IS 13268 - 1992-DM Plant

11/3/2015
IndianStandard:DEMINERALIZATIONPLANTGUIDELINES
PREAMBLE(NOTPARTOFTHESTANDARD)
Inordertopromotepubliceducationandpublicsafety,equaljusticeforall,a
betterinformedcitizenry,theruleoflaw,worldtradeandworldpeace,thislegal
documentisherebymadeavailableonanoncommercialbasis,asitistherightofall
humanstoknowandspeakthelawsthatgovernthem.
ENDOFPREAMBLE(NOTPARTOFTHESTANDARD)
IS13268:1992
IndianStandard
DEMINERALIZATIONPLANTGUIDELINES
UDC628.165.04
BIS1992
BUREAUOFINDIANSTANDARDS
MANAKBHAVAN,9BAHADURSHAHZAFARMARG
NEWDELHI110002
March1992
PriceGroup6
i
WaterSectionalCommittee,CHD013
FOREWORD
ThisIndianStandardwasadoptedbytheBureauofIndianStandards,afterthe
draftfinalizedbytheWaterSectionalCommitteehadbeenapprovedbytheChemical
DivisionCouncil.
Demineralizedwaterisrequiredforawiderangeofindustriesinvolving
productionofchemicals,pharmaceuticals,fertilizers,steel,power,etc.Besidesitsother
uses,themajoruseofdemineralizedwaterisasboilerfeedwaterinboilers,ranging
fromlowpressuretosupercriticalpressure.Withtheadventofhighpressureandsuper
criticalpressureboilers,thequalityofdemineralizedwaterhasacquiredgreater
importance.Thismakesitessentialtodevelopandmakeavailabletherequired
specificationfortheguidanceofuserstoprocureandinstalefficientandeconomical
systemforproductionofdemineralizedwater.
Thespecificationfordemineralizationplantvariesfromoneplacetoother
dependinguponthesourceofwateravailable,ionicloadofwater,treatedwaterquality
desired,regenerantavailability,etc.Thesefactorsaretobetakenintoaccountfor
https://law.resource.org/pub/in/bis/S02/is.13268.1992.html
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properselectionofdemineralizationplant,andtodeveloptheirdetailedspecifications.
IndianStandard
ii
DEMINERALIZATIONPLANTGUIDELINES
1SCOPE
1.1
Thisstandardcovers(a)thebasicdetailsofdemineralizationplant,(b)brief
guidelinesforframingthespecificationofdemineralizationplant,(c)briefdetailsof
varioussystemscurrentlyinuseforproductionofdemineralizedwater,and(d)the
variousconsiderationsrequiredformakingthebuyersspecificationcompleteinall
respects.
1.2
Attemptshavebeenmadetoexposethebuyerstodifferentsystemsof
demineralizationplant,sothatitmaybeeasierforthemtocompareandselectthebest
possiblesystemsuitingtheirparticularrequirements.
2REFERENCES
TheIndianStandardslistedbelowarenecessaryadjunctstothisstandard:
ISNo.
Title
252:1973
Causticsoda,pureandtechnical(secondrevision)
265:1987
Hydrochloricacid(thirdrevision)
3FACTORSFORDRAWINGUPSPECIFICATION
3.1
Thefollowingfactorsaretobekeptinviewbeforedrawingupthespecification
fordemineralizationplant:
a. Thesourceofwater(riverwater,wellwater,etc)availablefortreatment
b. Qualityoftreatedwater
c. Enduseofdemineralizedwater
d. Theavailabilityofregenerantsinthevicinityoftheproposedplant
e. Disposalofregenerationwastesand
f. Theavailabilityofutilities,suchassteam,instrumentair,etc.
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3.2QualityofFeedWater
3.2.1
Thequalityofwatertobetreatedplaysanimportantroleindrawingupthe
specifications.Thesystemhastobedesignedtoprocessrawwateravailablefrom
differentsources,suchasrivers,tubewells,rivulets,wells,ponds,lakes,etc.
3.2.2
Thefirststepistomakeadetailedanalysisofrawwaterforvariousparameters
includingorganics,colour,suspendedsolids,iron,manganesebesidesotherdissolved
solids.Theanalysisofrawwatershallbecarriedoutthroughouttheyeartodetermine
itsprofilevariationswiththechangeofseasons.Recordsofanalysisofatleasttwoyears
shallbemadeavailablebeforefixingupthetreatedwaterquality.Sufficientmarginin
variousconstituentsofwatermaybekeptinordertotakecareofvariationsinthe
comingyearsbasedonyearlyseasonalvariationsinwateranalysis.Thetubewellwater
compositiondoesnotvarymuchwiththeseason,sointhatcase,itbecomeseasierto
fixupthedesignparametersofwateranalysisbutinsurfacewater,fluctuationsare
quitehigh,soitbecomesdifficulttoarriveatthedesignedanalysis.However,aproper
assessmenthastobemadeforfixingupdesignedwateranalysis.
3.2.3
Thenextistoproperlypretreattherawwatertoobtainwatersuitableforfeeding
intodemineralizationplantastheionexchangeresinusedindemineralizationplantare
susceptibletovariousconstituentscommonlypresentinwaterincludingiron,
manganese,colour,suspendedsolids,residualchlorine,etc.Thefeedwaterfor
demineralizationplantshallbefreefromchlorine,organics,iron,manganese,
suspendedsolidswithin2to3mg/l.Itshallalsobefreefromoilandgreasetoensure
longlifeoftheionexchangeresins.Alltheseconsiderationshavetobekeptinviewin
thedesignofademineralizationplant.
3.3RegenerantChemicals
Theavailabilityofregenerantchemicalsintheneighbourhoodof
demineralizationplantalsoplaysadecisiveroleforfixingtheguidelines.Itis
economicaltomakeuseofchemicalsavailableinnearbyareasforregenerationof
variousionexchangeresins.Thiswillalsoleadtosubstantialsavingsinstoragecapacity
ofchemicalsintheplantduetotheiravailabilityatashortnotice.Regenerant
chemicalslikehydrochloricacid(IS265:1987)andpurecausticsoda(IS252:1973)
usedshallconformtotherelevantIndianStandards.
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3.4DisposalofRegenerationWastes
Thedisposalofregenerationwastesplaysanimportantrole.Thetoxicity,acidity
andalkalinityofthewastewaterhavetobewithinthespecifiedlimits.Thesearestrictly
monitoredvisavispollutioncontrolandenvironmentalprotectionmeasures.
Normally,thepHofeffluentsofdemineralizationplantvariesdependinguponthe
regenerationofcationoranion.Incaseofcationregeneration,thewasteacidcomesto
drain,whereas,incaseofanion,the
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wastealkaliisdrained.Onmixingofbothacidicandalkalinewastestheeffluent
getsneutralizedtoacertainextent.However,itisessentialtoensurefullneutralization
toaboutpH7.5beforethedisposaloffasplanteffluent.
3.5UtilityandCost
3.5.1
Properassessmentoftheavailabilityofutilitiesisimperativebeforeputtingup
theplant.Dependingupontheavailability,thecompletescopeofdemineralization
plantcanbedeveloped.Insomecasesheatingofregenerantisrequired,forwhich
arrangementforsteamistobemadeotherwiseelectricalheatingistoberesortedto.
Besidesthis,compressedairmayberequiredforoperatingvarious
instruments/mechanicalequipment.Iftheexistinginfrastructuredoesnotinclude
arrangementsforsupplyofcompressedair,thesamearetobeprovidedinplants
specification.
3.5.2
Thetypeofoperation,namely,automatic,semiautomaticormanualhasgota
majorbearingonthecostoftheplant.Insomecasesonlymanualoperationis
preferredwhereasinothercasessemiautoorautooperationisbeingconsidered.In
casesemiautooperationisdesired,propercarehastobetakenindevelopingthe
specificationbecausethisgreatlydependsuponmanyprocesssequences.
3.5.3
Theprocesssequenceadoptedfortheplant,requiresspecialattentionasitmakes
theplantoperationmoreeconomical.
4BASICPARAMETERS
4.1
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Considerableimportanceistobegivenfordeterminationofthebasicparameters
soastogetaplantsuitingtherequirementsoftheclient.
4.1.1
Buyerspecificationconsistsof(a)design,(b)engineering,(c)procurement,(d)
transportation,(e)storage,(f)erection,and(g)commissioningofalltheworkincluding
mechanical,electrical,instrumentationbesidescivilwork.
NOTESometimescivilworkisexcludedfromthescope,and
includedinthescopeofmaincivilcontractor,whoexecutescivilworkfor
theentireplantincludingdemineralizationplant.Itbecomesadvantageous
toadoptthis,asthecompleteresponsibilitylieswithasinglecivil
contractor,followingthesamenormsforthecompletefactory.Ithasgot
certaindisadvantagesaswellbecauseincreasedcoordinationisneeded
betweendemineralizationplantsupplierandcivilcontractortocomplete
thecivilworkintimesothattheerectionworkofthedemineralization
plantisstartedasscheduled.Hence,itispreferredtohaveonesource
responsiblefordemineralizationplantsupplyinallrespectsincludingcivil
works.
4.1.2
Thespecificationshallclearlygivetheminimum,normalandmaximumflow
ratesdesiredforthesystem.Theflowandnumberofstreamsrequiredlargelydepend
ontherequirementofdemineralizedwaterintheenduseinotherplantswhichhasto
beassessedpriortoframingthespecifications.Thenumberofstreamsarealsotobe
clearlyidentifiedasitmakesabigcostimpactintheplant.Sometimes,itispreferredto
have100percentsparestream,whereasinothercases,nosparestreamisdesiredasit
isbeingcompensatedbycreatingalargecapacityforstoringtreatedwater.Thesingle
streamdemineralizationplantisdesignedwithhighercapacitytogetextrawaterfor
storagetotakecareofanyextremeurgency.However,itisdefinitelypreferabletogoin
foraminimumoftwostreams.Onecangoforanynumberofstreams,butthenthe
costoftheplantwouldincreasewithincreaseinnumberofthestreams.Therefore,an
optimumbalancehastobestruckforfixingthenumberofstreamsforagivenenduse.
4.1.3
Theheadersystemshallalsobeclearlymarkedintheplantspecification.
Sometimes,itisdesirabletohaveasingleheadersystem,whereasinothercases,
separateheadersforeachstreamarefavoured.Insomecases,amixedapproachis
beingadoptedhavingbothsingleheader,andseparateheadersforsomeoftheprocess
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fluidstreams.Singleheadersystemishavingcertainflexibility,asanyunitofthis
streamcanbeeasilyconnectedtootherunitortheotherstream.Sosingleheader
systemiscommonlypreferred.Someclientsdopreferindividualstreamsbutthecost
implicationsrequiretobelookedintoseriously.
4.2StorageCapacity
Thestoragecapacitiesforthefeedwatertank,degassedwatertank,
demineralizedwatertankandacidandalkalitankarealsotobepredetermined,and
clearlydefinedinthespecificationofdemineralizationplant.
4.2.1FeedWaterTank
Thefeedwatertankcapacitylargelydependsupontheavailabilityoffeedwater,
chancesoffailureoffeedingsystem,fluctuationsinthepressure,andflowoffeed
water.Butinmostofthecases,thistankactsasabuffertank,andisnotprovidedwith
morethan2to3hourscapacitywhichisjustsufficienttoprovidesuctiontothefeed
waterpump,soastomaintainconstantpressuretothedemineralizationplantsystems.
4.2.2DegassedWaterTank
Thecapacityofdegassedwatertanklargelydependsuponthefrequencyofthe
regenerationofionexchangeresins,wastewaterusedintheregenerationandextra
capacitydesiredforemergencyintheplant.Allthesefactorsshallbekeptinviewwhile
evolvingtheminimumcapacityofdegassedwatertanksothatitcoversallthe
contingenciesintheplant.Normallyit
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issizedathalfanhourpumpingcapacityofdegassedwaterpump.
4.2.3DemineralizedWaterTank
Thecapacityofthedemineralizedwatertankgreatlyvariesfromoneclienttothe
other.Thecapacityisnormallyfixedonthebasisofexigenciesoccurringintheplant,
thevariationsinuseofdemineralizedwaterindownstreamplants,useof
demineralizedwaterforregeneration,etc.Normally,inpowerplantsclientspreferto
havethestoragecapacityfor16to24hours,butinotherplantsitisbeingkeptfor4to
8hours.However,thereisnostrictruleforitasthisentirelydependsupontheclients
requirements.
4.2.4AcidandAlkaliTank
Thestoragecapacitiesofacidandalkalitanksrequiredforregenerationsarealso
tobeclearlyindicatedinthespecification.Thesecapacitiesaredependentuponthe
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considerationofthetimeittakestoprocurethechemicalsatplantsite.Whereitmay
take1015daysforobtainingthechemicals,itbecomesadvisabletogoinforatleast
onemonthsstorageattheplantsite.Innormalcases,whereatankerofacidoralkaliis
expectedwithin4to6daystime,storagecapacityofaminimumof15daysmaybe
desirable.Wherevertheregenerantchemicalsareavailableintheplant,alimited
storageof3to4daysonlymaybeconsidered.
5FEEDWATER
5.1
Beforedevelopingasystemandfixingspecificationsfordemineralizationplant,
thesourceoffeedwateranditsavailabilityhasgottobeestablished.Sometimes,water
isavailableintheformoffilteredwaterafterproperchlorination,coagulation,
flocculation,clarificationandfiltration.Thefilteredwaterisbeingdirectlyfedtothe
feedwatertankfollowedbyionexchangersforproductionofdemineralizedwater.
However,itbecomesessentialtoestablishwaterquality,whichshallbefreefrom
colour,organics,etc.Incaseofanycolour,organicsorfreechlorine,thewaterhasto
betreatedwithactivecarbontotakecareofminorquantitiesofcontaminantscoming
infeedwater.Incaseofunfilteredwater,theactivecarbonfiltersaretobeprecededby
filtersforwhichpressuresandfiltersarenormallyusedsometimesdualmediafilter
havingsandandanthracitearealsoused.
5.2
Fordechlorination,sometimessodiumsulphiteisused,whichisdosedinfeed
waterbeforefiltration.Sometimesthesystemishavingonlyonedosingpot,wheresolid
sodiumsulphiteisaddedalongwithwatertomakesolution.Thesolutionthusprepared
isdosedatadesiredrateunderpressurebeforefiltration.Inothersituation,asolution
preparationtankwithagitatorisprovided.Thesolutionisdosedtofeedwaterbymeans
ofsulphitedosingpump.
6DEMINERALIZATIONSYSTEM
6.1
Therearedifferentkindsofsystemsfortreatmentofwaterinordertoget
demineralizedwater.Nowadays,asthecostofregenerantchemicalishigh,itis
advisabletoselectaneconomicalsystemtoreducerecurringcostonchemicals.Systems
inoperationaredescribedinbrieftoguidethebuyersinselectingaviableandstable
demineralizationwaterplant.
6.1.1
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Cationexchangerunithavingstrongacidiccationexchangeresinfollowedby
anionexchangerunithavingstrongbasicanionexchangeresinwithoutanydegasser
systeminbetween.Thissystemispreparedforwaterhavinglessalkalinityof100ppm
andcapableofgivingdemineralizedwatersuitableforlowpressureandtoacertain
limitformediumpressureboilers.Besides,thissystemcancomehandyalsofor
industriesusingdemineralizedwaterforprocessing.Inthissystem,bothcocurrentand
countercurrenttechniquescanbeadopteddependinguponthequalityoffeedwater,
butcountercurrenttechniqueismoreeconomical(seeFig.1).
6.1.2
degassersystemhavingdegassertower,anddegassedwatertankfollowedbystrong
basicanionexchanger.Thissystemgivesdemineralizedwaterforlowpressure,andtoa
certainlimitformediumpressureboilersaswell.Herealso,bothcocurrentand
countercurrentregenerationtechniquescanbeuseddependinguponthequalityoffeed
waterbutcountercurrenttechniqueismoreeconomical.Thissystemissuitablefor
waterhavingmoderatealkalinityofabout250mg/lalkalinity.Herealsostrongbasic
anionexchangeresinofType1orType2isuseddependingupontherequirementof
silicaleakage(seeFig.2).
6.1.3
Cationexchangerunithavingstrongacidiccationexchangeresin,followedby
anionexchangerunithavingstrongbasicanionexchangeresin,followedbymixedbed
exchangerunit,havingamixtureofstrongacidiccationexchangeresin,andstrong
basicanionexchangeresinType1.Thissystemgivesimprovedqualitydemineralized
water,sometimescalledpolishedwaterbecauseoftheuseofmixedbedexchangerunit
whichisalsonamedaspolishingunitbecauseofitsbasicroletopolish(refine)the
demineralizedwater.Herealso,cocurrentorcountercurrentregenerationtechniques
canbeadoptedforbothcationandanionexchanger,butformixedbedexchangeritis
alwayspreferabletoadoptcocurrentregeneration.Thissystemgivesdemineralized
waterofhighpurity,whichisrequiredforuseinmediumpressure,highpressure
boilersandotherchemicalprocessingindustrieswherepurityofwaterisofmajor
concern.Thesystemissuitableforwaterhavingalkalinitylessthan100ppm.Herealso
inanionexchanger,strongbasicanionexchangeresinofType1orType2canbeused
dependinguponsilicaleakage(seeFig.3).
3
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FIG.1FLOWDIAGRAMSHOWINGTHEARRANGEMENTOFADEMINERALIZATION
PLANT
PLANTWITHADEGASSERTOWER
FIG.3FLOWDIAGRAMSHOWINGTHEARRANGEMENTOFADEMINERALIZEDPLANT
WITHAM IXEDB EDUNIT
6.1.4
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degassersystemhavingdegassertoweranddegassedwatertankfollowedbyanion
exchangerunithavingstrongbasicanionexchangeresinfollowedbymixedbed
exchangerunithavingamixtureofstrongacidiccationexchangeresinandstrongbasic
anionexchangeresinofType1.Herealsobothkindsofregenerationtechniquesasin
5.1.3beuseddependinguponthequalityofdemineralizedwaterdesiredexceptfor
mixedbedunit.Thesystemyieldsdemineralizedwaterofhighpuritywhichisusefulfor
mediumandhighpressureboilers.Thissystemissuitableforwaterhavingmoderate
alkalinityof250ppm.UseofType1orType2strongbasicanionexchangeresinin
systemdependsgreatlyuponleakageofsilicafromthesystemcan(seeFig.4).
4
FIG.4FLOWDIAGRAMSHOWINGTHEARRANGEMENTOFADEMORALIZATION
PLANTWITHADEGASSERANDAMIXEDBEDUNIT
6.1.5
Thecationexchangerunitinthesystemsdescribedabovemayfurtherbesplit
intoasystemconsistingofweakacidcationexchangerunithavingweakacidiccation
exchangeresin,followedbystrongacidcationexchangerunithavingstrongacidic
cationexchangeresin.Thissystemismoreusefulforwaterhavinghighalkalinityof
morethan300ppmandhighhardnessofmorethan300ppm.Themodifiedsystems
arecommonlyadoptedtoconservetheregenerantchemicals.Here,theregenerationis
adoptedinthoroughfaremannerinvolvingpassingofregenerantfromoneunittothe
otherunitinseries.Normally,theregenerationisbeingdonefromstrongacidcation
resintoweakacidcationresinbyadoptingcocurrentthoroughfaretechnique,thatis,
usingboththeregenerationincocurrentmannerinseriesorusingcountercurrent
thoroughfareregenerationstechniqueinvolvingcountercurrentregenerationofstrong
acidcationexchangerinserieswithcocurrentregenerationofweakacidcationresin
(seeFig.5).
6.1.6
Theanionexchangerunitintheabovesystemscanalsocontaintwoseparate
anionexchangersinvolvingweakbaseanionexchangerfollowedbystrongbaseanion
exchanger.Thissystemisalsousedtoconservetheregenerantchemicalsandtomake
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theplantmoreeconomicalbyadoptingeithercoccurentthoroughfaretechnique,
involvingregenerationofbothweakbaseandstrongbaseanionunitincocurrent
mannerinseriesorcountercurrentthoroughfaretechniquewithcountercurrent
regenerationofstrongbaseanionexchangeresinwithcocurrentregenerationofweak
baseanionexchangeresininseriesisadopted.Thesystemisusedwhenthewateris
havingahighamountofchloridesandsulphates(seeFig.6).
6.1.7
Inthesystemsgivenin6.1.1and6.1.2,sometimesitbecomesdesirabletogoin
forweakbaseanionexchangerinplaceofstrongbaseanionexchangerspeciallyin
caseswheresilicaremovalisnotsocriticalfromthefeedwater.
6.1.8
Inthesystemgivenin6.1.1to6.1.6forstrongbaseexchanger,sometimesType
2strongbaseanionexchangeresinisusedinplaceofType1strongbaseanion
exchange
PLANTWITHAWEAKACIDCATIONANDAMIXEDBEDUNIT
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PLANTWITHAWEAKBASEANIONANDAMIXEDBEDUNIT
resin.Thissystemisusefulwhensilicaleakagedesiredinthedemineralizedwater
isslightlyhigher.
6.1.9
Thesystemsometimesnecessitatestomakeuseoftwomixedbedexchangerunit
inseries,thatis,onemixedbedunitfollowedbyanothermixedbedunitinplaceof
onlyonemixedbedunit.Suchsystemsarenormallyemployedtogethighlypure
demineralizedwaterwhichissuitableforhighpressureorsupercriticalpressureboilers
orincaseswherehighlyrefinedwaterisrequired.
6.1.10
Thecationexchangerunitinthesystemgivenin5.1.2mayalsobeselectedin
twoseparatecationexchangerunits,eachhavingstrongacidcationexchangeresin
wheretheregenerationismadebycountercurrenttechniqueforsecondcation
exchangerunitandthethoroughfaremannerinserieswithfirstcationexchangerunit.
Thisprocessbecomesmoreadvantageousthanonesingleexchanger,asittakescareof
anyextraleakagecomingfromthefirstcationexchangerandtherebygivesmuchbetter
treatedwaterthaninsingleexchangerunit.Thissystembecomesmoreusefulwith
higherdissolvedsolidsinfeedwater.
6.2
Anyoneoftheabovedescribedsystemscanbeselectedforincludinginthe
specificationsbyclient.However,analysisofwaterandeconomicsoftheprocessplay
thedecisiverole.Asisevidentfromabove,theregenerationtechniqueplaysan
importantroleforachievingthedesiredqualityofdemineralizedwater.Depending
uponthemodeofregeneration,performanceofexchangersvaries.Soitbecomes
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importanttofixthemodeofregenerationinthespecificationsitselfbytheclient.
6.3
Theminimumdepthofresinusedintheaboveexchangersshallnotbelessthan
91.5cm(3feet).
7EQUIPMENT
7.1
Theequipmentdetailsconstituteanimportantcriteriontobegiveninthe
specification.Basicparametersforeachandeveryequipmentaretobegiveninthe
specification.
7.1.1PressureSandFilters
Thepressuresandfiltersshallbeeitherofverticalorhorizontaltypewhichisto
beclearlymentionedintherequirement.Normally,verticalsandfiltersarepreferred
exceptincases,wherehigherflowisrequired.Theflowforthefiltersmayclearlybe
establishedsoastocovertherequirementofdemineralizedwater,wastewaterfor
regenerationofexchangers,andfilteredwaterforbackwashingthefilters.Back
washingoperationisadoptedforcleaningthefilterbed,andtomakethebedloose,for
reducingpressuredropwhilerunningtheplant.Thebackwashingoffiltersisdoneby
eitherfilteredwateraloneorbyairandfilteredwatertogetherorindependently.The
desiredmodeofbackwashingistobeclearlyspecifiedinthespecification.
Thestoragetankshallbelocatedeitherovergroundatadesiredheighttogetthe
sufficientpressureforbackwashingoronthegroundlevel.Inthelattercase,extra
pumps(1.5kg/cm2)arerequiredforbackwashingthefilters.Airrequirementfor
backwashingshouldalwaysbemetbytherotaryairblowers.Servicesairof3to6
kg/cm2pressureshallneverbeusedforairscouringasitwillchurnupthefiltermedia.
Forprovisionoffilteredwatertank,itselevations,specificationoffilteredwaterpumps
andairblowersshallclearlybestipulatedtogetthecompletesystem.Theguaranteeof
thefilteredwatercomingoutoffiltershallbegiveninthespecificationbasedonwhich
filterisdesigned.Ingeneral,turbidityisspecifiedforfilterdesignandwateroutletof
filtershallcontainturbiditylessthan2NTU.
6
Thematerialofconstructionoffilteristobegivenclearly.Thevoidspaceabove
thepackedbedmaybementionedwhichisnormallykeptabout50percentofthe
packedheight.
Thestandarddesignspecificationareasfollows:
a. Airblown0.4to0.5kg/cm2airdischargepressure0.015to0.025m3/m2secof
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filterbedarea(airrequirement)
b. Backwashpump1.5kg/cm2dischargepressureat101/m2secoffilterbedarea
(backwashrequirement)
c. Filterpump3to4kg/cm2dischargepressure,1.3to4.11/m2secofbedarea
(filterationrate)
d. FiltermediaFinesand:(30cm):
Grade0.45to0.5mmCoarsesand:25cm
Grade0.8to1.2mmFinepebbles:10cm
Graee3to6mmMediumpebbles:10cm
Grade6to12mmCoarsepebbles:20cm
Grade12to25mm.
7.1.2ActiveCarbonFilter
Theactivecarbonfilter,whereverdesired,istobeinstalledafterpressuresand
filterswhichconsistofactivecarbonpackingcapablefordechlorination,deoilingand
decolourationalongwithremovaloftracesofironandorganics.Thegradeofactive
carbontobeusedforthepurposeshallalsobementioned.Themodeofbackwashing
thesefilterswithfilteredwaterisalsotobementioned.Herealsoasimilararrangement
forbackwashingasgivenaboveforthepressuresandfiltersistobegiven.Normally
arrangementforbackwashofactivecarbonfilter,andpressuresandfiltersare
common,asatnostagesimultaneouslybackwashofbothactivecarbonfilterand
pressurefilterisexpected.Even,ifitsohappens,backwashingoftheunitscanbeeasily
staggered.Theguaranteeofthequalityoftreatedwatershallbeincorporatedinthe
specification.Thequalityparametersofthetreatedwatershallconformtolimitsas
follows:turbidity(<1NTU),chlorine(<0.01mg/l),andiron(<0.01mg/l).The
materialofconstructionofthebodyandlining,ifany,istobespecified.Normally,
epoxyliningispreferredoninsidesurface.Thevoidspaceabovethepackedbedmaybe
specifiedwhichiskeptabout50percentofpackedbed.
Designspecification:
a)Activatedcarbonbeddepth
3mminimum
12mmaximum
6mnormal
b)Contacttimeofwaterwithactivatedcarbon
15minutesminimum
30minutesnormal
7.1.3ExchangerUnit
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Thedetailsoftheexchangerunitsaretobeclearlyspecifiedkeepinginviewthe
requirementsoftheclient.Thesealsoincludetherequirednumberofinspection
windows,numberofmanholesandothermechanicalrequirements.Theinternal
arrangementoftheexchangeristobelefttothebiddersasitdependsuponthetypeof
systemadoptedbythemeitherheaderlateralsystemorstraineronbedplatesystemfor
propercollectionanddistributionofwateruniformlythroughexchangerbed.The
minimum,normalandmaximumflowthroughexchangermayclearlybespecified.The
voidspaceabovethepackedresinbedmayclearlybementioned,whichisnormally
keptabout75percentoftheresindepthforcationandanionexchangers,whereasfor
mixedbeditispreferabletokeepminimum100percentofthemixedbedresindepth
forexpansion.Thequalityoftreatedwaterguaranteedascomingoutofeachexchanger
maybegiveninthespecificationbasedonwhichexchangersaretobedesigned.
Normallyforcationexchangersthereshallbeleakageofsomesodiumionswhich
dependsupontheregenerationleveloftheexchanger.Forcationexchangers,the
leakageofhardnessisconsiderednilandsodiumleakageisbeingpermittednormallyin
therangeof1to2mg/l.Thetermregenerationlevelreferstotheamountofregenerant
chemicalusedfortheregenerationofexchangerresin.Foranionexchangersthereis
someleakageofchlorideionandsilicaion,dependinguponthetypeofanionexchange
resinusedinthesystem.Withanyleakageofsodiumionfromcationexchanger,there
isaresultantincreaseinleakageofaniontherebyincreasingconductivityandsilica
contentofdemineralizedwater.Theconductivityanddesiredsilicacontentoftreated
watercomingoutofanionexchangershallbeclearlydefinedinthespecificationfor
design,sothatoptimumregenerationlevelcanbeselectedbothforcationandanion
exchangerunits.Theguaranteedwaterqualitydesiredfrommixedbedunitshallalsobe
clearlydefinedinthespecificationsothattheunitmaybedesignedaccordingly.
7.1.4DegasserTower
Thedeggassertowerrequirementmayalsobeclearlydefinedwithrespecttoits
flowrate,typeofpacking(stainlesssteelorglazedceramic),etc.Theguaranteedwater
qualitycomingoutofdegassershallalsobeclearly
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givenforwhichcarbondioxideshallbenormallyintherangeof4to8mg/las
calciumcarbonate.Necessarymanhole,handhole,etc,maybeclearlyspelledoutto
facilitateeasymaintenance.Towerisnormallyplacedonsomeheighttogiveagravity
flowtodegassedwatertankplacedbelowit,wheredegassedwatercomingoutofthe
toweriscollectedandfedtodownstreamsystems,andotherusesintheplant.The
degassedwatertankinsideisnormallylinedwithacidandalkalineresistanttilesto
preventhardnessandsilicapickupfromthewallsbytheacidicwater.Normally,
degasserwatersystemiskeptcommonforthestreams,butsometimesinstallationsmay
berequiredstreamwisewhichistobeclearlyindicatedinthespecification.The
numberofairblowersrequiredforthedegassertowershallbementionedwhichis
normallykepttwoforeachtower.Thenumberofdegassedwaterpumpsmayalsobe
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clearlyspecified,sothatthebiddersareabletogivethesametypeofsystem.Sometimes
pumpsaredesignedfor50percentcapacityonlywhereasinothercaseitispreferable
tohavepumpcapacityof100percent.Themainconsiderationistheeconomicofthe
recurringcostoftheplant.
8ACIDHANDLINGSYSTEM
8.1
Thedetailsofacidhandlingsystemandregenerationequipmentdesiredforthe
systemshallbementionedinthespecification.Thedetailsofacidstoragetankcapacity
requirementhasbeengivenin4.2.4.Normally,sulphuricacidorhydrochloricacidis
usedforregenerationofthecationexchangeresin.Theacidsupplytoplantismadeby
roadtanker.Incases,whererequirementisverylarge,provisionofrailtankerisalso
madeinadditiontoroadtanker.Asthesulphuricacidismuchmoredangerous,extra
precautionsaretobetakenforitshandling.Acidtankersaresometimespreferredtobe
placedonheight,soastogetthegravityflowfromtheacidtankertoacidstoragetank
indemineralizationplant.Thetransferofacidfromacidtankertoacidstoragetankis
beingdonenormallybypumps,butsometimesthistransferisalsoeffectedby
pressurizingthetankerbyair.Inthiscase,theacidtankershallbecapableof
withholdingthatmuchairpressure,asotherwiseitwouldleadtofailureoftankcausing
aseriousaccident.Thematerialofacidtransferpumpsaretobesuitablyselected
dependinguponthetypeofacidused.Separateregenerationequipmentarerequiredfor
usewithsulphuricacidandhydrochloricacid,respectively.Generally,polypropylene
pumpsareusedforhydrochloricacidseriesandstainlesssteelpumpsforsulphuricacid
series.
8.1.1RegenerationEquipment
8.1.1.1
Incaseofsulphuricacid,theacidstoragetanksshallbefullyguardedtoavoid
contactofmoistairwithstoredacid,forwhichsilicagelbreathershallbeprovided.In
addition,propersealshallalsobeincludedinoverflowlinetoactasavacuumbreaker.
Acidfromstoragetankiswithdrawneitherbygravityorbypumpsandsenttoacidday
tank,ortoacidmeasuringtank,dependingupontherequirement.Theacidmeasuring
tanksaregivenseparatelyforeachexchanger(cationexchangerormixedbed
exchanger)astherequirementofeachisdifferent.Sometimes,theacidisfeddirectlyto
ionexchangerunitswiththehelpofaciddosingpumps.Theonlinedilutionofacidis
donebyprovidingamixingtee,butextraprecautionistobetakeninchoosingsuitable
materialofconstructionofmixingtee(normallystainlesssteelforsulphuricacidseries),
toavoidfrequentfailuresduetothecorrosiveactionofacidandheatofdilutionacid
whichisrequiredtobedilutedfrom98percenttodesiredregenerantconcentration
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rangingfrom1.5to5percent.Separateaciddosingpumpsarerequiredforcationunit
andmixedbedunit.Theacidfromeachacidmeasuringtankwhicharenormallyputon
sufficientelevation,istakenbygravitytoaciddilutiontanksplacedatgroundlevel
wheretheconcentrationisreducedtoabout20to30percent.Thisdiluteacidatthe
desiredconcentrationistakenwiththehelpofwaterejectortodifferentexchangersfor
furtheronlinedilutionusedforregeneration.Acidconcentrationisveryimportantfor
regenerationofcationexchangerbecausethepresenceofmorehardnessinwaterleads
toprecipitationofcalciumsulphateduringregeneration,therebyleadingtoimperfect
regeneration.
8.1.1.2
Incaseofhydrochloricacidstoragetank,properprecautionsshallbetakento
avoidhydrochloricacidvapourgoingoutofthetanktothesurroundings,forwhich
fumeabsorbersshallbeprovided.Acidfromstoragetankistransferredinsimilar
fashionasinthecaseofsulphuricacidmentionedin8.1.1.1.Theonlinedilutionis
donebywaterejector(normallyeboniteejectorforhydrochloricacidseries)forgetting
desiredconcentrationofregenerantconcentrationtoabout3to5percent.Sufficient
carehastobetakentocontroltheacidfumeintheplantareabyprovidingfume
absorberswherevernecessary.Herealso,separateacidmeasuringtanksfordifferent
exchangerunitsaretobeprovided.Informationisalsotobeprovidedonthematerial
requiredforconstructionofequipmenttohandleacid.
9NEUTRALIZATIONSYSTEM
9.1
Neutralizationsystemisanotherimportantaspectparticularlyintheperspective
ofpollutioncontrolmeasures.Allthewastewaterscomingoutduringregenerationof
exchangersarerequiredtobecollectedinapitwhichistobeneutralizedbefore
discharge.Normallytwo
8
sectionsinneutralizingpitareprovided,eachsectionbeingcapableofholding
totalwastewatercomingoutofallexchangersatatime.Sometimes,thenuetralization
pitisdesignedtotakeupeither12hoursor24hourscollectionsofwastewatercoming
outduringregenerationofexchangersbutthiswilladdtothecostofplantsasthepits
requireasuitableliningoverRCCstructuretohandleacid/alkali.Properpumpingand
recirculatingarrangementforeffluentmixingarealsotobeprovided.Sometimes,
additionalairgridisprovidedinthepitforthoroughmixingofalkali/acidforcomplete
neutralization.Properspecificationsaretobedevelopedforthissystemsuitingclients
requirement.Limeisnormallyusedforneutralizationforwhichlimepreparationtank
andfeedingarrangementbygravityshallalsobeincludedinthespecifications.
Otherwise,properacid/alkalimixingistobespecifiedinthespecifications.
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9.2
Thedetailsofalkalihandlingsystemandregenerationequipmentdesiredforthe
systemshallbeclearlymentionedinthespecifications.Detailsofalkalistoragetankare
givenin4.2.4.Normallyonlycausticsodaisusedforregenerationofanionexchange
resininanionandmixedbedexchangerunits,butsometimesammoniaisalsousedfor
regenerationofweakbaseanionexchangeresinspecially,inthenitrogenousfertilizer
plantproducingammonia.
9.2.1
Ammoniasolution(10percent)ispreferredtobestoredinthestoragetank,
whichshallbeproperlysealedtoavoidanyvapourofammoniaescapinginto
atmosphere.Thissolutionisfedtoexchangerwiththehelpofpumporwaterejectorto
getthefinalconcentrationofammonia(about4percent)requiredforregenerationof
exchanger.
9.2.2
Thecausticsodasolutiontanksdetailshavebeengivenin4.2.4,whichshallbe
partofthespecification,butthetanksshallbeprovidedwithairbreathertoavoid
carbondioxdeintakefromatmospherewhichcouldleadtoformationofsodium
carbonate.Propersealing,therefore,isalsotobeprovided.
Thealkalitanknormallystorescausticlyesolution(about4047percent)coming
bytanker(roadorrail)dependingupontherequirementofalkaliintheplant.The
alkalipumpsareusedfortransferofalkalisolutionfromthetankertostoragetank,
fromwhere,itistransferredtoalkalidayoralkalimeasuringtankbygravityorbyalkali
transferpumpsdependingupontheelevationofthetank.Thealkalidaytankis
designedforstoringalkalirequiredforregenerationofvariousexchangersinaday.The
alkalimeasuringtanksareseparatelyprovidedforanionexchangeresinofanionand
mixedbedexchangerunits.Thetransferofalkalifrommeasuringtanktoanion
exchangercanbedoneeitherbyalkalidosingpumpswithonlinedilutionbyalkali
ejectortoachievedesiredconcentrationofalkalisolutionforregenerationwhich
normallyrangesfrom2to5percent.Butforregenerationofalkalitomixedbedunit
thealkaliejectorisusedtogetthedesiredalkalisolutionconcentrationintherangeof
4to5percent.Useofalkalidosingpumpsisalsopreferredspeciallyincasewhere
pressuredropexpectedishigh,suchasinthoroughfareregenerationsystem.
Sometimes,itbecomesdifficulttogetlyesolutioninthevicinityoftheplant,
thenalternatearrangementofpreparingalkalisolutionistobemadeatthesiteby
gettingsolidalkaliintheformofflakesorsolid.Forthispurpose,aseparatealkali
solutionpreparationtankhastobeprovidedequippedwithproperstirring
arrangement.Inaddition,thealkalitransferpumpsarerequiredfortransferringalkali
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solutionpreparedinthetank,whichshallalsobeusedforrecirculationofalkali
solutioninthetankforpropermixingofsolidtopreparethesolution.Atleastone
causticpreparationsolutiontankshallbeincludedinthespecificationtotakecareof
anyextremeemergency,incaselyesolutionisnotmadeavailableduetosomereasons
beyondcontrol.
10GENERALANDCONSTRUCTIONALFEATURES
Itisessentialtodescribegeneralandconstructionalfeaturesofvarious
equipmentinthespecification,includingthemodeoftheiroperation,locationofthe
plant,etc.
10.1GeneralFeatures
Thesecover(a)modeofoperation(b)locationoftheplant,(c)typeof
instrumentationdesired,and(d)electricalsystemrequirement,etc.
10.1.1ModeofOperation
10.1.1.1
Forsmallplants,manualoperationispreferred,astheoperationofthesmallsize
valvesdoesnotposeanyproblem.Further,withtheinstruction,thetotalcostofthe
plantgoesup,whichdiscouragesrecoursetosophisticationinsmallplants.Nowadays,
duetooperationaldifficultiesandtominimizetherecurringcost,thelabourcostisto
bereduced,whichencouragesonetogoinforsemiautoandautooperationofthe
plant.Themodeofoperation,therefore,hastobeclearlyspecified.
10.1.1.2
Semiautooperationincludestheoperationofvariousvalvesthroughselector
switcheslocatedinthecontrolpanelsothattheoperatorscanoperatetheplantfrom
thecontrolpanel.Sometimessemiautooperationincludesstoppingoftheplantduring
servicerunbythe
9
selectorswitch,andthereaftertheregenerationistobecarriedoutbymeansof
sequencetimerorprogrammelogiccontroller.Thissystemrequiresalotofprecision,
maintenance,workmanship,reliability,andsmoothnessinoperationofvarious
instrumentsandvalves.Although,suchkindofsystemisbecomingpopular,onehasto
considerbeforehandthefactorsmentionedearlier.Completeautooperationisnotat
alldesirableinIndiabecauseofthelargevariationinnightanddaytemperature.
However,still,someclientprefertogoinforautomaticplants.Naturally,successwill
dependupontheregularmaintenanceofvariousinstrumentsandautovalvesin
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operation.
10.1.2LocationofthePlant
Thisbecomesanimportantfactorforthetotalcostoftheplant.Inpowersector
itisnormallypreferabletogoinforcompletelycoveredplantbutinotherchemical
industries,includingfertilizers,trendshavesetintogoinforopenplants.Theopen
plantismoreeconomicalcomparedtoacoveredplant,buttherearesomeoperational
hazardswhichmayhavetobefacedbytheoperatorsduringmonsoon,winters,and
summers.Incase,theplantismadesemiautotypeitreallybecomesadvantageoustogo
inforopenplant,asfrequentvisitofoperatorstofieldisavoided.However,ultimately
thechoicebetweenopenandcoveredplantremainswiththeclient.Butthetype(open
orcovered)mustbeincludedinthespecification.
10.1.3Instrumentation
Nowadays,moreandmoreonlineinstrumentsareincludedintheplants.This
givesinstantaneousanalysisofwateratvariousstagesoftheplant.Moreandmore
instrumentsarethereinsemiautoandautoplantstocontroltheregenerationand
servicerun.
10.1.3.1
Infilters,mostofthetimemanualoperationispreferredbutinsomecasesauto
operationisselected,incaseofautooperation,anyhighpressuredropacrossthebed
leadstoautomaticbackwashingfollowedbyrinsingofthefilterbeforeputtingfor
servicerun.Fordetectionofpressuredropacrossthebed,differentialpressure
indicatoralarmisused,whichisconnectedwithoperationofserviceandbackwash
valvesofthefilter.Further,flowindicatorintegratoronindividualfiltersarerequired
besidesrecorder.Sometimes,inmanualplant,useofonlywatermeterinthefeedline
ispreferred.Incaseofautoorsemiautooperation,thevalvesincludedforoperation
arepneumaticallyoperatedgatevalvesandonlyinsomecases,whereinstrumentairis
notavailable,motorizedvalvesareused.Inletandoutletoftheindividualfiltershave
pressuregaugeswhichdependuponclientsrequirement.However,outletpressure
gaugeisdefinitelyrequiredtoassessthepressuredropacrossthebed,butinletpressure
gaugecanbeavoided.
10.1.3.2
Theexchangersarerequiredtohavemoreinstrumentationparticularlyinauto
andsemiautoplants.Itisdesirabletohaveflowindicatorintheinlet.Sometimes,only
oneflowindicatorisprovidedintheinletwithawatermeterintheoutlettoassessthe
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totalquantityofwatercomingoutduringservicerunorinbetweentworegenerations.
Sometimes,differentialpressureindicatorisalsoprovidedtoassessthepressuredrop
acrossthebed,otherwiseonlypressuregaugesareprovidedininletandoutletpipes.
Thecationexchangeunitisrequiredtohavesodiuminindicatingmetertoindicatethe
leakageofcations,forwhichoneprobeisputintheoutletoftheexchanger.Theanion
exchangerunitisprovidedwithconductivityindicatortoassesstheconductivity,and
evensometimeswithsilicaanalysertoestimatethesilicacontentinthetreatedwater.
Insomecases,evenonline,pHmeterisprovidedintheoutletoftheunit,butnormally
pHismeasuredinthelaboratoryonly.Themixedbedexchangershaveconductivity
meter,silicaanalyser,pHmetertogivetheindicationsofqualityoftreatedwater.
Sometimes,onlyaconductivityindicatorisprovidedandrestofthemeasurementsare
carriedinthelaboratory.Besidesabove,pneumaticcontrolvalvesareprovidedforeach
operationontheexchangers,sometimesmotoroperatedvalvesareselectedinplaceof
pneumatictypespeciallyattheplacewhereinstrumentairisnotavailableforuse.In
case,autoorsemiautooperationoftheplantisnotenvisaged,mostoftheinstruments
onexchangerscanbediscarded,exceptflowindicator,andintegratorwhichareneeded
inallcircumstances.
10.1.3.3
Onregenerationside,handlingofacid,alkalitanksandtheirfeedingsystemsare
involved.Herealso,agoodinstrumentationisrequiredforautoandsemiautoplants.
Theinstrumentationdependsuponthetypeofoperationforfeedingregenerantto
exchangers.Thetanksshallhavelevelswitches,sothatproperlevelsinvarioustanks
canbemaintained.Thesystemshallbeprovidedwithsufficientpneumaticor
motorizedcontrolvalves,besidestheautooperationofpumpsorblowerswherever
necessary.Variousstagesofoperationarebettercontrolledbythetimerswhichhaveto
besetinadvanceduringoperationoftheplant.Nowadays,useofprogrammelogic
controlisalsoadoptedforthesesystems,wheretheprogrammeofoperationissetin
advance.Thebasicrequirementsoftheinstrumentsinthesystemshallbegiveninthe
specification,basedonwhichthesystemshallbedesignedforoperation.
10.1.3.4
Someinstrumentsarerequiredforinletandoutletpipelinestoandfromthe
battery
10
limitsoftheplant.Normally,onwaterincominglinesinstrumentscontain
pressureindicators,recorders,pressureswitch,etc.Sometimesuseofwatermeteris
madeonlyforrecordingtotalwaterflowtotheplant,speciallyincaseofmanualplants.
Fortreatedwaterline,manyonlineinstrumentsareneeded,suchaspressureindicator,
flowindicator/recorder,conductivityindicator,pHindicator/recorder,silicaanalyser
recorder,sodiumanalyser,recorder,chlorideanalyserrecorder,etc,dependingupon
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therequirement.Innormalplants,eventheoutgoinglinehasminimumflowindicator
andpressureindicator.Fortheneutraleffluentline,itbecomesessentialtoprovideat
leastapHindicatortoassessthepHoftheeffluentoftheplant,whichhastobe
neutralbeforedisposal.However,specificinstrumentsonvariouslinescannotbelisted
theirinstallationvariesfromplanttoplant.Allthesame,requirementsofthese
instrumentsaretobeclearlymentionedinthespecification.
10.1.3.5Instrumentcontrolpanel
Thedetailsofinstrumentcontrolpanelmayclearlybegiveninthespecification
sothatallnecessaryinstrumentsareprovidedonthepanel.Therequirementof
enunciationsforalarmsmayclearlybementionedinthespecification.Thecontrol
panelvariesaccordingtothesystemadopted.Butthisleadstorequirementof
airconditionedroomforsatisfactoryperformanceofinstrumentsincorporating
integratedcircuits,relaysandsolidstatesystemprovidedincontrolcircuits.
10.1.4ElectricalSystem
Requirementsofelectricalsystemaretobebroadlyconvertedinthespecification
sothattheplantcanaccordinglybedesigned.Sometimes,onlyhighvoltagepoweris
availablewhichcallsforprovisionofastepdowntransformerinthesystemwhichshall
bementionedinthespecification.Thespecificationofcontrolcentres,switches,and
locationofpushbuttonsmayclearlybementionedindetailsothattheseitemsare
providedintheplantaccordingly.
10.2ConstructionalFeatures
Theimportantconstructionalfeaturesofthevarioustanks,exchangersmaybe
mentionedinthespecification,sothatthesystemisdesignedaccordingly.Theaspects
coveredincludethematerialofconstruction,andgeneralfeaturesofthetanks,
exchangers,etc.
10.2.1Filters
Asthefilterscontainfeedwaterandnoacid/alkaliiscomingincontact,only
mildsteelvesselsarerequired.Sometimesepoxyorbitumenliningisdesiredsothat
ironpickupfromthevesselisminimized.Thefiltershaveproperarrangementsfor
collectionanddistributionofwatersothatnochannellingoccursinsidethepacked
bed.Thebasicdetailsmayonlybementionedtoenablethedesigneroftheplantto
meettheproperperformanceandguaranteedrequirements.
10.2.2ExchangerVessels
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Alltheexchangersrequiresomekindofprotectiveinnerliningovermildsteelto
protectitfromcorrosiveliquids.Normally,rubberliningoreboniteliningissuggested,
butnow,useofFRPorpolymethaneisalsorecommended.Properdistributionofwater
andregenerantsaretobeprovidedinsidethevesselsothat,itisuniformlydiscributed
alloverthepackedbed.Insmallerdiametervessels,onlyonedistributorisenoughfor
puttingbothwaterandregenerantbutinothercasesitispreferabletohaveseparate
waterandregenerantdistributors.Forcollectionofthetreatedwater,goodsystemis
requiredforwhichlateralheadersystemorbedsupportsystemisprovided.Asthe
collectorsystemworksasdistributionsystemduringbackwashingofthevessels,it
requiresspecialdesign.Incaseofcountercurrentregeneration,theregenerantflows
frombottom,sothecollectionsystemwhichrequiresagoodarrangementforuniform
distributionthroughoutthebed.Inthiscase,amiddlecollectorisalsoprovidedfor
dischargingthewatercomingduringtheregenerationinmixedbedexchangersalso,
similarkindofarrangementismade.However,thedetailsofconstructionalfeaturesare
tobelefttothesystemdesignertobeworkedoutonthebasicrequirementandtreated
waterguaranteeatdifferentstages.
10.2.2.1Backwashoutletstrainers
StrainersofstainlesssteelorPVCconstructionareinstalledinthebackwash
outletofexchangertopreventresinlossduringbackwashoperation.
10.2.2.2Resintraps
Resintrapsareinstalledatthetreatedwateroutletofeachexchangertocaterthe
resinleaksthroughleakystrainersorloosenedstrainersinthecollectingsystemduring
serviceruns.
10.2.3WaterStorageTanks
RCCtanksareusedwithbitumenliningforfeedwaterstorage.Incaseof
degassedwatertank,acidicwaterfromdegassertowerisstored,soproperliningis
desiredfrominside.Normally,rubberliningissuggestedforthispurposebutnowadays,
FRPliningisalsosuggested.Incaseofdemineralizedwatertankorpolishedwater
tank,liningbecomesessentialfrominsidetoavoidcorrosionandironpickupinthe
treatedwater.Insomecases,onlyepoxylining
11
issuggestedfrominside,butinothercasesrubberliningisalsorecommended.
Theneutralizationpitforstoringwastewaterduringregenerationisnormallymadeof
RCCwithsuitableliningfrominside.Epoxy,acidalkaliresistanttitlesandbricks
suitablyjoinedarealsoused.Thedetailsofsuchliningaretobeclearlymarkedinthe
specification.
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10.2.4RegenerantTanks
Forconcentratedsulphuricacidonlymildsteeltanksaretobeused,whereas
dilutesulphuricacidshallrequirestainlesssteeltanksorsomespeciallinedtanks
particularlywhereitisgettingdilutedasheatevolvedinthosetanksisquitehigh
suitablecorrosiveresistanceliningmaterialisusedforsustainingthetemperaturerise.
Teflonliningforsuchtanksshallbeideal,butduetoitslimitedavailability,special
rubberliningissuggested,whichistobeproperlymaintainedduringoperation.The
temperatureofthesolutionisneverallowedtogobeyond7080Ctoprotectthe
lining.
IncaseofhydrochloricacidFRPliningorrubberliningforinsidesurfaceisquite
useful.Incaseofcausticsodaorsodiumcarbonatesometimesnoliningforinside
surfaceisprovided,butitisadvisabletogivesomeliningtoavoidingressofextrairon
fromthevessel.Theseliningsmaybeofepoxy,rubberorFRP,whichistobeclearly
speltoutinthespecification.
10.2.5Others
Forpressurevessels,dishedendsaretobeprovidedforsomeatmospherictanks
alsodishedendbottomsarerequired.Forhorizontalcylindricaltanklikedegassed
watertank,largesizeacid/alkalitanks,etc,alsodishedendsarerequired.Proper
breatherseals,etc,arerequiredinvarioustankstochecktheharmfulvapoursescaping
out,andalsotochecktheingressofmoisture.Suitableonlinetrapsarealsodesiredto
checkthelossofvariouspackingsincaseofanydamageincollectionsystemduring
operation.
12
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