DEMINERALISATION PLANT CALCULATION

PROJECT : M/s. Gujarat Ambuja Enquiry No. :

Assign No. :
CONSULTANT : M/s.TCE DATE : 18/02/04

SCHEME : DM STREAMS : Two

FLOWRATE (M3/HR) NORMAL : 5 MAXIMUM : 5.000

NETT OUTPUT M3 PER CYCLE : 90 PER DAY : 90.000

STREAM OPERATING CYCLE : HR SERVICE - 18 HR REGN - 4.000

Load on Design
Design
SAC Analysis
DESIGN ANALYSIS expressed as ppm Analysis
considered for
Considered
SBA after DGT

as such as CaCo3 1 2 3 4
Alum Lime Chlorine Naocl
Chemical Dosage (ppm as such) 0 0 0 3
Cations : Calcium 40.000 100 100.000 100.000
Magnesium 8.252 34 33.998 33.998
(Total Hardness) 48.252 134 0 133.998 133.998
Sodium 0.000 0 2.5833 2.583 15.183
Potassium 0.000 0 0.000 0.000
Total Cation 48.252 134 136.582 149.181
Anions : Chlorides 11.350 16 0 2.5803 18.584 18.584
Sulphates 14.420 15 0 14.997 14.997
Nitrates & Nitrites 1.976 2 1.620 1.620
Flourides 0.000 0 0.000 0.000
Phosphates 0.000 0 0.000 0.000
(EMA) 27.746 33 35.201 35.201 35.201
M Alkalinity 139.000 114 0 0 113.980 113.980
P Alkalinity 0.000 0 0.000 0.000 6.000
Total Anions 166.746 147 149.181 149.181 41.201
Other : Reactive Silica 10.000 8 8.300 8.300
Carbon Dioxide 0 0 0.000
Iron 0.040
Free Chlorine
D. O. Value
pH 8.000
Total Dissolved Boilds 225.038 0 Load on SAC 149.181
Supended Solids Load on SBA 49.501
BOD / COD

Page 1 GUJ
 DESIGN RATION FOR VARIOUS UNITS
TH Ca SiO2 SO4 ALK. Na CO2
T. ALK TC TA TA -EMA TC TC TA
1.176 0.670 0.168 0.711 0.76 0.102 0.121

PROCESS CALCULATION
1.000 2.000 3.000 5.000 6.000 7.000
PARAMETER UNIT MB - Catio MB - Anio SBA DGT DGS SAC
Regenerant Chemical -- A-101 D C-20
Regeneration Mode --
Regenerant Temperature Deg. C 25.0 25.0 25.0 25.0 25.0 25.0
Normal Flow per stream M-3/hr 5.0 5.0 5.0 10.0 5.0 5.0
Maximum Flow per stream M-3/hr 5.0 5.0 5.0 10.0 5.0 5.0
2.000 hr 126.0 126.0 18.0 18.0
Nett output per cycle M-3 630.0 630.0 90.0 90.0
Waste Water : Down stream units M-3 1.6 1.6 1.6 3.9
Waste Water : Self M-3 0.0 0.0 2.3 2.4
Waste Water : Up Stream units M-3 1.6 1.6 3.9 6.2
Gross output per cycle M-3 631.6 631.6 93.9 96.2
Ionic load as CaCO3 Mg/Ltr 1.0 0.2 49.5 149.2
Work done per cycle as CaCO3 Kg. 0.6 0.1 4.6 14.4

MB Design actual lts. 0.018 0.036

MB Design Hydraulic lts. 0.050 0.075
1.0 2.0 3.0 4.0 5.0 6.0
PARAMETER UNIT
Regeneration level (100%) kg/m3 100.0 80.0 50.0 50.0
Exchange capacity (as CaCO3) kg/m3 50.0 4.2 33.5 57.5
Correction factor ( Mechanical) -- 0.7 0.7 0.9 0.9
Correction factor -- 0.904 0.930
0.999
0.992
Design Exch. Capacity (as CaCO3) kg/m3 35.0 2.9 27.245 47.730
Effective Resin Volume M-3 0.050 0.075 0.171 0.301
Buffer Resin Volume (mm) M-3 - - -
Active Resin Volume M-3 - - - -
Inert Resin Volume (mm) M-3 - - 0.029 0.050
Total Resin Volume M-3 0.050 0.075 0.200 1.579 0.350
Unit Diameter* mm 400 500 500 1000 650
Unit Cross-sectional area M-3 0.126 0.196 0.196 0.785 0.332
Velocity 39.811 25.479 50.955 15.076
Total Resin Bed Depth mm 1000.0 1018.9 2000.0 2010.9 1056.6
Free Bord required % 100% 100% 50% 0% 100%
Height on stright mm 2000.0 2037.8 3000.0 2010.9 2113.2
HOS-considered mm 2000 2250 3300 2250 2250
Chemical per regn. (100%) kg 5.024 6.029 8.526 15.034
Ionic load per cycle (as CacO3) kg 0.632 0.105 4.646 14.351
Regeneration efficiency % 9.177 1.391 43.592 69.678
Unutilised chemical (as CaCO3) kg 6.251 7.431 6.011 6.245
Neutralising Chemical type -- NaOH HCl HCl NaOH
Chemical for Neut(100%)MB not regeneratedkg 0.187 NaOH
Chemical for Neut. (100%) MB regenerated kg 0.691 HCl
Size of tank (ltrs) 50.238 75.357 106.570 150.338
Size of tank (ltrs)-considered -- 75.0 100.0 150.0 200.0

* Since the resin quantity actually required is very less, the basis of MB design is Hydraulic Load.
Hence the size of MB is Dia. 500 x 2000 mm considering linear service velocity 45 m/hr. We will

Page 2
be providing the resin bed deph of 1000 mm (total) with 400 mm cation resin and 600 mm anion resin.

800.0
600.0 1.000 MB
400.0
200.0 2.000 MB
0.0

M -3 /h r
M -3 /h r

M g /L tr
Deg. C

Kg.
hr
--

M -3
M -3
M -3
M -3
M -3
3.000 SBA

Regeneration
Regenerant
Normal
Maximum
Flow
Temperature
Waste
Mode
Nett
Flow
perWater
2.000
output
Waste
stream
per
Waste
stream
: per
Down
Water
Gross
Water
Work
cycle
Ionic
stream
:output
Up
done
: load
Self
Stream
units
per
per
ascycle
cycle
CaCO3
units as CaCO3
5.000 DGT

6.000 DGS

7.000 SAC

Page 2
.000 MB - Cation

.000 MB - Anion

.000 SBA A-101 D

CaCO3
.000 DGT

.000 DGS

.000 SAC C-20

Page 2
Effluent Water Calculation

Step Operation Basis Flow m3/hr Time Min Volume m3 Remarks

MB
1 Backwash 3 m/hr 0.377 10 0.063 Ex SBA
2 Acid Injection 5.024 0.402 15 0.100 DM Water
Downflow 1.5 m/h 0.188 - 0.047 Ex SBA
3 Acid Rinse 2 BV 0.201 30 0.100 DM Water
Downflow 1.5 m/h 0.188 - 0.094 Ex SBA
4 Alkali Injection 6.029 0.603 15 0.151 DM Water
Upflow 4.5m/hr 0.565 - 0.141 Ex SBA
5 Alkali Rinse 2 BV 0.301 30 0.151 DM Water
Upflow 4.5m/hr 0.565 - 0.283 Ex SBA
6 Drain Down - 10 -
7 Air Mixing 10 -
8 Final Rinse 5.000 15 1.250 Ex SBA
135 1.878 Ex SBA
0.502 DM Water
SBA
1 Backwash 3 m/hr 0.589 5 0.049 SAC Water
2 Alkali Injection 8.5 0.426 30 0.213 DM Water
3 Slow Rinse 3.5 BV 0.796 45 0.597 DM Water
4 Final Rinse 5.000 15 1.250 SAC Water
95 1.299 SAC Water
0.810 DM Water

SAC
1 Backwash 9 m/hr 2.985 5 0.249 Filtered Water
2 Acid Injection 15.0 0.601 30 0.301 DGT Water
3 Slow Rinse 2.5 BV 0.601 75 0.752 DGT Water
4 Final Rinse 5.000 10 0.833 Filtered Water
120 1.052 DGT Water
1.082 Filtered Water

Total DM Water 1.312

Total SBA Water 1.878
Total SAC Water 1.299
Total DGT Water 1.052
Total filtered Water 1.082
Total Effluent 6.624

MB waste 1.312
SBA Waste 1.878
SAC Waste 2.351

Page 3
EFFLUENT TDS

SAC

Quantity TDS

Acid Injection 0.300677 50000

Slow rinse 0.751692 511
Backwash 0.24874 511
Fast rinse 0.833333 511
2.134442

TDS of SAC Effluent 7482.468

SBA

Quantity TDS

Alkali Injection 0.21314 40000

Slow rinse 0.596793 10
Backwash 0.049061 511
Fast rinse 1.25 511
2.108995

TDS of SBA Effluent 4360.091

MB

Quantity TDS
CATION
Acid Injection 0.100475 50000
Down Flow 0.047098 10
Acid Rinse 0.100475 1
Down Flow 0.094196 10
Backwash 0.062797 10
0.405042
Anion

Quantity TDS

Alkali Injection 0.150713 40000

Up Flow 0.141294 10
Alkali Rinse 0.150713 1
Up Flow 0.282587 10
Final Rinse 1.25 10
1.975307

Total 2.380349
TDS of MB Effluent 4645.887
Total Effluent when MB not regenerated
4.243437 m3

TDS 5930.641

Total Effluent when MB regenerated

6.623786 m3

TDS 5468.947
C-20 HCl counter current regeneration

HCL g/l Capacity eq/lt

50 30 0.8 1.15 57.5
40 1.03
50 1.15
60 1.24
70 1.32
80 1.39
90 1.44
100 1.49
120 1.57

% Na Factor A Correction factor

10.17736 0 0.92 0.930177
10 0.93
20 0.94
30 0.95
40 0.96
50 0.98
60 0.99
70 1
10.17736 80 1.01 0.870355
90 1.03
100 1.04

% Alk Factor B Correction factor

76.40387 0 0.94 1.020585
25 0.97
50 1
75 1.02
99 1.03

Bed depth Factor C Correction factor

1000 900 0.94 0.946667
1200 0.96
1500 1
1800 1.04
2000 1.07
2500 1.1

% Na Factor D Correction factor

10.17736 0 1.03 1.034071
50 1.05
99 1.08
For 10 hrs. operation

% Alkalinit Factor E Correction factor

76.40387 0 0.96 0.980777
50 0.97
99 0.99

For 15 hrs. operation

% Alkalinit Factor E Correction factor

76.40387 0 0.97 0.988083
50 0.98
99 0.995

For 18 hrs. operation

% Alkalinit Factor E Correction factor

76.40387 0 0.976 0.992466
50 0.986
99 0.998

For 20 hrs. operation

% Alkalinit Factor E Correction factor

76.40387 0 0.98 0.995389
50 0.99
99 1

For < 25 hrs. operation

% Alkalinit Factor E Correction factor

76.40387 0 0.99 1
50 1
99 1
A-101 D NaOH counter current regeneration

NaOH g/l Capacity eq/lt

50 30 0.65 0.92 46
40 0.82
50 0.92
60 0.98
70 1.04
80 1.06
100 1.08

% SO4 Factor D Correction factor

71.11165 0 0.94 1.025334
25 0.97
50 1
75 1.03
99 1.06

% CO2 Factor E Correction factor

12.12099 0 0.97 0.988181
20 1
30 1.02
50 1.05
75 1.08
99 1.12

For NaOH at 25 o C
% SiO2 Factor F Correction factor
16.76737 5 1 0.952931
10 0.98
20 0.94
30 0.9
40 0.88
50 0.86

D SiO2 Factor G Correction factor

ppb
39.63749 50 0.9 0.889637
100 0.95
200 1
300 1.04

Basic Silica leakage ppm

NaOH g/l Capacity eq/lt
50 30 0.05 0.024
40 0.036
50 0.024
60 0.017
80 0.01
 % SiO2 Factor A Correction factor
16.76737 1 0.2 1.676737
5 0.5
10 1
20 2
30 3
40 4
50 5
A-101 D NaOH counter current regeneration

NaOH g/l Capacity eq/lt

50 40 0.62 0.67 33.5
50 0.67
60 0.7
70 0.73
80 0.76
100 0.79
120 0.82

% SO4 Factor D Correction factor

71.11165 0 0.92 1.033779
25 0.96
50 1
75 1.04
99 1.08

% CO2 Factor E Correction factor

12.12099 0 0.97 0.988181
20 1
30 1.02
50 1.05
75 1.08
99 1.12

For NaOH at 25 o C
% SiO2 Factor F Correction factor
16.76737 5 0.98 0.956465
25 0.94
50 0.87
75 0.82

D SiO2 Factor G Correction factor

ppb
74.84895 50 0.9 0.924849
100 0.95
200 1
300 1.04

Basic Silica leakage ppm

NaOH g/l Capacity eq/lt
50 40 0.012 0.01
50 0.01
60 0.008
70 0.006
80 0.005
100 0.003
120 0.002
 % SiO2 Factor A Correction factor
16.76737 1 0.2 1.676737
5 0.5
10 1
25 2.5
50 5
75 10
CONVERSION FACTORS

CATIONS mg/lit CaCo3 ANIONS mg/lit CaCo3

Ca 0.0499 2.5 Cl 0.0208 1.41
Mg 0.0823 4.12 SO4 0.0208 1.04
Na 0.0435 2.18 No3 0.0161 0.81
Ba 0.0146 0.73 HCO3 0.0164 0.82
Fe 0.0358 1.79 F 0.0526 2.63
K 0.0256 1.28 Phosphate 0.0316 1.58
Mn 0.0364 1.82 Silica 0.0166 0.83
NH3 0.0554 2.77 SO3 1.25
Sr 0.0228 1.14
CaO --- 1.786
MgO --- 2.48