DEMINERALISATION PLANT

DM PLANT

WATER TREATMENT
Introduction:- The natural water contains solid, liquid and gaseous impurities and therefore, this water cannot be used for the generation of steam in the boilers. Impurities in water:1. Undissolved and suspended solid 2. Dissolved salt and minerals 3. Dissolved gases 4. Others materials oil and acids
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Undissolved and suspended solid

Turbidity and Sediment:- Turbidity in the water is suspended insoluble matter including coarse particle (mud, sediment, sand etc.) that settle rapidly on standing. Amount range from almost zero in most ground water and 60000 ppm in muddy and turbulent river water. The turbidity of feed water should not exceed 5 ppm. These materials can be removed by settling, coagulation and filtration. their presence is undesirable because heating or evaporation produces hard stony scale deposits in the heating surface & clog fluid system. A standard amount measurement of hardness is taken as being the amount of Calcium Carbonate(CaCO3) in the water and is referred to in part per million (ppm). Sodium and Potassium salts:- These are extremely soluble in water and do not deposit unless highly concentrated. Their presence is troublesome as they are alkaline in nature and accelerate the corrosion. Chlorides:- Majority of the chlorides cause increased corrosive action of water. Iron:- most common soluble iron in water is ferrous bicarbonate. The water containing ferrous bicarbonate deposits becomes yellowish and reddish sediment of ferric hydroxide if exposed to air. Majority of ground water contains less than 5 ppm but even 0.3 ppm can create trouble in the feed water system by soft scale formation and accelerating the corrosion. Manganese:- It also occurs in similar form as Iron and it is also equally troublesome. Silica:- Most natural water contains silica ranging from 1 to 100 ppm. Its presence is highly objectionable as it forms very hard scale in boilers and forms insoluble deposits on turbine blades. In modern high pressure boilers its presence is reduced as low as 10 -15 ppb. Microbiological growth:- Various growth occurs in surface water. The micro- organism include diatoms, molds, bacterial slimes, algae, manganese & sulphate reducing bacteria and many others. These can cause coating on heat exchanger and clog the flow passage and reduce the heat transfer rates. Colour:- Surface water form swampy areas become highly colored due to decaying vegetation. Color of feed water is objectionable as it causes foaming in boilers and may interfere with treatment processes. It is generally removed by chlorination or adsorption by activated carbon. 3

Dissolved salt and minerals

Calcium and Magnesium Salts:- The calcium and Magnesium salts in the water in the form of carbonates, bicarbonates, and sulphates and chlorides. The presence of these salts is recognized by the hardness of the water. The hardness of the water is classified as temporary and permanent hardness. The temporary hardness is caused by the bicarbonates of Calcium and Magnesium and can be removed by boiling. The boiling converts the soluble bicarbonates into less soluble carbonates which can be removed by simple blow down method. The permanent hardness of the water is caused by the presence of chlorides, sulphtes and nitrates of calcium and magnesium and they can not be removed just by boiling because they form a hard scale on heating surfaces. Others:-Any salt which dissolved in water solids into positively charged Cations and negatively charged Anion and since these permits to conduct electricity, these salts are called electrolytes. Some of the most common Cations are Ca, Mg, Na and Fe and rarely ammonium manganese. This Cations are associated with Anions like Bicarbonates, carbonates, Hydroxides ( the sum of which is termed as alkalinity), sulphates and Chlorides. Presence of nitrates and phosphates is normally not very common. In the water treatment field, the preferred method of expression of these dissolved impurities is in terms of Equivalent Calcium carbonate, abbreviated to as CaCO3. This is because CaCO3 is a good common denominator as it has a molecular weight of 100, which facilitates calculation, temperature and pressures.
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Dissolved gases
Oxygen :- It is present in surface water in dissolved form with variable percentage depending upon the water temperature and other solid contents in water. Its presence is highly objectionable as it is corrosive to iron, Zinc, brass and other metals. It causes corrosion and pitting of water lines, boiler exchanger. Its effect is further accelerated at high temperatures. Carbon dioxide:- The river water contains 50 ppm and well contain 2 to 50 ppm of CO2 . it also causes the corrosion of stream, water and condensate lines. It also helps to accelerate the corrosion action of oxygen. The other gases are H2 S, CH4 ,N2 and many others but their percentages are negligible, therefore, their effects are not discussed here.
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Others materials oil and acids

Free mineral acid:- Usually present as sulfuric or hydrochloric acid and causes corrosion. The presence is reduced by neutralization with alkalies. Oil :- Generally, the lubricating oil is carried with steam into the condenser and through the feed system to the boiler. It causes sludge, scale and foaming in boilers. It is generally removed by strainers and baffle separators.
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Terminology
Total alkalinity or M- Alkalinity:- Alkalinity to methyl Orange indicator P Alkalinity:-Alkalinity to phenolphthalein indicator EMA:- The equivalent Mineral acidity a measure of the natural salt ( Chloride+sulphate+Nitrate) content of raw water. The test for FMA gives a check on the operating action of SAC unit. Rinsing should be stopped when the FMA is 10% to 15% higher than EMA. Whenever Sulfuric acid is used as regenerant, effluent contains the sulphates of Ca, Mg & Na. calcium sulphate has a low solubility and precipitation may occur in the resin bed. The capacity is proportional to the Total Cation content of the raw water. TC= M alkalinity+EMA or( ALK+ Cl,SO4 & No3) 1 ppm of NaOH in the SBA outlet water results in conductivity of 6 mS/cm and a Ph of more than 8.3. The P alkalinity figure will give the sodium slip. Silica being a weak acid in less easily removed than mineral acids. TA= EMA+M ALK+free Co2 or EMA+Silica+6 ppm CO2 . If the cation exchange resin exhaust first, the treated water conductivity will rise. At exhaustion of the Cation resin the treated water Ph will increase. If the anion resin exhaust s first , the treated water Ph will decrease.
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ACTIVATED CARBON FILTER

It is mild steel vessel painted with epoxy based paint. Bell mouth type single arm distributor is provided for inlet. Bottom collecting system is of header lateral type. Header is of mild steel and screwed with PVC laterals. Small holes are drilled throughout the lateral. Bottom dish end filled with concrete. Different layers of under bed material charged to prevent carbon leak. Each layer consist of different sizes of pebbles with bigger size at the bottom most and fine silex on top. 1 to 1 pebbles 100 mm to 1/4 pebbles 100 mm 3/8 to 1/8 pebbles 100 mm to 1/10 crushed gravel 100 mm Activated carbon 1250 mm Regeneration is done two stages Backwash Flow rate 62 m/hr. Rinse Flow rate 90 m/hr.

 This is mild steel vessel lined internally with rubber. A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows. The middle and bottom collecting system are of header lateral type. The header is of mild steel rubber lined and rubber covered to which PVC lateral are fitted. Strainers which prevent resin from escaping are screwed to the bottom of the laterals. Mark V strainers have been used for bottom collecting system whereas mark 801 strainers for middle collector. Bottom dished portion is filled with concrete. The vessel is charged with strongly cationic resin (INDION 225). Indion 225 is in a bead form and is a cross linked polymer )Polystyrene Divinyl Benzene). When the quality of outlet water from SAC with respect to Sodium ions is deteriorated, then the unit should be regenerated. Backwash:- Backwash operation is carried out to loosen bed and to remove the suspended impurities from the resin. Backwash operation is carried out once in 7 regeneration or when pressure drop across the unit increases beyond acceptable limits of 0.5 kg/cm whichever occurs earlier. When backwash is given, double quantity of acid is to be injected to ensure bottom layer of resin is highly regenerated. Flow- 55M/Hr)
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DM STRONG ACID CATION

DM STRONG ACID CATION

Sub surface Wash:- The sub surface wash is carried out for each regeneration. Flow- 55M/Hr and for 5 minutes) Acid Pre Injection:-This stage is carried out to set the power water flow and down flow to the required conditions before injecting acid. Injection rate 27.2 m/hr and down flow is 32.7 m/hr for 5 minutes. Acid Injection/ Buffer Down flow:-HCL acid of 5% concentration is injected at total flow of 32.7m/hr into SAC, by means of Ejector. The acid is injected thorough SAC bottom collecting system and effluent is taken out through middle collector to drain sump. During injection to prevent fluidization of SAC bed, a down flow of 32.7 M/hr water is maintained. Up rinse/Displacement:- The excess acid in SAC unit after acid injection is taken out by allowing the water to flow at 27.2 m/hr for 30 minutes. with down flow of 32.7 m/hr. Final Rinse:- This operation is carried out to remove excess acid and librated cations from SAC unit. The operation is carried out for 5 minutes.
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DM SAC REGENERATION
Step DM ACF Flow rate m/hr Inject flow m/hr Time Min.

Backwash Rinse DM SAC Backwash (optional) M/C flush Acid pre injection Acid Injection Acid Displacement 1 Acid Displacement 2 Rinse

55 90 55 55 32.7 32.7 32.7 54.4 90

10 2 10 5 2 20 30 22 10

27.2 32.7 27.2 54.4

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DEGASSIFIER
Degassifier operation is carried out to eliminate free carbon dioxide in decationised water by giving a forced draft of air by means of fan blowers at 55 mm WC. CO2 free water is then collected in degassed water tank and pumped to anion units.

Dia / Height Media

1.4*3.5

Pall ring of 50mm*500mm (HDPE)

Quantity 3 m

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 This is mild steel vessel lined internally with rubber. A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows. The water is distributed from the top inlet strainer assembly with SS mesh fixed on it to prevent resin carry over during backwash stage. Alkali distributor is provided with three arms with inverted bends with PVC spacers and blank flange for proper distribution of regenerant during regeneration. Bottom collecting system of WBA is of header and lateral type. It consists of mild steel rubber lined and rubber covered header into which PVC laterals with mark 79 strainers are fitted. The vessel is charged with Anion resin ( INDION 850).The regeneration of unit is done in thoroughfare with SBA. The outlet water is free of Free Mineral Acidity with only silica and negligible quantity of chloride present in it.
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WEAK BASE ANION

 This is mild steel vessel lined internally with rubber. A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows. The water is distributed from the top inlet strainer assembly with SS mesh fixed on it to prevent resin carry over during backwash stage. Regeneration inlet nozzle is provided mild steel rubber lined/ rubber cover bend with blank flange and spacer at the end to distribute the regenerant evenly on the resin bed. Bottom collecting system of SBA is of header and lateral type. It consists of mild steel rubber lined and rubber covered header into which PVC laterals with mark V strainers are fitted. The vessel is charged with strongly base Anion resin ( INDION FFIP) when the desired output from the pair of WBA & SBA is obtained or when the quality of treated water from SBA outlet with respect to silica is deteriorated then the unit should be regenerated in through fare with SBA using NaOH as regenerant

STRONG BASE ANION

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STRONG BASE ANION

SBA Backwash:- Flow 11.4 m/hr for 15 minutes WBA Backwash:- Flow 11.4 m/hr for 10 minutes Alkali Pre Injection:- This operation is carried out to set the power water flow rate before injecting alkali. Flow rate is 18.7 m/hr in WBA and 9.3 m/hr in SBA unit for 2 minutes. Alkali Injection:- 4% caustic solution at flow rate of 11.2 m/hr is injected in SBA unit for 30 minutes by means of primary and secondary ejector. Alkali Displacement :- The unused alkali in SBA unit after caustic injection is transferred to WBA with help of ejector (Through fare). Flow rate is 30m/hr for 30 minutes. Rinse :- This operation is carried out to remove excess caustic and librated anions from both SBA & WBA units. The operation is carried out simultaneously but independently. WBA unit is rinsed at 44 m/hr for 40 minutes while SBA at 27 m/hr for 54 minutes.

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WBA SBA REGENERATION

Operation SBA Backwash WBA SBA 11.4 Time 5

WBA Backwash
Caustic pre injection Caustic injection

17.1
18.7 22.5 9.3 11.2

5
2 20

Caustic Displacement
WBA Rinse SBA Rinse

18.7
44

9.3
27

18
40 54
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CONDENSATE TREATMENT
Urea and Ammonia process condensate is collected in a buffer tank and then passed through activated carbon filter and strong acid cation unit. The treated condensate is passed through the Degassifier tower and collected in DM water storage tank which is further polished with mixed bed units along with the turbine condensate and DM water. The condensate from turbine which is normally clean is filtered by micron cartridge and polished with mixed bed units. TC:- Micro cartridge filter 3 No's Capacity 120m/hr This condensate may be lined up in DM /PW tank on quality. APC/UPC :- CPU A/B Capacity 125m/hr Mixed bed:- MB A/B/C/D Capacity 170 m/hr
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DM 2 FEED WATER ANALYSIS

Parameter Turbidity NH3 Methanol
Urea CO2 Oil/Grease Fe Flow Temp.

APC 1 NTU 40 ppm 80 ppm

Nil 40 ppm Nil 1 ppm 114 m/Hr 41C

UPC 1 20 Nil
20 20 Nil Nil 98.4 45

SC Nil 4 Nil
Nil Nil Nil Nil 60 52

TC Nil 4 Nil
Nil Nil Nil Nil 260 52

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DM 2 Outlet Quality
Parameter Oil Turbidity Fe NTU ppm Unit CPU Nil 1 0.02 MB Nil Nil 0.01

Conductivity
SiO2 NH3 ppm ppm

5
NA NA

0.2
0.02 Nil
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 It is mild steel vessel painted with epoxy based paint. Bell mouth type single arm distributor is provided for inlet. Bottom collecting system is of header lateral type. Header is of mild steel painted externally and internally with epoxy and screwed with PVC laterals. Small holes are drilled throughout the lateral. Bottom dish end filled with concrete. Different layers of under bed material charged to prevent carbon leak. Each layer consist of different sizes of pebbles with bigger size at the bottom most and fine silex on top. 1 to 1 pebbles 100 mm to 1/4 pebbles 100 mm 3/8 to 1/8 pebbles 100 mm to 1/10 crushed gravel 100 mm Activated carbon 1250 mm Regeneration is done two stages Backwash Flow rate 72 m/hr. Rinse Flow rate 72 m/hr.

CPU ACF

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 This is mild steel vessel lined internally with rubber. A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows. The middle and bottom collecting system are of header lateral type. The header is of mild steel rubber lined and rubber covered to which PVC lateral are fitted. Strainers which prevent resin from escaping are screwed to the bottom of the laterals. Mark V strainers have been used for bottom collecting system whereas mark 801 strainers for middle collector. Bottom dished portion is filled with concrete. The vessel is charged with strongly cationic resin (INDION 225). Indion 225 is in a bead form and is a cross linked polymer )Polystyrene Divinyl Benzene). When the quality of outlet water from SAC with respect to Sodium ions is deteriorated, then the unit should be regenerated. Backwash:- Backwash operation is carried out to loosen bed and to remove the suspended impurities from the resin. Backwash operation is carried out once in 7 regeneration or when pressure drop across the unit increases beyond acceptable limits of 0.5 kg/cm whichever occurs earlier. When backwash is given, double quantity of acid is to be injected to ensure bottom layer of resin is highly regenerated. Flow- 55M/Hr)
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CPU SAC

CPU SAC
Sub surface Wash:- The sub surface wash is carried out for each regeneration. Flow- 55M/Hr and for 5 minutes) Acid Pre Injection:-This stage is carried out to set the power water flow and down flow to the required conditions before injecting acid. Injection rate 30 m/hr and down flow is 32.7 m/hr for 2 minutes. Acid Injection/ Buffer Down flow:-HCL acid of 5% concentration is injected at total flow of 17.4m/hr into SAC, by means of Ejector. The acid is injected thorough SAC bottom collecting system and effluent is taken out through middle collector to drain sump. During injection to prevent fluidization of SAC bed, a down flow of 17.4 M/hr water is maintained.(20 minutes) Up rinse/Displacement:- The excess acid in SAC unit after acid injection is taken out by allowing the water to flow at 14.5m/hr for 30 minutes. with down flow of 17.4 m/hr. Final Rinse:- This operation is carried out to remove excess acid and librated cations from SAC unit. The operation is carried out for 5 minutes.

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DM 1 CPU SAC REGENERATION

Operation Backwash M/C flush Acid Pre injection Acid injection Flow 34 34 17.4 17.4 14.5 17.4 Inject flow Time 10 5 2 20

Acid Displacement 1
Acid Displacement 2 Rinse

17.4
29 136

14.5
29

30
22 5
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DM 2 CPU SAC 1/2

Step Backwash Flow 56 m/hr injection NA Time 10 minute

Middle collector flushing

Settle Bed Power water Acid injection Acid Rinse Settle bed Fast Rinse

56
NA 31.8m/hr 31.8m/hr 31.8m/hr NA 165m/hr

NA
NA 26.5m/hr 26.5m/hr 26.5m/hr NA NA

2
2 2 20 25 2 20
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Pre-requisites to start CPU SAC regeneration

Select ACF 1/2 in auto service from key board PCP 1/2 any one selected in auto PDG 1/2 any one selected in auto VA 2 of SAC is closed MHL-1A/B is full MHL-1A/B tank is selected Select regeneration operation in auto mode Select SAC program from the CRT keyboard Select SAC-1or 2 in regeneration mode from CRT key board
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MICRO CARTIDGE FILTER

Number off Model Max/Min flow Pr drop in Min/max Filter type No of Cartridge per filter Degree of filtration 3 Cuno 10 micron 120/72.5 m/hr 0.5/1.5 kg/cm Micro wynd polypropylene 30 10 microns

Material of construction MS (Epoxy painted)

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Mixed Bed
This is mild steel vessel lined internally with rubber. A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows. The middle and bottom collecting system are of header lateral type. The header is of mild steel rubber lined and rubber covered to which PVC lateral are fitted. Strainers which prevent resin from escaping are screwed to the bottom of the laterals. Mark V strainers have been used for bottom collecting system whereas mark 801 strainers for middle collector. Inlet water distributor is of three arms with strainers to avoid escape of resin during backwashing. Bottom dished portion is filled with concrete. The vessel is charged with strongly cationic resin (INDION 225) and strongly basic anion (FFIP). Cation resin is regenerated with HCL and anion resin with NaOH. Backwash:- This operation is carried out to separate the resin prior to injection of chemicals. Due to difference in densities, the resin get separated in two layers during the backwashing, with cation forming layer and anion forming layer.(10 minutes Subsurface Wash:- This operation is carried out to clean the middle collector strainers to ensure proper distribution / collection during injection of chemicals. (2 minutes
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Caustic pre injection:-water flow for caustic injection is established through alkali ejector. Simultaneously water is fed to the unit through bottom collecting system. The effluent is taken out through middle collector system. This ensure minimum diffusion of caustic into cation resin. (2 minutes Caustic injection:- Once the pre injection flows are established the 5 % alkali solution from the CDT is passed through anion resin by opening ejector suction valve.(15 minutes Caustic Rinse / Up flow:- After completion of the caustic injection water is continued to pass to displace / fully utilize the regenerants from pipe works and also through the resin bed. Acid Pre injection:- Water flow for acid injection is established through acid ejector. Simultaneously water is fed from inlet and effluent taken out from bottom collecting system. Acid injection / Down flow:- Once the pre injection flows are established the 5 % acid solution from the ADT is passed through cation resin by opening ejector suction valve.( 10 minutes Acid Rinse:- After completion of the acid injection water is continued to pass to displace / fully utilize the regenerants from pipe works and also through the resin bed. Drain Down:- Water from the vessel is drained up to about 300 mm above the top surface of resin bed( approx half of top inspection window.) 10 minutes Air Mix :- Air is passed from the bottom of the unit to mix the individual resin thoroughly. The mixing and movement of the resin bed can be observed through inspection windows. (10 minutes) Final rinse :- DM water is taken from inlet and drained from the rinse outlet for specified time to remove excess regenerants from the bed.. The unit is rinsed partially during this operation. Rinse to Recycle:- To avoid wastage of water the rinsing is completed by recycling the water back to DMT till the acceptable treated water quality is achieved.
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MIXED BED

DM 1 MB REGENERATION
Operation Backwash M/C Flush Flow Inject flow Time 10 2

m/hr
34.2 15.2

m/hr

Acid Pre injection

Acid injection Acid Displacement Caustic Pre injection Caustic injection

5.7
5.7 5.7 17.1 17.1

19
22.8 19.5 21.6 26

1
10 15 1 15

Caustic Displacement
Drain down Air Mix Final Rinse Rinse to Recycle

17.1
456 170 170

45.6

20
5 10 10 20
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DM 2 MB Regeneration
Step Middle collector flushing

Flow m/hr
35

Injection

Time 2

m/hr
NA

Backwash
Settle bed Power water Alkali injection Alkali slow rinse Settle bed Acid power water Acid injection Acid slow rinse

35
NA 20.8 20.8 20.8 Na 9 9 9

Na
Na 17.4 17.4 17.4 NA 10 10 10

10
2 2 15 15 2 2 15 15

Drain Down
Drain down cont. Air Mixing Refill Fast Rinse

NA
NA NA NA 176

NA
NA NA NA NA

4
1 10 2 10 30

Pre-requisites to start MB regeneration

MAK tank is full MHL-2 tank is full VA-2 of MB is closed PDM 1/2/3/4 selected in auto PDG 1/2 selected in auto BMB 1/2 selected in auto Select regeneration in Auto mode Select MB program from CRT key board Select particular MB in regeneration mode
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Air scour & Open manhole backwash

Open the manhole Drain water till level is about 300 mm above the resin bed Insert the air hose halfway into resin bed Start air scoring throughout the resin Continue operation for 15 minutes. Give backwash Drain the vessel Scrape off 6 mm layer from the top of the resin bed and discard this. Close the manhole cover.
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Alkaline Brine Treatment of WBA/SBA

Prepare solution of 10% NaCl and 2% NaOH making 3 bed volume of WBA and SBA resin Backwash the unit thoroughly and the alkali brine prepared was injected into SBA, letting the effluent coming out of SBA drain outlet. After 10 minutes the brine is injected into WBA thoroughfare SBAs without any power water and the effluent will come out from WBA and is drained. One bed volume is let to pass through SBA and WBA. Second bed volume of brine solution is allowed to pass through both SBA & WBA units and when the units are full with solution , the injection is stopped and allowed to soak for 12 hours. After soaking the units, drain down the vessels and final part of the brine solution is injected through both SBA &WBA. After completing injection both units were rinsed at normal rinse flow rate till the chlorides in the effluent are nil. Then the units WBA/SBA were given double regeneration.
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Alkaline Brine Treatment of MB

Prepare solution of 10% NaCl and 2% NaOH making 3 bed volume of MB resin First the MB unit was backwashed and first batch was injected through alkali inlet distribution header letting the effluent to come out through rinse outlet (VA6) The second batch of brine solution is again injected into the MB unit and is allowed to soak for12 hours. After soaking the unit , the vessel is drained out and the final batch of brine solution is injected. After that the unit should be rinsed thoroughly till the effluent coming out contains nil chloride. The MB unit was then given a double regeneration with double quantities of regenerant chemicals.
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