YOUR PROBLEMS

1 of 7

http://www.ieiknowledgepark.com/DM.htm

YOUR PROBLEMS & OUR SOLUTIONS

Index

Problems related to demineralization plants

What is a Demineralization Plant?

What is demineralized water used for?
Why are there numerous types of resins used in demineralization plants?
What is co-current flow regeneration?
What is counter-current flow regeneration?
What is mixed-bed demineralization?
What is the quality of the treated water from a demineralization plant?
How do I size a demineralization plant?
What is a degasser tower?
How is conductivity measured?
Troubleshooting of DM plant
Decrease in capacity between two successive regenerations
Treated quality not upto the standard
Mixed bed quality not good
High Residual CO2 from degasser
Unit rinse takes long time
Flow rate too low
Pressure drop across the bed increasing day by day
Flooding in degasser
Resin being lost
Ejector not working
Incorrect reading from rota-meters
Improper reading from flow recorder integrator
Level electrodes system for measuring and dilution tank not functioning properly
Leakage from acid injection/unloading/transfer pumps
Corrosion in concentrated acid tanks and lines
Improper opening and closing of pneumatically operated valves
Improper operation of certain regeneration cycle
Solid state programme not functioning properly

What is a Demineralization Plant?

Go to Top

Demineralization plant is employed for removal of minerals or dissolved salts from the water. Salts on dissolving dissociate
into electrically charged particles called ions: for example common salt will be split into sodium ion (a positively charged
ion or cation) and chloride (a negatively charged ion or an anion). If such a solution is brought into contact with a suitable
ion exchange material (called resin), some ions from the solution are taken up by the resin and an equivalent number are
transferred from the resin to the solution. Ion exchange is thus a reversible interchange of ions between a liquid and a
solid.
A simple Demineralization Plant consists of two beds of chemically treated resin beads operating in series. The first
column- cation exchanger- converts the dissolved solids in the raw water to the equivalent acids; these acids are removed
as the water passes through the second column- anion exchanger. The final product from this process consists essentially
of pure water. When exhausted, the cation exchange resin is regenerated with acid and the anion exchange resin with
alkali.
In essence the DM plant comprises of resin vessels with charge of strong cation and anion resin; control-panel

2/3/2015 12:15 AM

YOUR PROBLEMS

2 of 7

http://www.ieiknowledgepark.com/DM.htm

encompassing a conductivity measurement and alarms, etc; acid and caustic injection facility from bulk, semi-bulk or
carboy containers.
What is demineralized water used for?
The high-purity water from a demineralization plant is typically used as feed water for high pressure boilers in many
industries; as wash water in computer chip manufacture and other micro-electronics manufacturing processes, as
pharmaceutical process water, and any process where high-purity water is a requirement. DM water is used as
process water in the manufacture of chemicals and fertilizers, food products such as soft drinks, automobiles for rinsing
of parts, textiles, etc.
Two-bed INDION DM plants are made in all sizes, from small portable units for laboratories to large multi-stream
installations for Thermal power stations, refineries, petrochemical and steel plants.
Why are there numerous types of resins used in demineralization plants?

Go

to Top

The type of resins employed and selected depends on numerous factors: Treated water quality required- If silica removal is
not required, anion exchange resin used in two- bed DM plants is usually INDION 850 weak base anion resin. If silica
level of 1.0 ppm can be tolerated, then INDION N-IP strong base Type -2 resin is offered. When water free from silica is
required, the anion exchanger is charged with INDION FF-IP strong base Type -1 anion resin.
Input water quality
Presence of organic foulants- In cases where water has high level of organic foulants such as humic and fulvic acids
occurring in natural surface waters, Macroporous resins such as INDION 810- Type 1strong base resin are better
suited for the application than INDION FF-IP
Flow through plant required
Considerations of minimization of operating costs in terms of regenerant chemical consumption: In order to reduce
regenerant chemical consumption in large plants, INDION 850 resin (which is very efficient for removal of strong
acids such as HCl and H2SO4 with minimal requirement of alkali for regeneration) is used in combination with
INDION FF-IP strong base resin which is best suited for removal of weak acids such as carbon dioxide and silica from
water
What is co-current flow regeneration?
Go to Top

The regeneration is usually carried out in three steps. Firstly, the ion exchange column is backwashed with an upflow of
water. The pressure vessel has about 50% free space above the resin bed (known as free board). This free space
allows removal of any entrained solids, and re-classification of the resin bed by backwashing. Backwashing also relieves
bed compaction. Secondly, a predetermined amount of acid or alkali is injected into the column in a downward direction
(same direction as the service flow or co-current) to displace sodium/calcium/magnesium in the cation exchanger and
chlorides/sulphates/alkalinity in the anion exchanger taken up during the service cycle. Lastly, the column is rinsed to
remove excess regenerant. The entire operation takes about 3 hours for a two-bed DM plant.
What is counter-current flow regeneration?
With counter-flow regeneration, the regenerant acid or caustic passes in the direction opposite to the flow of water during
the service cycle. With counter-flow regeneration, the fresh regenerant enters at the bottom of the resin bed and passes
in an upward direction (opposite to the downflow direction during service cycle- or counter-current). Hence, bottom layer of
the resin bed is always in highly regenerated condition. This means lower leakage or slip of ions during the service cycle
producing better quality of treated water than the co-current method.
What is mixed-bed demineralization?
Go to Top

The mixed bed is a single column of INDION 225 cation exchanger and INDION FF-IP anion exchanger mixed together.
Water passing through the column comes into contact with these materials and is subjected to almost infinite number of
demineralizing stages. Thus demineralized water of extreme purity is produced.
As with two-bed demineralizers, mixed bed units are regenerated with acid and alkali: but the ion exchange resins must be
separated before this can be done. Bed separation is accomplished by backwashing: this carries the lighter INDION FF-IP
resin to the top of the bed and the heavier INDION 225 sinks to the bottom. Two completely separated layers are thus
formed, into which the acid and alkali solutions and rinse water are introduced through specially designed distributors. After
regeneration, the two resins are mixed with compressed air.
Normally mixed bed unit treats water from the two-bed DM plant that is already of high purity and their ionic load is low.
They can consequently be operated at high flow rates, and are of relatively smaller size.
What is the quality of the treated water from a demineralization plant?

Go

to Top

2/3/2015 12:15 AM

YOUR PROBLEMS

3 of 7

http://www.ieiknowledgepark.com/DM.htm

Electrical
conductivity
is
used
to
express
the
purity
of
demineralized
water.
Depending
on
the
application pH and/or reactive silica in DM water may also be specified as parameters to measure the purity of DM water.
The quality of the water depends on the type of scheme used:
Cation-Anion-Polishing Mixed Bed
For standard plants our guarantees are as follows:
1) Conductivity 0.1 micromhos /cm-1.0 micromhos/cm. at 25C (We guarantee conductivity of 0.1 micromhos/cm in very
large projects only)
2) Sodium 0.01 mg/l - pH: 7 +/- 0.2
3) Reactive silica 0.02 mg/l -0.05 ppm
Cation-Anion (Counter-Current Regeneration)
For standard plants our guarantees are as follows:
1) Conductivity 0.5 to 1.0 S/cm at 25C- 30 micromhos/cm (We guarantee conductivity less than 10 micromhos/cm in
large projects only)
2) Sodium 0.05 to 0.1 mg/l - pH: 7.5 - 9.0
3) Reactive silica 0.025 mg/l - less than 0.5 ppm (with FF-IP we can guarantee less than say 0.3 ppm)
Cation-Anion (Co-Current Regeneration)
With typical co-current regeneration, the outlet quality will depend on the regenerant applied, resin employed and raw
water quality
1) Conductivity 5 to 30 S/cm at 25C- conductivity can be upto 2 to 5 % of conductivity of raw water
2) Sodium 0.5 to 3 mg/l
3) Silica 0.1 to 0.3 mg/l - less than 1.0 ppm
How do I size a demineralization plant?
Go to Top

For the sizing of a demineralization plant, a good in-depth water analysis is normally required which gives the breakdown of
total anions and total cations and any potential organic foulants. The final water quality specification, as well as flow rate
and water used per day is required.
What is a degasser tower?
The alkalinity or bicarbonates and carbonates present in raw water appear as carbonic acid or dissolved carbon dioxide at
the outlet of cation exchanger. Weak base anion resin such as INDION 850 does not remove weak acids such as carbon
dioxide or silica. The demineralized water is therefore passed through a degassing tower for removal of carbon dioxide or
CO2 . The tower, made of rubber-lined steel is filled with packing rings through which the demineralized water percolates.
Low pressure air introduced at the bottom of the tower scrubs out CO 2, and the degassed water collects in a sump beneath
the tower.
How is conductivity measured?
Go to Top

All INDION DM plants are provided with conductivity indicators that have two basic elements: a conductivity cell with
electrodes of special design between which demineralized water flows and a sensitive milliammeter for measuring the
current passing between the electrodes. This current is proportional to conductivity of the water.
Troubleshooting of DM plant

Go to Top

Defects

Causes

Remedies

Decrease in capacity
between two successive
regenerations

a. Increase in ionic load

Check by analysis

b. Flow recorder defective

Check

c. Insufficient chemicals used

Check

d. Resin dirty

Give prolonged backwash

e. Plant being used intermittently

Avoid this

f. Channelling in bed

Check and ensure uniform distribution

/collection
g.

Resin fouled

If cation, give HCl wash; if anion, resin

2/3/2015 12:15 AM

YOUR PROBLEMS

4 of 7

http://www.ieiknowledgepark.com/DM.htm

h. give alkaline brine treatment

Resin deteriorated
Check and replace charge

i. Resin quantity insufficient in unit

Check and top up

Treated quality not upto the

a. Cation exhausted
standard

Check

b. Anion exhausted

Check

c. Mixed bed exhausted

Check

d. MB resin not in uniform mixed state

Repeat air mix and rinse

e. Some valves like backwash leaking

Check

f. Na slip from cation high

Check raw water analysis; change in

Na/TA and SiO2/TA ratio; use more
chemicals

g. SiO2 slip from anion high

Check raw water analysis; change in

Na/TA and SiO2/TA ratio; use more
chemicals

h. Unit idle

Check

i. Unit not sufficiently rinsed

Rinse to satisfactory quality

j. Excessive/low flow rate

Adjust to between unit min/max flow

rate

k. Channelling

Check and ensure uniform

collection/distribution

l. Resin fouled

Check resin and give alkaline brine/ HCL

treatment
m.

Resin deteriorated

Check resin and replace

a. Resin not separated during backwash properly

Give extended backwash after

exhausting the bed

b. Air mix not proper

Repeat

c. Final rinse not proper

Repeat

Mixed bed quality not good

d. Some valves may be leaking and contaminating the Check and examine
treated water

High residual CO2 from

degasser

a. It can be due to choked suction filter of degasser air Check and clean filter
blower
b. Improper air flow to the degasser

Check damper, speed of blower,

discharge pressure

c. Degasser blower not in operation

Check and operate blower

d. Air seal not fitted/broken resulting in short

circulating of air

Check and replace fitting

2/3/2015 12:15 AM

YOUR PROBLEMS

5 of 7

http://www.ieiknowledgepark.com/DM.htm

Unit rinse takes long time

a. Flow rate too high

Increase flow rate

b. Unit exhausted

Regenerate unit

c. Backwash valve passing

Check and rectify

d. Anion resin organically fouled

Give alkaline brine treatment

e. MB air mix not satisfactory

Carry out air mix once again

f. Acid/alkali pockets formed in unit

Faulty design check and rectify.

Temporarily backwash (followed by air
scour if MB) and rinse again

a. Choked valve and suction strainer of pump

Check

b. Cavitation in the pump

Check

c. Low inlet pressure

Check-pump

d. Distribution or collecting system choked

Check

e. Resin trap at outlet choked

Check and clean

f. Control valve shut due to low off-take

Increase off-take

a. Defective valves

Check

b. Packed resin bed and resin fines present

Give extended backwash with open

manhole and scrap off fines from top
surface of the resin

c. Collecting system choked

Check, repeat backwash

d. Pressure gauge defective

Check and rectify/ replace

a. Very high air flow rate

Reduce air flow rate by adjusting

damper

Flow rate too less

Pressure drop across the

bed increasing day by day

Flooding in degasser

b. Packed tower chocked due to dirt or broken packing Open and check
material

Resin being lost

a. Excessive backwash pressure

Check inlet pressure and reduce if

necessary

b. Faulty collecting system

Examine same for breakage

c. Inlet strainer damaged

Check and replace

a. Low power water pressure

Check

b. Air lock in the unit

Backwash & open air release

c. Choked or defective valves

Examine and rectify

Ejector not working

2/3/2015 12:15 AM

YOUR PROBLEMS

6 of 7

Incorrect reading
rota-meters

http://www.ieiknowledgepark.com/DM.htm

d. Ejector nozzle may be choked

Check

e. Too much back pressure from the unit

Check for chokage of collecting system;

passage of inlet/outlet valves

f. Bulge in pipe lining

Check and rectify

a. Chocked orifice lines/orifice

Check and clean

b. Dirty glass and float

check and clean

Improper reading from flow

a. Choked impulse lines/orifice
recorder integrator

Check and clean

b. DP transmitter requires recalibration

Recalibrate

c. Leakage in signal tube between transmitter and

panel

Check
Check

d. Low air pressure for DP transmitter or recorder

Level electrodes system for

measuring and dilution tank a. Improper contact between electrodes and control
cabling
not functioning properly

Leakage from acid

injection/unloading
/transfer pumps

Corrosion in concentrated
acid tanks and lines

Improper opening and

closing of pneumatically
operated valves

Check contact and rectify

b. Shorting of the two electrodes due to moisture or

any foreign material

Check and dry the contacts of moisture

and dirt

c. Improper working of the level controllers

Check

a. Improper adjustment of the mechanical seal

Check and adjust

b. Low strength of sulphuric and presence of ferrous

sulphate

Check concentration and take

appropriate action

a. Low concentration of sulphuric acid

Check silica gel breather in acid storage

tank and replace silica gel charge if
exhausted

b. Lining of HCl tank/pipe line damaged

Rectify

a. Defective solenoid valves

Check

b. Leakage in airline from solenoid valve to the

respective control valve.

Check
Check

c. Improper contact of micro switch giving false

indication to panel

Check

d. Fused mimic lamp giving false indication to the

panel

Improper operation of a
certain regeneration cycle

a. Defective relays in the control circuit

Check and replace relays

2/3/2015 12:15 AM

YOUR PROBLEMS

7 of 7

Solid state programme not

functioning properly

http://www.ieiknowledgepark.com/DM.htm

a. The controller can be kept in "hold" due to the

reasons explained under operation

Remove conditions which cause "hold"

of controller

b. Improper operation of the controls for the controller Press test switch & check the complete
cycle
c. Defect in the inside of the controller
Check the instruments thoroughly from
inside. Meanwhile, operation may be
continued by using bypass toggle
switches

Go to Top

2/3/2015 12:15 AM