DM & PT PLANT

DEMINERALISING PLANT
1 INTRODUCTION

1.1 PLANT CAPACITY & SALIENT FEATURES

The plant was designed to supply 55 m3/hr polished water. The potable water is supplied to the power station and colony whereas the polished water is consumed in boilers to produce steam (for power generation). The plant comprises of two chains in demineralization and 3 pressure vessels for potable water production section. There is a clarified water tank common to both sections. From the clarified water tank, water is pumped by (2+1) Pumps to potable water filters. After filtration, the water is supplied for use as potable water. From the same tank, water is fed to DM water pressure filters, active carbon filters, cation exchangers and degasser by means of (2+1) clarified water pumps. After degasification, the water is pumped to weak base anion, strong base anion; and mixed bed exchangers units working in series. After achieving the designed quality, the polished water is stored in DM water tanks, from where it is drawn for use in waste heat recovery boilers. Small amount of polished water is used for internal consumption in DM water plant i.e., regeneration in DM plant.

1.2 WATER QUALITY

(a) Feed Water Quality : The plant is designed on the following water compositions:

Turbidity pH Sodium & Potassium Calcium Magnesium Total Cations Sulphate Bicarbonates Chlorides Total Anions Iron Silica Residual Chlorine Oraganic Matter

: : : : : : : : : : : : : :

30 NTU 7.3 to 8.0 120 ppm as CaCO3 118 ppm as CaCO3 55 ppm as CaCO3 293 ppm as CaCO3 92 ppm as CaCO3 166 ppm as CaCO3 35 ppm as CaCO3 293 ppm as CaCO3 1.0 ppm as CaCO3 25 ppm as CaCO3 0.05 ppm as CaCO3 Nil

It is assumed that the above quality of water will remain fairly constant throughout the year. Any major variations in the same will be reflect on the output of various ion exchangers, quality of treated water and also on chemical consumption. (b) Water Quality at Exit of Anion Exchangers: : Not Detectable : 0.2 ppm as Sio2 (max) : 10 micro siemens (max) : 7.5 to 8.5 D.M. Water Quality ( Exit Mixed Bed Exchangers) : : 0.02 ppm (max)
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Hardness Silica (Total) Conductivity PH (C)

Total Electrolyte : 2 ppm (max)

Hardness (Total) : Nil Silica as Sio2

Iron as Fe pH Conductivity (d) (e) Iron Turbidity (f) (g) CO2 2. Sodium Content Outlet Turbidity

: Nil : 6.8 to 7.3 : 0.1 micro siemens (max) : 2 NTU (max) : Nil : Nil : 2 NTU (max) : 2 ppm as CaCO3 (max) : 5 ppm as CO2 (max)

Free CO2 as CO2 : Nil

Water Quality at Exit of Pressure Filters: Water Quality at Exit of Active Carbon Filters :

Free Chlorine Content

Water Quality at Exit of Cation Exchangers : Water Quality at Exit of Degasser Tower :

PROCESS OF TREATMENT

The process of demineralization consists of the conversion of salts like NaCl, CaSO4, Ca(HCO3)2 etc. to their corresponding acids like HCI,H2SO4, H2CO3 by cation exchange resin (in hydrogen form) and removal of these acids by anion Exchange resin (in hydroxide form), thus removing all dissolved ionic impurities from water & converting water in pure form. A) Ion Exchange Resins : Ion Exchange resins used in DM water plants are synthetic organic compounds made by copolymerisation of various organic compounds. Most commonly used are Styrene & divinyl benzine (for the basic resin beds). These beds are further subjected to the process of sulfonation to make cation

resins; chloromethylation and amination to make the anion resins. These processes attach the main functional groups to the resin matrix giving it the cationic or anionic characteristics. B) Cation Exchange Process : Two types of cation exchange resins are mainly used in DM water plants, weak acidic and strong acidic. Selection of any of these resins depends upon the feed water quality and final water quality desired from the plant. In softening plants, cation exchange resin is used in sodium form whereas in DM water plants, it is used in hydrogen form. The main cations in water are Ca++, Mg++ & K+, These are exchanged with mobile hydrogen ion of cation resin and is represented by the following equations: 1. a. b. c. 2. a. b. c. d. e. Weakly Acidic Cation Resin : RH + NaHCO3 2RH + CaCO3 2RH + Mg (HCO3)2 Strongly Acidic Cation Resin : 2RH + Na2SO4 RH + NaHCO3 2RH + CaSO4 2RH + Mg (HCO3)2 2RH + CaSiO3 2RNa + H2SO4 RNa + H2CO3 R2Ca + H2SO4 R2Mg +2 H2CO3 R2Ca +2H2SiO3 RNa + H2CO3 R2Ca + H2CO3 R2Mg + 2 H2CO3

Water from cation exchangers is sent to degasser where carbonic acid breakes into water & CO2. H2CO3 H2O + CO2 In this way, Carbonic acid load is reduced.

When the resins (weak or strong acid) are exhausted as indicated by leakage of cations in the outlet water. These are regenerated by Hydrochloric acid or Sulphuric acid to bring back the resin in hydrogen form & is represented by the following equations (shown in 3). 3. a. b. c. C. Regeneration : 2RNa + H2SO4 R2Ca + 2HCI R2Mg + H2SO4 Anion Exchange Process : 2RH + Na2SO4 2RH + CaCI2 2RH + MgSO4

Two types of anion exchange resins are mainly used in DM water plants, weakly basic & strongly basic. The selection of any of these resins depends upon the feed water quality and final water quality desired from the plant. In DM water plant, these resins are used in hydroxide form. The main anions in water are Cl-, SO4--, NO3-, CO3-- & HCO3-. These are exchanged with mobile hydroxyl ion of anion resin and is represented by the following equations: 1. a. b. c. 2. a. b. c. d. e. Weakly Basic Anion Resin : ROH + HCL 2ROH+ H2SO4 ROH + HNO3 Strongly Basic Anion Resin : ROH 2ROH ROH 2ROH 2ROH + HCL + H2SO4 + HNO3 + H2SiO3 + H2CO3 RCL + R2SO4+ RNO3 + R2SiO3 R2CO3 H2O 2H2O H2O + + 2H2O 2H2O RCL + H2O R2SO4 + 2H2O RNO3 + H2O

3. a. b. c. d. e. D.

Regeneration : RCl R2SO4 RNO3 R2SiO3 R CO3 + + + + + NaOH 2NaOH NaOH 2NaOH 2NaOH ROH + NaCI 2ROH+ Na2SO4 ROH + NaNO3 2ROH+ Na2SiO3 2ROH+ Na2CO3

Inlet water Quality :

The feed water to ion exchange resin must be cold, clean and colourless for efficient functioning of ion exchange resins. The water should be free from suspended matter, organic matter, oil, heavy metals like iron and aluminum, algae etc. These impurities would collect on or inside the resin particles and shall reduce their ion exchange capacity. Hence such water is pre-treated by coagulation, filtration etc. before allowing it to pass through ion exchange resins. Ion exchange resins can act as filter also, but it causes reduction in its ion exchange capacity and resin bed may require occasional cleaning or replacement. E. Mixed Bed Unit When the water is passed through cation exchange resin and then to strongly basic anion exchange resin, it removes most of the dissolved ions present in the water. In order to produce still pure treated water having conductivity less then or equal to 0.02 ppm, a mixed bed unit is used. A mixed bed consists of mixture of strongly acidic cation exchange resin and strongly basic anion exchange resin. Sometimes the mixed bed unit is known as polisher because it is used for getting water having conductivity around 0.2 micromhos/cm. It acts effectively due to infinite series of demineralising pairs. Good treated water quality can be obtained from a mixed bed unit using relatively lower quantities of regenerants.
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PRE -TREATEMENT PLANT

This plant has the capacity to produce 3000 m3/hr of clarified water to meet the total requirement of DM Plant and softening Plant. The various processes involved are as below:

AERATION
The raw water from reservoir is being pumped through 750 mm dia inlet pipe to the aerator. Cascade aerator is used to remove volatile impurities from raw water. The raw water is discharged at the top of the aerator through a concentric pipe and flows down wards in steps. By aeration, the water absorbs O2 from atmosphere which helps in oxidation of organic matters. The iron dissolved in the water is precipitated as Fe2O3.

COAGULATION
From the aerator, water flows directly to the flash mixer through open cannel; where chlorine, lime and alum (Aluminum Sulphate) are dozed by the pumps and then flows through a RCC channel by gravity. The added chemicals are thoroughly mixed with the raw water in flash mixer agitator (with stainless steel mixing paddle), it is operated through a reduction gear with an electric motor. Alum as coagulant acts very efficiently in alkaline medium. Lime furnishes residual alkalinity and thus promotes coagulation efficiency. Chemical reaction takes place as under: Al2(SO4)3 + 18H2O + 3Ca(OH)2 3CaSO4 + 2Al(OH)3 + 18H2O

FLOCCULATION & CLARIFICATION

The chemically treated water is fed to the two Clariflocculators each have capacity of 1500 M3/hr. The clariflocculators are circular tanks of 40.8 me. in dia. The clariflocculation consists of two zones for removal of impurities. First, the flocculation zone (dia=2 me) where the microflocs with the help of slow speed-agitator and the second clarification zone for solid liqid separation. Water enters the clarifier through central shaft and flows into the flocculation zone through ports located at the top of the central shaft. With the help of 4 nos. of slow speed agitator or floculators, microflocs is being accumulated. The flocculated water flows towards the bottom where the solid and liquid separation takes place. The flocs settle to the bottom and is collected towards the centre of the clarifier by means of scrapers attached to a rotating bridge. The sludge collected at the centre is discharged through 250 NB CI pipe. To control the discharge of sludge, a constant bleed arrangement and blow off valve have been provided. Clarifier and water from clarification zone over flows into launders. Clarified water from launders flows into the discharge by using a telescopic valve which can be varied (in position) with resect to top water level, to achieve different discharge rates. Over and above this arrangement 250 mm dia CI sludge valve is also provided for occasional blow off. These two valves are located in the sludge feed and can be operated as and when required. A rotating bridge in M. S. structure is provided for supporting the flocculators, scraping the sludge towards discharge points. The bridge rests on the central pillars and on the clarifier wall by end carriage. The carriage moves on M.S. Rail laid on the top of clarifier wall. The rotation is achieved

by operating motor and carriage drives. Power supply to various electrical drive in the bridge is given through a slippering assembly.

CHLORINATION PLANT
The clarified water is mainly used for service water requirement (cooling of various equipments) and to feed water to D.M. Plant and softening plant, which is free from all suspended solids, colloidal solids and other impurities. The analysis of raw and clarified water is given below : SNo Property 1. 2. 3. 4. 5. pH Turbidity Iron as Fe Manganese As Mn. Free CO2 Raw Water 8.4 10.8 0.06 0.02 Clarified Water 7.8 <5.0 0.02 0.02

This plant is designed to produce 3000 M3/hr of clarified water. The water from the reservoir is fed through 2+1 nos. raw water pumps (of capacity 750 M3/hr, speed 970 rpm, power 50 hp through 750 mm dia M.S. pipe). The water is aerated in cascade aerator. Lime (1+1 tanks), alum (3 nos. tanks) are dosed by their respective tanks. Two nos. flash mixers driven by 5 HP motor of 30 rpm are used for thorough mixing of chemicals. Two nos. of clariflocculators of 1500 M3/hr capacity, each having dia of 40.8 me were constructed. Each clariflocculator is provided with mild steel frame bridge rotating at a speed of 2.5 rpm driven with the help of reduction gear box. Agitators are driven by (4 nos.) 8.0 rpm HP motors. The settled sludge is scrapped to center and is removed by two manual operated valves. The clarified water is stored in tanks (two nos.).
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