Академический Документы
Профессиональный Документы
Культура Документы
troubleshooting guide
ask yourself:
table of contents
Chapter 3 Primary Anion Exchanger . . . . . . . .10 Chapter 4 Mixed Bed Demineralizer . . . . . . . .15
introduction
When the performance of an ion exchange resin bed has changed, it is a clear indication that at least one factor in the entire process has changed. Therefore, a very effective method of troubleshooting an ion exchange resin bed is to view the demineralizer station or plant as being directly affected by several factors. To summarize, we can look at four areas: 1. What goes into the bed? This includes the feed stream, especially the current TDS, the backwash and rinse water, and the chemicals used for regeneration. 2. What is going on as far as what comes out of the bed? This includes instrumentation that measures pressure drops and both quality and quantity of effluent. 3. The mechanical aspects of the plant, which include pumps, valves, the vessel internals and fittings. 4. The ion exchange resin - its condition, age and the quantity in the vessel.
This guide has been assembled as a checklist of areas that can affect the performance of the ion exchange process.
Possible Cause
Reduced Throughput
Increased ionic loading
Solution
- Check influent water hardness - Increase regenerant - Add capacity
Channeling, poor distribution Suspended solids loading Broken or clogged distributors Low flow Premature break
- Check backwash; extend if needed - Repair - Maintain minimum flow - Check previous run throughput - If normal regenerant does not restore capacity, double regenerate - Adjust end point - Check metering pumps, eductors, piping, etc. - Regenerant dosage - Do brine elution study (brine curve) - Check dilution flows, time settings - Apply correct amount at correct concentrations
Resin loss Excessive backwash Underdrain failure De-crosslinked resin Flotation by dissolved gas Normal bead attrition
Check temperature and flowrate Check and repair (resin trap?) See oxidation Effluent flow control Top off
Possible Cause
Reduced Throughput
Resin age
Solution
- Up to 5% / yr loss in capacity considered normal - Analyze resin to determine remaining useful life
Resin oxidation Presence of oxidants (chlorine) and oxygen in presence of catalysts (iron) causes de-crosslinking which reduces wet volume capacity (eventually high P) Resin fouling Iron, manganese, aluminum fouling and precipitates
- Chemical pretreatment of feedwater/activated carbon filter - Replace resin when moisture content exceeds 65%
- Check water supply (analysis) - Check backwash - Check regenerant chemicals for contaminants (analysis) - Clean resin by air-scour and backwash and chemically if required - Clean resin with appropriate cleaner (compatible with resin) - Check end-of-rinse set points - Readjust rinse time to suit - Check for fouling (see above)
Microbiological fouling
Excessive rinsing
Possible Cause
Poor Effluent Quality
Flow rates too high Insufficient reaction time (kinetics) Flow rates too low Poor distribution, channeling
Solution
- Reduce flow
- Place one or more units in standby to increase flowrate - Recycle treated water to inlet - See Resin fouling above under Reduced Throughput - Check resin level and add resin as needed
Resin fouling
For counter-current regeneration: loss of inert (inactive) resin allows resin migration which, in turn, causes high leakage In counter-current regeneration, it is important to use soft water for regenerant dilution and displacement rinse
Valve partially closed Internal distributor blockage With resin, iron, debris
Possible Cause
High Pressure Drop
Flow rates too high Insufficient reaction time (kinetics) Plugged underdrain Resin or subfill in collectors, outlet strainers Increased suspended solids loading in influent Resin fouling
Solution
- Reduce flow
- Inspect internals
- Mid-cycle backwash
- Check for loss to sewer during backwash and rinses - Inspect and repair - See Resin loss above under Reduced Throughput
Possible Cause
Reduced Throughput
Increased ionic loading
Solution
- Check influent water analysis - Increase regenerant - Add capacity
Channeling, poor distribution Suspended solids loading Broken or clogged distributors Low flow Premature break
- Check backwash; extend if needed - Repair - Maintain minimum flow - Check previous run throughput - If normal regeneration does not restore capacity, double regenerate - Adjust end point - Check metering pumps, eductors, piping, etc. - Regenerant dosage - Check dilution flows, time settings - Apply correct amount at correct concentrations
Resin loss Excessive backwash Underdrain failure De-crosslinked resin Flotation by dissolved gas Normal bead attrition
Check temperature and flowrate Check and repair (resin trap?) Effluent flow control Top off
Resin age
- Up to 5% / yr loss in capacity considered normal - Analyze resin to determine remaining useful life
Possible Cause
Reduced Throughput
Resin oxidation Presence of oxidants (chlorine) and oxygen in presence of iron (catalyst) causes de-crosslinking which reduces wet volume capacity (eventually high P) Resin fouling Calcium sulfate, iron, manganese, aluminum fouling and precipitates
Solution
- Chemical pretreatment of feedwater/activated carbon filter - Replace resin when moisture content exceeds 65%
- Check water supply - Check backwash - Check regenerant chemicals for contaminants - Clean resin by air-scour and backwash and chemically if required - Clean resin with appropriate cleaner (compatible with resin) - Check end-of-rinse set points - Readjust rinse time to suit - Check for fouling (see above)
Microbiological fouling
Excessive rinsing
- Check resin - If severely fouled, replace resin - If moderately fouled, clean resin with an HCl soak (caution check materials of construction for compatibility with HCl) - Check influent water calcium concentration (% of total cations) - Check and adjust acid concentration (stepwise regeneration) and flowrate - Check pretreatment
Possible Cause
Poor Effluent Quality
Solution
Notes: For weak acid cation exchangers regenerated with H2SO4, acid strength should not exceed 0.8 % with a flowrate of 2 gpm/ft3. In countercurrent regeneration, it is important to use decationized or demineralized water for regenerant dilution and displacement rinse. Once sulfuric acid injection is started, never stop flow. If acid injection must be interrupted, stop concentrated acid flow but let dilution flow run until all acid is displaced. Excess sodium in treated water ran past breakpoint - Check and adjust set points - Check regenerant dosage and quality - Investigate conversion to upflow or hydrochloric acid regeneration - Check bed sample vs discharge pipe sample (before and after valving); special caution on backwash inlet valve - Check limit stops on valve operators - Check air pressure on pneumatic valves - Check sealing gaskets on multiports - Check for physical damage due to water hammer
Leaky valve
Flow rates too high Insufficient reaction time (kinetics) Flow rates too low Poor distribution channeling
- Reduce flow
- Place one or more units in standby to increase flowrate - Recycle treated water to inlet - See Resin fouling above under Reduced Throughput
Resin fouling
Possible Cause
Poor Effluent Quality
For counter-current regeneration, a loss of inert (inactive) resin allows resin migration which, in turn, causes high leakage
Solution
Valve partially closed Internal distributor blockage With resin, iron, debris
Plugged underdrain Resin or subfill in collectors or outlet strainers Increased suspended solids loading
- Inspect internals
- Mid-cycle backwash - Check filtration ahead of demineralizer - See Resin fouling above
Resin fouling
Possible Cause
Low Pressure Drop
Solution
NOTE: Low pressure drop is not necessarily a problem in itself; however, it may be a symptom of a problem. Reduced flow - P decreases with flow (normal)
Increased temperature
- Check for loss to sewer during backwash and rinses - Inspect and repair - See Resin loss above under Reduced Throughput
Possible Cause
Reduced Throughput
Increased ionic loading
Solution
- Check influent water analysis - Increase regenerant - Add capacity
Channeling, poor distribution Suspended solids loading Broken or clogged distributors Low flow Premature break
- Check backwash, extend if needed - Repair - Maintain minimum flow - Check previous run throughput - If normal regeneration does not restore capacity, double regenerate - Adjust end point - Check metering pumps, eductors, piping, etc. - Regenerant dosage - Check dilution flows, time settings - Apply correct amount at correct concentrations - Check CO2 at the outlet of the clearwell: should be less than 5 ppm. If not: - Check air filter on blower; replace if dirty - Inspect packing (rings) in column. If dirty or slimed, replace packing.
10
Possible Cause
Reduced Throughput
Resin loss Excessive backwash Underdrain failure De-crosslinked resin Flotation by dissolved gas Normal bead attrition Resin age -
Solution
Check temperature and flowrate Check and repair (resin trap?) See oxidation Effluent flow control Topoff
- Up to 5% / yr loss in capacity considered normal - Analyze resin to determine remaining useful life
- Do not exceed 120F anytime for type I styrenic strong base anion resins - Do not exceed 95F anytime for type II styrenic or type I acrylic strong base anion resins
Excessive rinsing Organic fouling (organics tend to hold on to sodium as they contain weak sites which retain sodium)
- Partial restoration of resin with a brine squeeze - Analyze resin for strong base capacity and replace resin if necessary - Incorporate routine brine squeezes into operation of plant - In the case of weak base anions, consider regeneration with ammonia - Recycle rinse water to reduce water usage - Adjust rinse end-point - Check caustic concentration (higher concentration requires more rinse water) - For high TOC waters, consider the installation of an organic trap - Analyze resin - Check for presence of cation resin in anion bed - Identify cause of presence of cation resin (leaky or broken strainer or lateral) and repair
11
Possible Cause
Reduced Throughput
Resin fouling Silica precipitation
Solution
- Lower caustic strength (2.5% suggested) - Thoroughfare regeneration (strong base anion/weak base anion): dump first portion of strong base eluate before feeding residual caustic to WBA resin - Check air filter on blower; replace if dirty, damaged or missing
- Check cation effluent - If cation effluent is within acceptable range, check anion resin
- Check for calcium and magnesium in cation and anion effluent - Insure that dilution and rinse waters are hardness-free - Check cation performance - Check for hardness in all waters used for regeneration to eliminate precipitates - Check regenerant specs for chloride and silica content (mercury cell or rayon grades of caustic are acceptable) - Check for leaking regenerant (caustic) valve
12
Possible Cause
Poor Effluent Quality
Leaky valve
Solution
- Check bed sample vs discharge pipe sample (before and after valving); special caution on backwash inlet valve - Check limit stops on valve operators - Check air pressure on pneumatic valves - Check sealing gaskets on multiports - Check for physical damage due to water hammer
Flow rates too high Insufficient reaction time (kinetics) Flow rates too low Poor distribution channeling
- Reduce flow
- Place one or more units in standby to increase flowrate - Recycle treated water to inlet - See Resin fouling above under Reduced Throughput - Check resin level at exhaustion and add resin as needed
Resin fouling
For counter-current regeneration, a loss of inert (inactive) resin allows resin migration which, in turn, causes high leakage In counter-current regeneration, it is important to use demineralized water for caustic dilution and displacement rinse
13
Possible Cause
High Pressure Drop
Increased flow rate
Solution
- P increases with flow (do not exceed specified P) - Check and adjust all valves
Valve partially closed Internal distributor blockage With resin, iron, debris Plugged underdrain Resin or subfill in collectors or outlet strainers Resin fouling
- Check for loss to sewer during backwash and rinses - Inspect and repair - See Resin loss above under Reduced Throughput
14
Possible Cause
Reduced Throughput / Poor Effluent Quality
Solution
NOTE: Most comments for cation and anion apply to mixed-bed demineralizers and for best performance always use mixed-bed grade resin. Poor primary exchanger performance Poor separation of mixed bed in first step of regeneration - Troubleshoot primary cation and anion exchangers - Check flowrates and temperature of backwash water - Check for proper resin vs mid-collector interface location - Insure use of mixed-bed grade resin - Add cation resin
Interface too low because of loss of cation resin Interface too high because of separation and anion trapped within cation bed Interface too high because of overcharging of cation resin Cross contamination
- Check flowrates and temperature of backwash water - Correct flowrates - Remove appropriate amount of cation resin - Result of poor separation of the cation and anion resins; improper interface location due to loss or overcharging of cation resin - Insure adequate blocking flow
Acid in the anion zone which causes SO4 leakage and early anion exhaustion
15
Possible Cause
Reduced Throughput / Poor Effluent Quality
Caustic in the cation zone which causes Na leakage and early cation exhaustion Insufficient displacement rinse which results in resin crosscontamination and high effluent conductivity Insufficient mixing after regeneration step caused by insufficient air flow Improper draindown prior to air mix
Solution
- Check water level prior to air mix - Adjust setting for water level - Perform a slow fill through the caustic distributor followed by a fast fill through the service inlet - Poor resin separation (see above) - Cross contamination (see above)
Fluidization and reseparation of the bed during refill due to excess flowrate
16
Sybron.IonExchange@Bayer.com www.ionexchange.com