WATER SOFTENER PLANT

For industries and commercial units, hard water poses a potential threat. The performance of boilers,
cooling towers and other associated equipment adversely affected by scaling caused by hard water.
Water Softener is considered as concrete solution for this problem, which prevents scale forming.
The Water Softener units are designed on the advanced Co current/counter-current principle that
ensures consistent good quality treated water. It reduces dissolved minerals (primarily calcium,
magnesium, some manganese, and metals such as ferrous iron ions) in hard water. These “hardness
ions” can cause several types of problems, as follows:

The minerals of calcium and magnesium carbonates tend to attach and stick to the surfaces of pipes and
water heats, resulting in scale buildup, which restricts water flow in pipes. In boilers, the mineral
deposits act as an insulation that impairs heat transfer to water. The net result of such thick scale
buildup is that more energy is required (resulting in energy wastage and inefficiency) to heat the water
in a boiler. With softened water, one saves energy in water heating.

The ions in the electrolyte can also lead to metal corrosion, causing corrosion in the plumbing
system within the house or the commercial building.

The Chemical Process of Water Softening: Ion Exchange

Salt-based water softening works on the principle of ion exchange or ion replacement, a reversible
process. (Ions are atoms or groups of atoms that can lose or gain electrons in water and therefore have
an electrical charge.) Calcium (Ca2+) and magnesium (Mg2+) ions in the hard water are exchanged
or replaced with sodium ions (Na+) during the reversible ion-replacement reactions, as sodium ions
leave the ion-exchange polymeric resins (or beads, or a class of minerals called Zeolites) and go
into water, while calcium and magnesium ions in the hard water are bound to the resins or beads.
Essentially, the ions switched places during water softening: sodium from resin matrix migrate
into the water, and calcium and magnesium move from water to attach to the resin matrix. The resin or
bead matrix is itself inert and does not participate in the chemical reaction, and its physical structure is
not changed during water softening.

In normal operation, hard water moves into the mineral tank and the calcium and magnesium ions move
to the beads, replacing sodium ions. The sodium ions go into the water. Once the beads are saturated
with calcium and magnesium, the unit enters a 3-phase regenerating cycle. First, the backwash
phase reverses water flow to flush dirt out of the tank. In the recharge phase, the concentrated
sodium-rich salt solution is carried from the brine tank through the mineral tank. The sodium collects
on the beads, replacing the calcium and magnesium, which go down the drain. Once this phase is over,
the mineral tank is flushed of excess brine and the brine tank is refilled.

However, water-softening polymeric resins do not last forever: Frequency of regeneration depends on
the hardness of the water; the amount of hard water treated or softened the size of the water- softening
system, and the capacity of resin to absorb hardness minerals. Over time, the resins’ capacity to
soften water by ion exchange decreases between regeneration, especially if the water also contains iron
or other metals.

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In general, the polymeric resins in traditional salt-based water-softening systems have to be
replaced every Three to Five years (depending on the hardness of water being treated and the
other factors) because the resins have been "spent" and cannot be regenerated any further.

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OPERATION PRINCIPLE

A typical water softening Plant consists of pre-filters, Water Softener Vessel with Resin, Brine Tank, and
accessories. The Water Softener units are available in a wide range of materials like FRP / LDPE/ MS
/MS Rubber Lined / Stainless Steel.

The filter feed pump takes water from raw water tank and feeds to the Dual media filter. Generally we
offer one working and one stand-by Softener columns for industrial use, which work
interchangeably. One column after regeneration goes in standby and continues filtration when
second column switches to regeneration. System produces softened water with constant flow rate.
Softener columns work simultaneously. When one column goes to regeneration, system produces water
with half of water flow rate.

FILTER PERFORMANCE

For regeneration of filtering material (ion resins) reagent (NaCl or’ Salt) is used. The filter columns are
filled with ion exchange resin (cationic), which reduces hardness and iron concentration in water.
The process control units perform manual/automatic regeneration. Capacity of filter material
is calculated according to the amount of resins and raw water quality. The Output between
regeneration (OBR) is also calculated based on the volume.

The five cycles are as follows:

 Service – the water is being softened.
 Backwash - the direction of flow is reversed and the silt, sediment and iron particles are
flushed from the resin. The backwash cycle on a typical softener requires a flow rate of
about 13 L/min (3 gallons per minute). Water consumption for the regeneration of most
domestic softeners is 300 to 450 L (70-100 gallons).
 Brine – the brine solution is slowly passed through the resin, until the resin retains as much
sodium as possible.
 Rinse – excess brine is rinsed from the resin.
 Fast rinse – the resin bed is compacted for maximum operating efficiency. The water softener
then returns to the service cycle.

“BLUE SEA” WATER SOFTENER

DESCRIPTION

The Industrial water softeners, manufactured by us offers down-flow softener consists of a mild steel
pressure vessel containing a bed of ion exchange material (commonly referred to as cation exchange
resin).

The vessels are provided with strainers at the top & bottom, each fitted with ring type strainers. These
ensure that the resin is retained in the unit and that brine and water are evenly distributed through the
resin bed. The unit is fitted with all necessary piping and multiport valves up to the raw water inlet and
soft water outlet.

Size or capacity and design depend upon following factors:

 Volume of water to be treated; Hardness of water; Regeneration frequency in a day

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NOTE
 The softener models BS S-10/B are fitted with single, lever operated side mounted six-
way multiport valve.

 The Brine (Salt Solution) requires to regenerate the softener is stored in the brine tank. The
specified quantity of clean salt (use vacuum grade salt) is put into this tank and water
is allowed into dissolve it to form brine. Silex material is spread in layers at the bottom of this
tank to filter the brine which is injected into the softener by means of hydraulic ejector.

 A “brine well” is (PVC/HDPE) is fitted in the brine tank inside which a brine control valve is
fitted to control the volume of brine injected & to stop the re-fill with water after a certain
Level is reached.

 Raw water pressure at the inlet should not exceed 3.0kg/cm2. Above this pressure, operation
of the multiport valve becomes difficult and can damage the lever on the valve. A pressure
gauge is fitted on the valve to check pressure at inlet.

Technical Specifications
Model BS S 10/B
Design Code IS: 2825 ASME Sec VIII Div. I
Typical flow 10 m3/h
Inlet/Outlet, BW in/out Connection size 2” NPT
Overall dimension (600 x 1650) mm (d * h)
Backwash flow rate 12 m3/h
Regeneration duration 30-40 min
Rinsing duration 20 min
Filtration velocity 0.8 – 1.8 m/s
Plate Thickness 5 & 6 mm
Filtration area 0.28 m2
Operating Pressure rating 3.0 kg/cm2
Design Pressure rating 6.0 kg/cm2
Operating temperature 27°C - 49°C
Vessel Construction Epoxy coated Mild Steel Stainless Steel
Resin type Cation 225 Na
Resin Quantity 550 lt
Resin Make ION EXCHANGE INDIA
Bed depth 0.8 meter minimum
Feed water hardness (considered) 1000 ppm
Treated water hardness (considered) 5 ppm
Output between regeneration 10 m3
Salt required for every regeneration 27.5 kgs
Volume of brine solution 950 lts
Regeneration duration 20-30 min
Flange BS 10/Table-D
Joint Efficiency (Shell & Dish end) 0.7
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Corrosion Allowance 1.0 mm
Radiography As per specification
Fontal pipeline 50 mm
Distribution system Lateral pipe
Valves 6 way Multiport valves (Auto)
Flow system Down flow

“BLUE SEA” ACTIVATED CARBON FILTER

What is Activated Carbon Filter?

It consists mainly of pure carbon; activated carbons are considered most powerful adsorbents. This
exceptional feature makes them ideal for utilizing in water treatment, where activated carbon filters
are widely used in purifying, removing odor, color, pesticide and benzene. These activated carbon water
filters also remove some metals, chlorine and radon from the water. An Activated Carbon Filter contains
carbon particles of various sizes ranging from 10 to 50 mesh. The carbon is made from burning coal in
the presence of oxygen. This carbon is further activated by steam or chemical method, where Steam
activated carbon contains very fine pore sizes that are ideal for adsorption of components from water.

An Activated Carbon Water Filter System follows Adsorption Technology and uses high-grade granular
carbon columns to remove organic contaminants from the water, where contaminated water is passed
through the carbon columns and contaminants present in the water are adsorbed onto the surface of
the carbon granules. We have Activated Carbon Granules of various Iodine Values (IV), usually 450 IV
to 1500 IV are utilized in water treatment.

There are two types of activated carbons available, Granular Activated Carbon (GAC) and Powdered
Activated Carbon (PAC); In general Granular Activated Carbon is made by steam activation of coal and
is widely used in purifying drinking water, whereas Powdered Activated Carbon is produced by steam
activation of lignite coal under carefully controlled conditions and is used in treating (remove toxic
organics along with BOD, COD and TOC) industrial wastewater.

Features & Advantages

Designed for commercial & Industrial uses Manual or automatic operation options
Durable FRP/ epoxy or mild steel tank Custom sizes and configurations
Maximum carbon utilization Ideal for pre-treatment

Technical Specifications
Model BS MGF 10/B
Design Code IS:2825 ASME Sec VIII Div.I
Typical flow 10 m3/h
Inlet/Outlet, BW in/out Connection size 2” NPT
Overall dimension (600 x 1650) mm (d * h)
Backwash flow rate 12 m3/h
Backwash duration 30-40 min
Filtration velocity 0.8 – 1.8 m/s
Plate Thickness 5 & 6 mm
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Filtration area 0.28 m2
Operating Pressure rating 3.0 kg/cm2
Design Pressure rating 6.0 kg/cm2
Operating temperature 27°C - 49°C
Vessel Construction Epoxy coated Mild Steel Stainless Steel
Bed depth 1 meter minimum
Flange BS 10/Table-D
Joint Efficiency (Shell & Dish end) 0.7
Corrosion Allowance 1.0 mm
Radiography As per specification
(IS- 8419 PART-I)-1977
Filtration media Anthracite - 1.4-1.5 mm
Gravel - 2.0-3.15 mm & 3.15-5.6 mm
Fontal pipeline 50 mm
Valves 6 way Multiport valves (Auto)
Backwash Manual backwashing as standard
Flow system Down flow

“BLUE SEA” MULTI-GRADE FILTER

What is Multi Grade Filter?

A Multi Grade Filter consists of vertical pressure sand filters that contain multiple layers of coarse and
fine sand (pebbles and gravels) in a fixed proportion. It is a kind of a deep filter bed with adequate pore
dimensions for retaining both large and small suspended solids and un-dissolved impurities like dust
particles. As compared to conventional sand water filter, this multi-grade filtration system works on
higher specific flow rates. It is also a low cost pre-treatment system for ion exchangers (deionizer and
softener) and membrane systems such as reverse osmosis etc. With high throughputs, high dirt-holding
capacity and capacity to reduce turbidity and TSS (< 5ppm) from water, it protects ion-exchange resins
and membranes from physical fouling due to suspended impurities present in the water.

Working Principle
The working principle of a multi-grade filter is quite straight forward. In a multi-grade filter, water is
passed through multi layers of filter media consisting graded sand, pebbles and gravels layers. The
contaminants in the water are captured in the media bed and filtered water passes into the discharge
manifold at the bottom of the tanks. The next and last step is backwashing, a process of effectively
removal of captured contaminants from the media bed. After back-washing the filter is rinsed with raw
water and after the required quality of water is achieved the filter is put back into service.

Features & Advantages

Designed for commercial & Industrial uses Manual or automatic operation options
Durable FRP or mild steel tank Custom sizes and configurations
Maximum carbon utilization Ideal for pre-treatment

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Technical Specifications
Model BS MGF 10/B
Design Code IS:2825 ASME Sec VIII Div.I
Typical flow 10 m3/h
Inlet/Outlet, BW in/out Connection size 2” NPT
Overall dimension (600 x 1650) mm (d * h)
Backwash flow rate 12 m3/h
Backwash duration 30-40 min
Filtration velocity 0.8 – 1.8 m/s
Plate Thickness 5 & 6 mm
Filtration area 0.28 m2
Operating Pressure rating 3.0 kg/cm2
Design Pressure rating 6.0 kg/cm2
Operating temperature 27°C - 49°C
Vessel Construction Epoxy coated Mild Steel Stainless Steel
Bed depth 1 meter minimum
Flange BS 10/Table-D
Joint Efficiency (Shell & Dish end) 0.7
Corrosion Allowance 1.0 mm
Radiography As per specification
(IS- 8419 PART-I)-1977
Filtration media Sand - 0.4-0.8 mm & 1.0-2.0 mm
Gravel - 2.0-3.15 mm & 3.15-5.6 mm
Fontal pipeline 50 mm
Valves 6 way Multiport valves (Auto)
Backwash Manual backwashing as standard
Flow system Down flow

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