tint, add Nickel Nitrate drop
wise until the green tint is achieved. Titrate the solution with Mercuric Nitrate until a faint but persistent violet
colour is observed (i.e. the end point)
CALCULATION
Chloride Content =
Expressed in ppm chloride as CaCO3

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Deionised/Demineralised Water
Distilled, deionised and demineralised water and measuring of the purity
It is quite difficult to find clear definitions and standards for distilled, demineralised and deionised water.
Probably the easiest way to familiarise in the topic of producing (ultra) pure water is to start with the oldest and
best-know method: distilling.
Distilled water is water that has been boiled in an apparatus called a "still" and then recondensed in a cooling unit
("condenser") to return the water to the liquid state. Distilling is used to purify water. Dissolved contaminants like
salts are left behind in the boiling pot as the water vapour rises away. It might not work if the contaminants are
volatile so that they also boil and recondense, such as having some dissolved alcohol. Very elegant stills can
selectively condense (liquefy) water from other volatile substances, but most distillation processes allow carry-over
of at least some volatile substances, and a very little of the non-volatile material that was carried into the water
vapour stream as bubbles burst at the surface of the boiling water. Maximum purity from such stills is usually 1.0
MWcm; and since there is no protection from carbon dioxide (CO2) dissolving into the distillate the pH is
generally 4.5-5.0. Additionally, you have to be careful not to re-contaminate the water after distilling it.
Deionisation: Process utilizing special-manufactured ion exchange resins which remove ionised salts from water.
Can theoretically remove 100 % of salts. Deionisation typically does not remove organics, virus or bacteria
except through ―accidental‖ trapping in the resin and specially made strong base anion resins which will remove
gram-negative bacteria. [4]
Demineralisation: Any process used to remove minerals from water, however, commonly the term is restricted to
ion exchange processes. [1]
Ultra pure water: Highly-treated water of high resistivity and no organics; usually used in the semiconductor
and pharmaceutical industries [4]
Deionisation entails removal of electrically charged (ionised) dissolved substances by binding them to positively or
negatively charged sites on a resin as the water passes through a column packed with this resin. This process is
called ion exchange and can be used in different ways to produce deionised water of various qualities.
Strong acid cation + Strong base anion resin systems

These systems consist of two vessels - one containing a cation-exchange resin in the hydrogen (H+) form and the
other containing an anion resin in the hydroxyl (OH-) form (see picture below). Water flows through the cation
column, whereupon all the cations are exchanged for hydrogen ions. The decationised water then flows through the
anion column. This time, all the negatively charged ions are exchanged for hydroxide ions which then combine
with the hydrogen ions to form water (H2O). [2]
These systems remove all ions, including silica. In the majority of cases it is advisable to reduce the flux of ions
passed to the anion exchanger by installing a CO2 removal unit between the ion exchange vessels. This reduces
the CO2 content to a few mg/l and brings about a reduction of the following strong base anion resin volume and in
the regeneration reagent requirements.
In general the strong acid cation and strong base anion resin system is the simplest arrangement and a deionised
water that may be used in a wide variety of applications can be obtained with it. [3]

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Strong acid cation + weak base anion + Strong base anion resin systems
This combination is a variation of the previous one. It provides the same quality of deionised water, while offering
economic advantages when treating water which contains high loads of strong anions (chlorides and sulphates). The
subtitle shows that the system is equipped with an extra weak base anion exchanger before the final strong base
anion exchanger. The optional CO2 removal unit may be installed either after the cation exchanger, or between the
two anion exchangers (see picture below). The regeneration of the anion exchangers takes place with caustic soda
(NaOH) solution first passing through the strong base resin and then through the weak base resin. This method
requires less caustic soda than the method described before because the remaining regeneration solution after the
strong base anion exchanger is usually sufficient to regenerate the weak base resin completely. Moreover, when raw
water contains a high proportion of organic matter, the weak base resin protects the strong base resin. [3]

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Mixed-bed Deionisation
In mixed-bed deionisers the cation-exchange and anion-exchange resins are intimately mixed and contained in a
single pressure vessel. The two resins are mixed by agitation with compressed air, so that the hole bed can be regard
as an infinite number of anion and cation exchangers in series (mixed bed resin). [2, 3] To carry out regeneration, the
two resins are separated hydraulically during the loosening phase. As the anion resin is lighter than the cation resin it
rises to the top, while the cation resin falls to the bottom. After the separation step the regeneration is carried out
with caustic soda and a strong acid. Any excess regenerant is removed by rinsing each bed separately. The
advantages of mixed bed systems are as follows:
- the water obtained is of very high purity and its quality remains constant throughout the cycle,
- pH is almost neutral,
- rinse water requirements are very low.
The disadvantages of mixed bed systems are a lower exchange capacity and a more complicated operating
procedure because of separation and remixing steps which have to be carried out. [3]
Next to the ion exchange systems deionised water can be produced with reverse osmosis plants. Reverse osmosis is
the finest filtration known. This process will allow the removal of particles as small as ions from a solution. Reverse
osmosis is used to purify water and remove salts and other impurities in order to improve the color, taste or
properties of the fluid. Reverse osmosis is capable of rejecting bacteria, salts, sugars, proteins, particles, dyes, and
other constituents that have a molecular weight of greater than 150-250 Daltons.
RO can meet most water standards with a single-pass system and the highest standards with a double-pass system.
This process achieves rejections of 99.9+% of viruses, bacteria and pyrogens. Pressure in the range of 50 to 1000 psig
(3.4 to 69 bar) is the driving force of the RO purification process. It is much more energy-efficient compared to phase
change processes (distillation) and more efficient than the strong chemicals required for ion exchange regeneration.
The separation of ions with reverse osmosis is aided by charged particles. This means that dissolved ions that carry a
charge, such as salts, are more likely to be rejected by the membrane than those that are not charged, such as
organics. The larger the charge and the larger the particle, the more likely it will be rejected. [4]

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Measuring of the purity

Water purity may be measured in various ways. One can attempt to determine the weight of all of the dissolved
material ("solute"); this is most easily done for dissolved solids, as opposed to dissolved liquids or gases. In addition
to actually weighing the impurities, one can estimate their level by the degree to which they increase the boiling
point or lower the freezing point of water. The refractive index (a measure of how transparent materials bend light
waves) is also affected by solutes in water. Alternately, water purity can be quickly estimated on the basis of
electrical conductivity or resistance — very pure water conducts electricity poorly, so its resistance is high.
pH-value
Pure water by definition is slightly acidic and distilled water will test out around pH 5.8. The reason is that distilled
water dissolves carbon dioxide from the air. It dissolves carbon dioxide until it is in dynamic equilibrium with the
atmosphere. That means that the amount being dissolved balances the amount coming out of solution. The total
amount in the water is determined by the concentration in the atmosphere. The dissolved carbon dioxide reacts
with the water and finally forms carbonic acid.
2 H2O + CO2 --> H2O + H2CO3 (carbonic acid) --> (H30+) (charged acidified water) + (HCO3-) (charged
bicarbonate ion)
Only recently been produced distilled water has a pH-value of approximately 7, but affected by the presence
of carbon dioxide it will reach a slightly acidic pH-value within a couple of hours.
Additional, it is important to mention that the pH of ultra-pure water is difficult to measure. Not only does high-purity
water rapidly pick up contaminants - such as carbon dioxide (CO2) – that affect its pH, but it also has a low
conductivity that can affect the accuracy of pH meters. For instance, absorption of just a few ppm of CO2 can cause
the pH of ultra-pure water to drop to 4.5, although the water is still of essentially high quality.
The most accurate estimation of the pH of ultra-pure water is obtained by measuring its resistance; for a given
resistance, the pH must lie between certain limits. For example, if the resistance is 10.0 MWcm, the pH must lie
between 6.6 and 7.6. The relationship between the resistance and pH of high-purity water is shown in the
figure below. [2]

By
Arun Kumar Bakshi
E. No. 250-3-786-0
Electrical resistivity versus pH of deionised water [2]
Beverages pH
Milk 6.5
Distilled water 5.8
Beer 4.0-5.0
Coffee 2.5-3.5
Orange juice 3.5
Soft drinks 2.0-4.0
Cola 2.5
Wines 2.3-3.8
(Stomach acid) 1.0-2.0
(Battery acid) 1.0
Compared with other beverages deionised water has apparently a slightly acidic pH-value.
According to the Merck Manual the human body uses buffers to balance the pH. If a person consumes something
acid, the blood will produce more bicarbonate and less carbon dioxide to neutralize the acidity. Likewise the
blood will produce more carbon dioxide and less bicarbonate if a alkaline substance is consumed. So drinking
distilled water will not put a human body in an acidic state.
Sources:
[1] F. N. Kemmer; The Nalco water handbook; 2. Edition; 1988
[2] www.purite.com
[3] Degremont; Water treatment handbook; sixth edition; 1991
[4] Osmonics Pure Water Handbook; 2. Edition; 1997

Ion Exchange Dmw2019

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Ion Exchange Dmw2019

Caricato da

Copyright:

Formati disponibili

Operational Manuals For Demineralisation Water Plant Supplied By

ION EXCHANGE (INDIA) LTD

OPERATION & MAINTENANCE

PUNJAB ALKALIES & CHEMICALS LTD. NAYA NANGAL

ION EXCHANGE (INDIA) LTD. 2nd FLOOR, NEETA TOWERS DAPODI,

CONSULTANT: UHDE (INDIA) LTD.

THE POWER BEHIND WATER Page 1

THE POWER BEHIND WATER Page 2

pleased to offer our services & advice to you.

THE POWER BEHIND WATER Page 3

ION EXCHANGE PROCESS: -

Na+ Cl- + H+R- ----------- > Na R

Mg+2SO4 -2 + 2H+R- ------------

Ca+2(HCO3)-2 + 2H+R- > Ca+2R2 -2 + 2CO2+2H2O (3)

THE POWER BEHIND WATER Page 4

HCl + ROH------------ > R Cl + H2O (4)

H2SO4 + 2ROH------------- > R2SO4 + 2H2O (5)

HCl + R -------------- > R HCl (6)

THE POWER BEHIND WATER Page 5

Na R + HCl -------------- > HR + NaCl (7)

MgR2 + H2SO4 <--------------- > 2 HR + MgSO4 (8)

R Cl + NaOH --------------- > ROH + NaCl (9)

R HCL + NaOH ---------------- > R + NaCl + H2O (10)

Inlet water quality: -

Capacity between regenerations: -

THE POWER BEHIND WATER Page 6

concentrations must be measured as mg/liter or ppm CaCO3.

Treated water quality: -

Units using strong base anion resins

THE POWER BEHIND WATER Page 7

NaCl + ROH ------------ > R Cl + NaOH

Units using weakly basic resins: -

For either exchange unit, regeneration is carried out in three stages.

THE POWER BEHIND WATER Page 9

Refer P & I Diagram No. A1-VD0002-01-01/C

==== > Service Raw Water < ============Regeneration (Backwash)

Flow Chart Of DM Water Plant

THE POWER BEHIND WATER Page 10

MGF ACF SAC SBA

AMT-2 CDT-2 CDT-1 AMT-1

FLOW CHART OF DM.WATER PLANT

Reference P & I diagram No A1-VD0002-01-01/C.

S.No. Design Parameters Units Raw Water Treated Water

1 Iron ppm as Fe Not Detectable <0.005

Multigrade Sand Filter (MGF)

Distribution/ Collection System

Top -- Inlet Bell mouth

THE POWER BEHIND WATER Page 12

Description Size Quantity per Unit (Kg)

Pebbles 1.5‖~ 1‖ 500

day. Activated Carbon Filter (ACF)

Distribution/ Collection System

Top -- Inlet Bell mouth

Description Size Quantity per Unit (Kg)

Pebbles 1.½‖ ~ 1‖ 300

Regeneration/ Backwash of ACF: - Once in a day.

THE POWER BEHIND WATER Page 13

Strong Acid Cation (SAC)

Waster Water per regeneration (Effluent) -- m3 12.6

Chemicals HCl (Hydrochloric Acid)

Distribution /Collecting System per Unit

Strong Base Anion (SBA)

THE POWER BEHIND WATER Page 14

Resin Quantity -- Liters 785