ASSOCIATION OF WATER TECHNOLOGIES Technical Reference and Training Manual 2. CHAPTER 2 External Treatment (Pretreatment) Table of Contents 4.0 INTRODUCTION 14 OVERVIEW 1.2. THE AWT BOILER PRETREATMETN MATRIX 2.0 AERATION 24 INTRODUCTION 2.2 PRINCIPLES OF AERATION 2.3 IRON AND MANGANESE OXIDATION 24 REMOVAL OF DISSOLVED GASES 2.4.1 Stripping Mechanisms 2.4.2. Effects of Temperature, Pressure and pH on Stripping Efficiency 2.5 AERATION EQUIPMENT 2.6 MONITORING AND TROUBLESHOOTING 3.0 CLARIFICATION 3.1 INTRODUCTION AND PRINCIPLES 3.2 CHEMICAL TREATMENT 3.2.1 Inorganic Coagulants and Flocculants 3.2.2 Organic Polyelectrolytes 3.2.3 Process Variables 3.2.4 Jar Testing 3.3 CLARIFIER OPERATING VARIABLES. 3.3.1 Rise Rate 3.3.2 Turbine/Rapid Mix Speed 3.33 pH 3.3.4 Temperature 3.3.5 Slow Mix/Flocculation Zone Center Well Observations 3.38 Rake Speed 3.3.7 Sludge Blanket Location 3.3.8 Solids in the Centerwell 3.3.9 Blowdown 24 Chapter 2 External Treatment 18 18ASSOCIATION OF WATER TECHNOLOGIES Technical Reference and Training Manual 3.4 CLARIFICATION EQUIPMENT 3.4.1 Horizontal Clarifiers 3.4.2 Upflow Clarifiers 3.4.3. Sludge Blanket (Solids Contact) Clarifiers 3.4.4 Tube Settlers 3.5 MONITORING CLARIFICATION PROGRAMS 3.6 TROUBLESHOOTING CLARIFIER PERFORMANCE 4.0 PRECIPITATION SOFTENING 4.1 INTRODUCTION 4.2 PRINCIPLES OF PRECIPITATION SOFTENING 42.1 Lime Softening 422 Lime-Soda Softening 42.3 Other Chemicals Used in Lime Softening Processes 42.4 Lime Softening Calculations 43 LIME SOFTENING OPERATIONS 5.0 FILTRATION 541 INTRODUCTION 5.2. PRINCIPLES OF FILTRATION 5.3 _ FILTRATION SYSTEMS 5.3.1 Filter Media 5.3.2 Sand Filters 5.3.3. Dual Media Filters 5.3.4. Mixed or Multi-Media Filters 53.5 Pressure Filters 5.3.6 Upfiow Filters 5.4 SPECIAL FILTRATION PROCESSES 5.4.4 Direct Or In-Line Filtration 5.4.2 Precoat Or Septum Filters 5.4.3 Microfitration 6.4.4 Uttafiltration 6.5 _BACKWASHING 5.6.1 Procedures 5.5.2 Backwash Water Supply 5.8 BAG AND CARTRIDGE FILTERS 5.7 ADSORPTION PROCESSES 5.7.1 Introduction 5.17.2 Dechiorination 2-2 Chapter 2 External Treatment seessASSOCIATION OF WATER TECHNOLOGIES Technical Reference and Training Manual 5.7.3 Removal of Organic Matter by Adsorption 5.7.4 Final Filtration 5.7.5 Principles of Operation 5.7.6 Control Tests 6.0 ION EXCHANGE - GENERAL 6.1 INTRODUCTION 6.2 PRINCIPLES OF ION EXCHANGE 6.3 _TYPES OF ION EXCHANGE RESIN PROCESSES 6.3.1 Strong Acid Resins 63.2 Weak Acid Resins 6.3.3 Strong Base Resins 63.4 Weak Base Resins 6.4 ION EXCHANGE RESIN CHARACTERISTICS 64.1 Resin Type and Structure 64.2 lon Exchange Capacity 64.3. Kinetics 6.5 PHYSICAL PROPERTIES OF RESINS 65.1 Particle Size 65.2 Classified Density 65.3 Water Retention Capacity 65.4 Physical Stabilty 65.5. Thermal Stability 65.6 Chemical Stability 65.7 Regeneration Efficiency 6.5.8 Organic Fouling Resistance 6.6 INSPECTING ION EXCHANGE EQUIPMENT 6.6.1 Mechanical inspection Checklist 66.2 Resin Bed Inspections 68.3 Operational Checks During Vessel Inspection 6.7 _ RESIN SAMPLING AND ANALYSIS INTERPRETATION 67.1. Resin Analyses 6.7.2. Total Organic Carbon (TOC) In Regenerant Effluent 6.8 CLEANING ION EXCHANGE UNITS 68.1 Routine Maintenance 68.2 Cleaning Severely Fouled Resin Beds 6.8.3 Inorganic Resin Contaminants 6.8.4 Organic Contamination 7.0 SODIUM ZEOLITE SOFTENING 7.4 INTRODUCTION 23 Chapter 2 External Treatment 68ASSOCIATION OF WATER TECHNOLOGIES Technical Reference and Training Manual 7.2. PRINCIPLES OF ION EXCHANGE SOFTENING 7.3 ZEOLITE SOFTENING OPERATIONS 7.3.1 Softening 7.32 Regeneration 7.3.3 Operations 7.34 Control Tests 7.4 TROUBLESHOOTING 7.5 BRINE ELUTION STUDIES 8.0 DEMINERALIZATION 81 INTRODUCTION 82 PRINCIPLES OF DEMINERALIZATION 8.2.1 Basic Demineralization Reactions 8.2.2 The Basic Demineralization Process 8.3 ALKALINITY REMOVAL 8.3.1 Strong Acid/Strong Base Resins plus Decarbonator 8.3.2 Weak Acid/Strong Acid Cation Resins plus Decarbonator 8.3.3 Demineralized Water Quality 8.3.4 Regeneration 84 DECARBONATION 8.4.1 Principles 8.4.2 Operating Problems 8.5 DEMINERALIZATION EQUIPMENT 86 CONTROL TESTING &.7 TROUBLESHOOTING 8.8 MIXED BED DEMINERALIZATION 88.1 Equipment 8.8.2 Effluent Expectations 8.8.3 Regeneration Practices 8.8.4 Control Testing 8.8.5 Troubleshooting 8.8.6 Inspection Procedures 9.0 CONDENSATE POLISHING 9.1 INTRODUCTION 9.2 TYPES OF POLISHING SYSTEMS 9.3. POLISHING FILTERS 24 Chapter 2 External Treatment 68 73 75 80 80 80 80 a1 81 83, 83, 84 84 84, 85 96 96 96 97ASSOCIATION OF WATER TECHNOLOGIES Chapter 2 Technical Reference and Training Manual External Treatment 9.3.1. Precoat Filtration 97 9.3.2. Magnetic Filters 7 9.4 ION EXCHANGE POLISHING 7 9.4.1 Deep Mixed Beds 7 8.4.2 Precoat Mixed Beds 98 9.4.3. Sodium Cycle Polishers 98 9.6 CONTROL TESTS 99 10.0 REVERSE OSMOSIS 100 10.1 INTRODUCTION 100 10.2 PRINCIPLES OF REVERSE OSMOSIS (RO) 101 10.3 SEMI-PERMEABLE MEMBRANES 102 10.3.1 Membrane Compositions 102 10.3.2. Membrane Comparisons 102 10.3.3 Membrane Modules 103 10.3.4 Membrane Fouling 104 10.3.5 The Sill Density Index (SD!) 105 10.3.6 Membrane Degradation 105 10.3.7 Organic and Microbiological Problems 106 10.3.8 Mineral Scale Formation 107 10.4 CHEMICAL TREATMENT IN RO SYSTEMS 107 10.4.1 Pretreatment Summary 108 10.4.2 Microbiocides 109 10.4.3 Mineral Scale Control 109 10.4.4 Cleaning Chemicals 109 10.5 MONITORING AND MAINTENANCE 109 10.5.1 Monitoring Data 110 10.5.2 Normalization "1 10.5.3 Maintenance and Cleaning 114 10.5.4 Storage and Layup 112 10.6 TROUBLESHOOTING 112 11.0 ELECTRODEIONIZATION 114 11.4 INTRODUCTION 114 11.2 PRINCIPLES OF ELECTRODEIONIZATION 414 12.0 GLOSSARY OF EXTERNAL TREATMENT TECHNOLOGY 7 12.1 REVERSE OSMOSIS SYSTEM DESIGN TERMS 47 42.2 ION EXCHANGE GLOSSARY 47 2-5ASSOCIATION OF WATER TECHNOLOGIES Technical Reference and Training Manual 43.0 REFERENCES 2-6 Chapter 2 External Treatment 120ASSOCIATION OF WATER TECHNOLOGIES Chapter 2 Technical Reference and Training Manual External Treatment CHAPTER 2 Pretreatment 1.0 Introduction 1 OVERVIEW Chapter 2 discusses pretreatment, or external water treatment technology. Pretreatment, as used in this context, means mechanical and chemical treatment of a raw makeup water supply, to make the water suitable for use as boiler fecdwater, cooling tower makeup, or process water. As explained in Chapter 1, the two related primary objectives of water treatment are to keep heat transfer systems clean and to protect the system equipment from corrosion and fouling damage. Makeup water supplies vary widely in both quality and purity, and available supplies may not be suitable for intended applications. The purpose of water pretreatment is to remove suspended and dissolved solids, dissolved gasses and other materials that can cause problems and that cannot be cost-effectively controlled by internal chemical treatment. Water pretreatment has a tremendous effect on the reliable and efficient operation of boiler, cooling and process water systems. Without effective pretreatment, chemical treatment would be either ineffective or too costly. Since there are limitations on what chemical treatment alone can do, such as handling very high suspended solids or high hardness waters, external treatment systems are installed to remove the contaminants or reduce them to levels that can be effectively treated. Pretreatment eyetems must be designed to meet specific on-site needs. Water used for cooling system makeup may be simply chlorinated if it is otherwise good quality water. However, in many large cooling systems, the makeup may be chlorinated, clarified and filtered and sometimes zeolite-softened. Water used for high pressure boiler feedwater will be further processed through reverse osmosis or demineralization, depending on the pressure. If returned condensate is contaminated, it may be treated by a suitable combination of these processes to bring the condensate back to feedwater quality. This is called condensate polishing (see chapter 3), The terms quality and purity are used throughout this manual, and are sometimes assumed to be interchangeable. They are not. Purity is a quantitative term that defines the amount of impurities of all types in a water. Quality is a qualitative term defining suitability for use. For example, a surface water supply may be good quality for cooling tower makeup, but poor quality, requiring pretreatment, for use as boiler feedwater (more on this in chapter 1.) There are many complex factors involved in the effective operation of external treatment systems. If the systems are not run effectively, system corrosion and 27