Bap - MBP System

BANGGAI AMMONIA PLANT (BAP) PROJECT Boustead Salcon Water Solutions
Pte Ltd
PROGRAM
 DAY 1
 Introduction
 Pretreatment (Ultrafiltration)
 Desalination (Seawater Reverse Osmosis)
 Day 2
 Desalination (Brackish Water Reverse Osmosis)
 Mixed Bed Polisher
PROGRAM
 Fundamentals
 Design Basis
 Process Flow Diagram
 System Description
 Operation Philosophy
 Daily Operation, Monitoring and Maintenance
 Start Up
 Shut Down
 Troubleshooting
 Safety Precaution
FUNDAMENTAL OF
ION EXCHANGER
(IX)
Introduction
 Ion exchange is the reversible exchange of ions

between a solid and a liquid in which there is no
substantial change in the structure of the solid
 Only soluble ionized substances can be removed by
ion exchange
 Resins are small plastic beads which are porous
 The structure of resin is a polymer on which a fixed
ion is permanently attached. To preserve the electrical
neutrality of the resin, each fixed ion must be
neutralized with a counter ion.
 Each ion going into the bead has to be replaced an ion
getting out of the bead (to preserve electrical
neutrality).
 Only ions of same electric signs are exchanged.
Type of Resin
Two major resin groups:

 Cations - exchange positive ions
 Anions - exchange negative ions
Fixed Ion
Polymeric
Skeleton Counter Ion
Cation resin Anion resin

Demineralization
Exchange of Cations:
2 R’H + Ca++  R’2Ca + 2 H+

R’H + Na+  R’ Na + H+
Decationization (All cations replaced by H+)

Demineralization
Exchange of Anions:
2 R’’OH + SO4  R’’2SO4 + 2 OH-

R’’OH + Cl-  R’’Cl + OH-
 H+ and OH- ions released from resins combine to

form water: H+ + OH-  H2O
Order of Affinity
 For ion exchange to be effective, there must be a

difference in affinity between the ion in the resin and
the ion to remove from solution.
 Order of affinity for cation resins:

Pb2+ > Ca2+ > Mg2+ > Na+ > H+
 Order of affinity for anion resins:

SO42- > NO3- > Cl- > HCO3- > F- > OH-
Mixed Bed Exchanger
Mixed Bed Exchanger
 Water will flow through a column which contain

both strong acidic cation resins and strong base anion
resin to produce high purity water
 Mixed Bed has a definitely capacity whereby resin

exhaustion takes place at the end of service cycle
 Regeneration of mixed bed exchanger by means of

chemical introduction will reactive these resins to
undergo another new cycle of service operation
Service - Exhaustion Cycle
Regenerated Exhaustion Exhausted

Column Column
Regeneration
 At the end of the exchange process, the resin beads

have loaded all cations and anions from the water. At
this stage, the resin beads are Exhausted.
 When the resins are exhausted, regeneration

(reversal of ion exchange process) is done to bring
the resins back to the fresh state.
R’Na + HCl  R’H + NaCl

R’’Cl + NaOH  R’’OH + NaCl
DESIGN BASIS OF
MIXED BED POLISHER
(MBP)
Design Basis
Feed Water Characteristic:

Source: Condensate and BWRO Product
MBP Configuration: (2 Duty, 1 Standby) x 50%
Design Product Flow Rate: 392 m3/h
Operating Pressure: 4 kg/cm2G
Operating Temperature: 40-50 oC
Pressure Drop of MBP System 1.5 kg/cm2G (Approximate)
Treated Water Quality:

pH 7 ±0.3
Conductivity 0.2 µS/cm @ 25oC
Total Dissolved Solids (TDS) 0.1 mg/L
Total Copper as Cu 0.003 mg/L
Total Iron as Fe 0.02 mg/L
Silica as SiO2 0.02 mg/L
Na + K 0.005 mg/L
Cl- 0.02 mg/L
Design Basis
Feed Water Quality ( Condensate & BWRO Permeate):

Parameters Unit Values
Process BWRO Ammonia Utility Average
Condensate Product Turbine/ Turbine/
Steam Steam
Condensate Condensate
Design Flow m3/hr 85.8 160 162.8 31.7
pH 9.0 – 9.4 6.5 – 8.5 9.0 – 9.4 9.0 – 9.4 8.6
Conductivity µS/cm < 25 < 16 < 10 < 10 < 20
Silica mg/L < 0.02 0.0005 < 0.02 < 0.02 0.013
Phosphate as PO4 mg/L 2.7E-07 0
Ammonia as NH3-N mg/L < 10 4.7E-05 <6 <6 4.6
CO2 mg/L < 10 0.10 2.0
CH3OH mg/L < 20 NA 3.9
Calcium mg/L 0.002 0.001
Magnesium mg/L 0.007 0.003
Potassium mg/L 0.05 0.018
Sodium mg/L 0.82 0.30
Total Copper mg/L <0.03 0.01
Sulfate mg/L 0.02 0.008
Bicarbonate mg/L 0.15 0.05
Chloride mg/L 1.31 0.48
Fluoride mg/L <0.001 0.0004
Boron mg/L 0.76 0.28
Nitrate mg/L <0.001 0.0004
Total Iron mg/L - -
Total Dissolved Solids mg/L < 10 < 10
PROCESS FLOW DIAGRAM
&
SYSTEM DESCRIPTION
FOR MBP SYSTEM
Process Flow Diagram
Location of Equipment for MBP System
Neutralization Pump Neutralization

Mixed Bed Polisher Priming Tank Pond
Regeneration
Blower
H2SO4 NaOH
MIXED BED EXCHANGER PHOTO
System Description
MBP Feed Pump

 To supply feed water (BWRO permeate blended with
condensate) into Mixed Bed Polisher
 Configuration: 2 x 100%
Mixed Bed Polisher

 To produce demineralized water which meets required
quality
 Service cycle: 72 hours, total throughput: 14112 m3
 Vessel are made of Carbon Steel Rubber Lined
 Counter current regeneration
Mixed Bed Polisher (MBP)
Service
Inlet
4% Caustic
Inlet
Regen
Outlet
5% Acid
Inlet Service
Outlet
Bottom Nozzle
Plate
Regen Header
Lateral
Regen Header
Lateral
Bottom Nozzle
Plate
System Description: Regeneration Unit
Regeneration Water Pump

 To supply demineralized water for Fast Fill/Final Rinse
during regeneration process
Regeneration Blower
 To supply air for resin mixing (Air Mix I & II) during
regeneration process
 To supply air to Neutralization Pond for mixing & blow out
ammonia gas
Acid/Caustic Ejector
 Concentrated Acid/Caustic is drawn out by Ejector
 Dilute with Demineralized Water before inject into MBP
MBP Regeneration Unit
Diluted
Acid/Caustic
Out
Ejector
Concentrated
Acid/Caustic In
Demineralized
Water In
System Description: Neutralization
System
Neutralization Pond
 All chemical waste in the plant shall be collected in this
Neutralization Pond
 Chemical wastewater shall be neutralized before discharge
 Acid and caustic are feed by gravity flow from Storage
Tank
 Blower air is connected to blow out ammonia
Neutralization Pump
 To transfer neutralized wastewater out from the plant
System Description: Neutralization
System
Acid &
Caustic Bulk
Storage Tank Priming
Tank
OPERATION PHILOSOPHY
OF
MBP SYSTEM
Overview of MBP System
MBP Inlet Flow
Transmitter MBP Strainer
Differential Pressure
Indicator Switch MBP Combine Outlet
pH Analyzer
MBP Combine Outlet
Silica Analyzer
Flow
Flow
Switch
Switch
MBP Outlet Neutralization Pump

Conductivity Analyzer Discharge pH
Analyzer
Operation Parameter
 Mixed Bed Polisher (MBP) in operation: 2 in parallel

 MBP Operation Parameter shall be set:
MBP Feed Pump
is sized for 2
MBP operating
capacity
1. Service throughput: Reference Value to trigger “Exhausted”

alarm.
2. Outlet Conductivity: Reference Value to trigger “Exhausted”
alarm.
3. Quality Rinse Timer: Reference duration for rinsing before
check conductivity
4. Conductivity Check Timer: Reference duration to continue
conductivity check before terminate the MBP operation.
Operation Philosophy: Service
Step 1: Quality Rinse (Rinse into Neutralization Pond)
Dump the water into

Neutralization Pond until pre-
set Quality Rinse timer is up.
Step 2: Quality Rinse (Conductivity Check)
Once Quality Rinse elapsed If conductivity no achieve,

timer is up. Check conductivity remains as this position until
of MBP product water. Conductivity Check Timer is up.
Step 3: Service ( Conductivity below set point)
Conductivity below set point, Service operation is continuous

Demineralized water will be directed to until Exhausted or Off by
Demineralized Water Tank. operator.
Operation Philosophy: Shutdown
 In case of Exhausted condition, MBP will proceed to

shutdown.
Parameter Instrumentations
Service Throughput met pre-set value Detected by FIT-23115 A/B/C
MBP Outlet Conductivity >H Detected by AIT-23112 A/B/C
Note: Operator to initiate Regeneration by either in “Auto” or “Manual”

mode.
Operation Philosophy: Shutdown
Step 1: Stop MBP Feed Pump

Step 2: Close Service Inlet & Outlet Valve All valves are in CLOSE
position.
Operation Philosophy: Regeneration
 Regeneration is required to restore the exhausted resin

back to its proper ionic form for service
 Regenerants: Sulfuric Acid & Caustic Soda
 Before start regeneration, ensure chemicals is above H
level.
H Level: Start Chemical Injection
L Level: Stop Chemical Injection

H2SO4/NaOH (Single Regeneration)
Day Tank
LL Level: Stop Chemical Injection
(Double Regeneration)
Regeneration process is carried out as below sequences:
 Step 1: Backwash
 Step 2: Settle
 Step 3: Chemical In
 Step 4: Slow Rinse
 Step 5: Drain Down
 Step 6: Air Mix I
 Step 7: Air Mix II
 Step 8: Slow Refill
 Step 9: Fast Refill Timing Chart\Appendix_MBE
Timing Chart.pdf
 Step 10: Final Rinse
A complete Single Regeneration take about 3 hours;

Double Regeneration take about 4 hours.
 Double Regeneration means doubles the amount of

chemical is injected for higher recovery of resin to
active state ( New Resin)
 Caustic In & Acid In time should be doubled; but

other step timings are remain unchanged
 Double Regeneration is also preferred in every 15-20

service cycle to boost the performance of the resin
MBP Regeneration Procedures
Start MBP Feed Pump,
if there is no MBP in
Step 1: Backwash service.
Stop MBP Feed Pump when timer
is up (if no MBP in service). All
Step 2: Settle valves in CLOSE position
Step 3: Chemical Injection
Chemical in continue until level

drop to L (Single Regen) or LL
(Double Regen)
Start Regeneration Pump.

Supply demin water to dilute
concentrated Acid/Caustic
Hydrometer: Measure Specific
Gravity
Specific Gravity of 5% H2SO4: 1.03
Specific Gravity of 4% NaOH: 1.04
How to Use Hydrometer:

1. Place test jar on flat surface
2. Fill the test jar with enough liquid to just float the
hydrometer (80% full)
3. Gently lower the hydrometer into the test jar, spin
the hydrometer as you release it
4. Make sure hydrometer do not touching the side of
test jar and it is floating freely
5. Take a reading across the bottom of meniscus
6. Calibrated the reading if required
Step 4: Slow Rinse
Close Conc. NaOH/H2SO4

Valve. Slow Rinse with
Demineralized Water
Open Conc H2SO4 drain valve

after Chemical In is completed.
Stop Regeneration Water
Pump when Slow Rinse step is
Step 5: Drain Down completed.
Open Backwash Out Valve &

Air Vent Out Valve to let air
flow into vessel.
Step 6: Air Mix I
Close Regen
Out Valve
when proceed
Close the Blower Drain Valve to Air Mix 1
before start the Regeneration
Blower.
Step 7: Air Mix II
Open Rinse
Out Valve at
last 1 min to
bring down
water level.
Close when
timer is up.
Remains in close position

when in Air Mix II
Step 8: Slow Refill
Start Regeneration
Water Pump. Refill
with Demineralized
Water
Stop Regeneration Blower when

Air Mix II step is completed.
Open Blower Drain Valve
Step 9: Fast Refill Start MBP Feed

Pump.
Stop Regeneration
Water Pump when slow
refill is completed.
Step 10: Final Rinse Close Air Out Vent valve

after 1 minute delay
If
Conductivity
below set
point:
Regeneration
Completed.
Rinsing is continue until

conductivity drop below set
point or pre-set duration is up.
OPERATION PHILOSOPHY
OF
NEUTRALIZATION
SYSTEM
Operation Philosophy: Neutralization
 Neutralization to be conducted before discharge

wastewater into Final Check Basin.
 Basically, neutralization will happen after regeneration
 Neutralization Process will proceed as:
Part 1 : Ammonia Stripping

Part 2: Neutralization
 Below timer shall be set before start up the system.
Dosing
Duration
Off Dosing
Duration
pH for Ammonia Stripping and Set time of each neutralization

step shall be set before start neutralization process.
Timing
Chart\Appendix_MBE
Timing Chart.pdf
Part 1: Ammonia Stripping
Step 1: Mixing & Air Blow
Regeneration Blower and

Neutralization Pump are
running
Close Regeneration Blower

Drain Valve when Regeneration
Blower is running
Step 2: NaOH Dosing

Start NaOH dosing
to raise pH to 11.5
If pH < H, long dosing time.

If H ≤ pH < HH, short dosing time
Step 3: Air Blow Extension

Stop NaOH
Dosing when pH
of 11.5 is achieved
Air Blow is continue until timer is up.

Step 4: pH Confirmation
Check pH after Air

Blow extension
step is completed.
If pH within range,
proceed to Step 7.
Step 5: H2SO4 Dosing
If pH > HH, long dosing time

If HH ≥ pH > H, short dosing time
Step 6: NaOH Dosing
If pH < LL, long dosing time

If LL ≤ pH < L, short dosing time
Step 7: Discharge
When pH is within range, H ≥ pH ≥ L,

discharge neutralized wastewater to
Final Check Basin
Wastewater discharge is continue until

Neutralization Pond level drop to LL.
Step 7: Discharge
If pH fall out of range during

discharge, repeat from Step 4,
pH confirmation.
Stop Neutralization Pump and Regeneration Blower

when water level is drop to LL. Open Regeneration
Blower Drain Valve when blower is stop
DAILY OPERATION
MONITORING &
MAINTENANCE
FOR MBP SYSTEM
Daily Operation Monitoring
 It is important for operators to follow daily

operation schedule
 Small issue can be detected earlier and

rectification work can be done before problem
develop into major problem
 Ensure proper operation of plant to achieve

performance
 Instrument data or trending should be checked

if abnormal reading/trend is found
Daily Operation Monitoring
Parameter Instrumentation Action/Remark
MBP Strainer DPIS-2114 A/B/C An indication as strainer

Differential Pressure cleaning is required.
MBP Inlet Flow FIT-23115 A/B/C Record the total service
throughput of MBP and
indication where MBP is
deemed to be Exhausted.
MBP Outlet Conductivity AIT-23112 A/B/C Indication that MBP is
exhausted. Regeneration is
required.
MBP Combine Outlet pH AIT-23122 A/B/C To confirm water quality of
demineralized water meet
quality
MBP Combine Outlet AIT-23123 A/B/C To confirm water quality of
Silica demineralized water meet
quality
Note: For others parameter, please refer to Alarm Set Point List for details.
START UP OF
MBP & NEUTRALIZATION
SYSTEM
Start-up Sequences
Chemical Storage & Dosing System
 Ensure sufficient chemical in NaOH Bulk Tank &

H2SO4 Bulk Tank
 Top up chemical into NaOH Day Tank (MBP) and

H2SO4 Day Tank (MBP) until H level
 Determine the consumption of chemical required

Chemical Dosage
NaOH for MBP Regeneration 430 L per regeneration (Single)
860 L per regeneration (Double)
H2SO4 for MBP 296 L per regeneration (Single)
Regeneration 592 L per regeneration (Double)
NaOH for Neutralization Subject to pH of wastewater
H2SO4 for Neutralization Subject to pH of wastewater
Resin Loading Procedures
Fill up with Feed
Water if Demin
 Polished (demineralized) water to be used for resin water is not
available
loading and regeneration
 Resin Loading Procedures executed as below:
Open Air Mix I

Fill valve and start
demineralized Regeneration
water into vessel Blower. Check
to about 300 mm resin movement
depth. of each nozzle.
Check that
bottom nozzles Add sufficient Replace nozzle
are properly cation resin to if necessary.
tightened cover the nozzle.
Check nozzle at
Drain the excess regen header.
water.
Observe header
pipe is level.
Replace Top
Open Backwash In
Add 90% of manhole cover.
Valve and boost
Cation Resin resin bed until
(about 4000L) reach top of Allow cation resin
through top middle sight glass. to soak for 6
manhole into hours.
vessel.
Close valve
quickly and let Start backwash
During filling, resin bed settle. and adjust
water level shall backwash flow
keep of 500 mm until resin can be
above resin. Drain water until
seen from upper
100 mm above
sight glass.
resin level.
Drain water until
100 mm above Inspect backwash
resin level Repeat for 3 to 5
wastewater
times.
sample.
If Demin Water is not
available, shall produce
sufficient cationize water
before load anion resin
Check cation level

shall be 10 to 15 mm
below the nozzle.
Fill up the vessel
with feed water until
Repeat backwash if
water is overflow
necessary
out.
Drain excess water Proceed to Start –

Open rinse outlet
to 500 mm above up Regeneration
valve and allow
cation resin level. (Double
rinse for 10 minutes.
Regeneration)
Add designed
Allow to soak for 6
volume of Anion
hours.
Resin.
Proceed to Rinse
MBP Start-up Procedures
Before Start-up Regeneration, ensure that:

 Sufficient demineralized water or cationized water in
Polished Water Tank
 H level of chemical in NaoH Day Tank (MBP) (2311-
L1F) and H2SO4 Day Tank (MBP) (2311-L2F)
 Neutralization Pond (2311-L1F) is ready to receive
regeneration wastewater
 Ensure all the manual isolation valves and
instrument isolation valves along the flow paths are
opened
1. At the HMI, select “AUTO” mode for below equipment:
 All On-Off Valves corresponding to MBP system
 MBP Feed Pump (2302-J/JA)
 Regeneration Water Pump (2311-L2J/JA)
 Regeneration Blower (2311-L1J/JA)
2. Select MB to “Regeneration” under “Auto” mode. Skip the

“Backwash” step as new resin are used. New resin tend to form
agglomerates in resin bed.
3. Regeneration process shall be started from “Chemical In” step.

Regulate valves at chemical dilution station to get required dilute
chemical.
4. Check concentration of diluted chemical.
5. Adjust Drain timing to ensure water level is 25 to 80 mm above resin.

Update the time on Timing Chart.
6. Observe through sight glass to ensure resin is properly mixed.

Extend Air Mix 1 & II timing if required.
7. After Slow Refill, ensure that the water level is at least 500 mm
above resin level.
8. Check the time start from Fast Refill until water is overflow out
from air out line. Update the Fast Refill timing in timing chart.
9. Final Rinse is continued until conductivity goes below set point.
10. Mark the resin level on sight glass for further reference.
Upon completion of Start-up Regeneration, select MBP into “Service” under

“Manual” mode. Select “Start” to initiate the service.
Service operation shall be proceeded. Check for any abnormalities.

Continue until all operating parameter reading are stable.
Neutralization System Start-up
Procedures
1. Before Start-up Neutralization, ensure that:
 Sufficient chemical in NaOH Bulk Tank and H2SO4 Bulk
Tank
 Ensure all the manual isolation valves and instrument
isolation valves along the flow paths are opened
2. At the HMI, select “AUTO” mode for below equipment:

 All On-Off Valves corresponding to Neutralization system
 Neutralization Pump (2311-L3J/JA)
 Regeneration Water Pump (2311-L2J/JA)
 Regeneration Blower (2311-L1J/JA)
3. Select Neutralization System to “Operation” under

“Manual” mode. Select “Start” to initiate the service.
Neutralization System Start-up
Procedures
4. Neutralization process shall be started from Ammonia
Stripping followed by Neutralization.
5. Operation shall be continued. Check for any abnormalities.
6. Determine the optimum pH for Ammonia stripping where

most ammonium hydroxide ions convert to ammonia gas.
7. Determine the optimum duration for long dosage and short

dosage.
SHUT DOWN OF
SYSTEM
MBP Shutdown Procedures
1. From the HMI, select “Off” to shutdown MBP form service.
2. At MCC, switch to “Off” mode for all the motor that are stopped
to prevent accidental start during shutdown maintenance.
3. Check all pressure gauges. If some point is still pressurized,

open the sampling/vent/drain valve along the line to release
pressure.
4. Close all isolation valves.

Neutralization System Shutdown
Procedures
1. From the HMI, select “Off” to shutdown Neutralization
System form service.
2. At MCC, switch to “Off” mode for all the motor that are
stopped to prevent accidental start during shutdown
maintenance.

pressure.

Shutdown Recommendation:
Unloading of Resin
1. From the HMI, select “Off” to shutdown MBP form service.
3. Drain down the water fully from vessel.
4. Connect resin unloading nozzle to filter bag.
5. Connect service water supply to top nozzle. With the aid of

water, resin will be flushed out.
6. Disposal of resin shall be arranged.

Shutdown Recommendation:
Storage of Resin
 Long Time Shutdown:
1. Flushing of Mixed Bed at daily basis & conduct
regeneration at monthly basis
2. After long shutdown:

 Drain off the soaking solution
 Backwash the resin bed
 Carry out double regeneration of resin
 Short Time Shutdown: Flush for 30 minutes every 3 days.

SHUT DOWN OF
CHEMICAL STORAGE &
DOSING SYSTEM
Shutdown Procedures
1. At MCC, switch to “Off” mode for all the motor that are
stopped to prevent accidental start during shutdown
maintenance.

pressure.
4. For Shutdown of more than 7 days, drain away the following

chemicals.
 SBS Storage Tank (2301-L9F)
 NaOCl Storage Tank (2301-L7F)
5. Concentrated chemical can be kept as its original condition.

TROUBLESHOOTING
OF
SYSTEM
Troubleshooting: MBP
Table below shows the common problems with trouble shooting

guide for Mixed Bed Polisher System
Problem Possible Causes Solutions
Increase of TDS in feed water  Analyze influent water

 Check pretreament
Loss of anion resin during  Reduce backwash flow rate
backwash  Top up resin
Loss of cation resin during  check the interface piping
Reduced throughput rinse or service and bottom nozzles
Channeling along resin bed  Reduce service flowrate
Resin dirty of excessive  Adjust backwash time or

pressure drop across vessel flow rate
Regenerant concentration and  Check regenerant flow rate
quantity and time
Poor Quality Effluent Anion leakage.  Check influent ionic load
with low pH and regeneration
Poor Quality Effluent Cation leakage.  Check influent ionic load
with high pH and regeneration
Troubleshooting: MBP

guide for Mixed Bed Polisher System
Valve partially close  Check and readjust valve if

necessary
Flowrate too high  Reduce flowrate
Excessive pressure Resin Fouling.  Check upstream

drop across the pretreatment
vessel Internal distributor blockage  Inspect and clean or replace
Resin fines  Remove by backwash
Resin decrosslink  Replace resin if necessary

Troubleshooting: Neutralization
System
guide for Neutralization System
Faulty Valve  Check and readjust valve if

necessary
Inefficient mixing  Check blower is functioning
Long Neutralization well
Time  Check perforated pipe is not
blocked
Dosing time setting is not  Adjust chemical dosing time
optimized
For Equipment Troubleshooting, shall refer to its

Operation Manual.
SAFETY PRECAUTION
Safety Precaution
IN USING ANY CHEMICALS, FOLLOW ACCEPTED SAFETY

PRACTICES. ALWAYS WEAR EYE PROTECTION AS
MINIMUM, IN CASE OF HANDLING CORROSIVE
CHEMICALS, WEAR FULL FACE COVER AND PROTECTIVE
CLOTHING. REFER TO RELEVANT MATERIAL SAFETY
DATA SHEETS AS SUPPLIED BY CHEMICALS
MANUFACTURERS.
BEFORE DRAINING ANY CHEMICALS FROM STORAGE

TANKS, RUN SERVICE WATER TO THE CHEMICAL DRAIN
POINT. SLOWLY OPEN THE CHEMICAL DRAIN VALVE AND
FLUSH GENEROUSLY WITH SERVICE WATER.
Safety Precaution
ALWAYS WEAR SAFETY HELEMT AND BOOSTS

AT ALL TIME WITHIN PLANT AREA
QUESTIONS ??
QUIZ
Quiz: MBP & Neutralization
1. Under Service “Auto” mode, how many unit of MBP are

operating in parallel?
2. What does the Mixed Bed Exchanger contain?
3. How to know the Mixed Bed is “Exhausted”?
4. When resin bed is exhausted, how to restore it back to fresh

state?
5. What is the difference between Regeneration & Double
Regeneration.
6. What is the step before MBP go into service?
7. If MBP Combine Outlet silica value is continuous high, what

should operator do.
8. Neutralization is split into 2 section. What are they?
9. Under what conditions, blower drain valve is opened?

THANK YOU

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BANGGAI AMMONIA PLANT (BAP) PROJECT Boustead Salcon Water Solutions

 Ion exchange is the reversible exchange of ions

Two major resin groups:

Cation resin Anion resin

2 R’H + Ca++  R’2Ca + 2 H+

Decationization (All cations replaced by H+)

2 R’’OH + SO4  R’’2SO4 + 2 OH-

 H+ and OH- ions released from resins combine to

 For ion exchange to be effective, there must be a

 Order of affinity for cation resins:

 Order of affinity for anion resins:

 Water will flow through a column which contain

 Mixed Bed has a definitely capacity whereby resin

 Regeneration of mixed bed exchanger by means of

Regenerated Exhaustion Exhausted

 At the end of the exchange process, the resin beads

 When the resins are exhausted, regeneration

R’Na + HCl  R’H + NaCl

Feed Water Characteristic:

Treated Water Quality:

Feed Water Quality ( Condensate & BWRO Permeate):

Neutralization Pump Neutralization

MBP Feed Pump

Mixed Bed Polisher

Regeneration Water Pump

MBP Outlet Neutralization Pump

 Mixed Bed Polisher (MBP) in operation: 2 in parallel

1. Service throughput: Reference Value to trigger “Exhausted”

Step 1: Quality Rinse (Rinse into Neutralization Pond)

Dump the water into

Step 2: Quality Rinse (Conductivity Check)

Once Quality Rinse elapsed If conductivity no achieve,

Step 3: Service ( Conductivity below set point)

Conductivity below set point, Service operation is continuous

 In case of Exhausted condition, MBP will proceed to

MBP Outlet Conductivity >H Detected by AIT-23112 A/B/C

Note: Operator to initiate Regeneration by either in “Auto” or “Manual”

Step 1: Stop MBP Feed Pump

 Regeneration is required to restore the exhausted resin

H Level: Start Chemical Injection

L Level: Stop Chemical Injection

Regeneration process is carried out as below sequences:

A complete Single Regeneration take about 3 hours;

 Double Regeneration means doubles the amount of

 Caustic In & Acid In time should be doubled; but

 Double Regeneration is also preferred in every 15-20

Step 3: Chemical Injection

Chemical in continue until level

Start Regeneration Pump.

How to Use Hydrometer:

Step 4: Slow Rinse

Close Conc. NaOH/H2SO4

Open Conc H2SO4 drain valve

Open Backwash Out Valve &

Step 6: Air Mix I

Step 7: Air Mix II

Remains in close position

Step 8: Slow Refill

Stop Regeneration Blower when

Step 9: Fast Refill Start MBP Feed

Step 10: Final Rinse Close Air Out Vent valve

Rinsing is continue until

 Neutralization to be conducted before discharge