Dow

Liquid Separations

The UPCORE System

Frequently Asked Questions on the
UPCORE System

Q1. How does the UPCORE system work? It looks

like Schwebebett the other way around.
Yes, the service flow used in the UPCORE* system is
the reverse to that used in Schwebebett (and
Amberpack) systems. The UPCORE system uses down
flow service which has many advantages and is the
direction used for most ion exchange plants in the
world - which typically use co-flow regeneration or an
air or water hold down counter flow regeneration
process. Regeneration is carried out upflow, again in
line with most counter flow regeneration processes.

Differences during operation

The two purposes of backwashing are:

1 to remove solids and debris
2 to release the pressure drop accumulated during
the service run.
The UPCORE system uses a unique way of removing
the solids filtered out in service during the compaction
step which precedes introduction of the regenerant.
The flow past the resin beads in this step is over ten
times that found in coflow or upflow packed bed
systems. This is because the resin is largely
compacted and not free flowing during the compaction

Schwebebett

UPCORE

stop in service flow

suspended solids filtration

upflow
packed against top
of vessel
fluidized (partially)
needs a recirculation pump
deep into the bed

backwash tank

mandatory

downflow
resting on floor
of vessel
fixed (totally)
no need for pump
surface on fixed
bed filtration
no need

DURING REGENERATION
regeneration flow
bed position

downwards
resting on floor of vessel

upwards
95% of bed packed
against top of vessel

GENERAL
layered bed anion

need a plate

no plate needed

DURING SERVICE
service water flow
usual position of resin bed

Overall the chemical efficiency and plant performance

are quite similar. However,the UPCORE system uses a
simpler design, resulting in lower capital cost, and is far
better suited to plant retrofits.
For a more in-depth comparison of the UPCORE
system to other ion exchange systems, see UPCORE
Brochure and a paper IWC-97-16 authored by C.Beltle
et. al. at the 1997 International Water Conference in
Pittsburgh.

Q2. Why is there no backwash tank?

step. The extra shear forces generated at this high flow

result in excellent cleaning, and the solids are ejected
in a fraction of the time compared with conventional
backwashing. The selection of the appropriate particle
size UPCORE grade inert resin and a suitable upper
distributor system are also important for successful
self-cleaning.
Additional information can be found in Suspended
solids removal for countercurrent ion exchange
systems IWC Paper presented in Pittsburgh by Dan
Rice and Andre Medete.

Backwash tanks are not necessary because of the

unique self-cleaning feature of the UPCORE system.
The resins are cleaned inside the vessel during each
regeneration cycle, there is no need to periodically
transfer the resin into an external tank.

*
*

T
*

r
S

Q3. How is the compaction done?

Q4. How does the self-cleaning work?

The high flow rate - which is typically in the range of the

service flow rate, but in the opposite, upward direction used during compaction lifts the resin bed within a short
time against the inert resin at the top of the vessel.
Once the resin is compacted, a much lower flow can be
used to keep it in the compacted position. This ensures
a sufficient contact time for the regenerant chemicals
during chemical injection.
This hysteresis effect can be seen from Figure 1.
In most cases, the pump needed for the compaction is
of similar size to that for the service and this means
that generally there is no need to add a new large
pump.
In certain cases, especially with a high TDS water, the
feed pump is not large enough to provide the necessary
velocity, thus requiring a new pump. (In retrofit cases, it
is sometimes possible to use the existing pumps
downstream of the degasser for compaction. Some
plants simply use the flow of a second demineralization
line for the short compaction steps or use condensate.
In certain cases, the regenerant pumps have enough
spare capacity to supply the full compaction flow.).

This question is closely related to Q2 about

backwashing and why no backwash-tanks are
necessary for the UPCORE system.
In theory, the higher the shearing forces present for
cleaning the resin beads the better. The water velocity
during compaction when the resin bed is cleaned is
10 times higher in the UPCORE system than the fully
expanded bed found during conventional backwashing
in other systems. This is illustrated in Figure 2.
However, the self-cleaning is only possible if
three conditions are met simultaneously:
correct flow velocity
correct granule dimension
correct nozzle slots opening
During pilot plant tests at an OEMs site, the following
profile of suspended solids removal was found during
compaction. A similar test using conventional
backwashing resulted in a much longer time needed to
remove the solids. Figure 3.

Figure 2.

Figure 1.

Resin Bed
Compaction %
Suspended Solids
Concentration (mg/l)

Step 3 Step 2

6000
5000

Step 4

4000

Step 1

Step 5

1.
2.
3.
4.
5.

Compaction
Injection
Displacement
Settling
Rinse

3000
2000
1000
0
0

Upflow Linear Velocity

0.2

0.4

0.6 0.8 1.0 1.2 1.4 1.6

Compaction Time (min)

1.8

2.0

Figure 3.

UPCORE
Compaction

Conventional
Coflow Backwash
Inert Resin
Freeboard

1X
1.5X

9X

Fines/
Contaminants

2.0X

Resin Bed
2.5X

9X

Freeboard

Flow is 1X

Flow is 3X

The UPCORE system thus provides an in-situ

backwash step which cleans the resins each
regeneration and does not need resins to be moved to
an external backwash facility. Of course the use of a
backwash tank is entirely a matter of choice - however,
the UPCORE system does not require such an option.
Indeed, in over 90% of cases, UPCORE plants are not
fitted with backwash tanks and the lead cation units
have operated successfully for well over 10 years
without a single conventional backwash. In the
remaining 10% of the cases, backwash-tanks or similar
special treatment resin cleaning units were already in
place.

Q5. What level of suspended solids can the

UPCORE system handle in the feed stream?
Ion exchange resins are not designed to filter out
suspended solids, BUT they effectively do act as a filter
in a similar way to sand filtration.
Most systems treating well-operated sand-filtered water
will show moderate solids buildup on the lead resin in
an ion exchange train typically a strong acid cation
resin. This results in a load of 0.3-0.5 kg/m2 of
suspended solids using a case of 100 m3/h service
flow; 5 meq/l TDS in the water; a vessel diameter of
2 meters and 1.0-1.5 mg/l solids in the feed.

Suspended solids are measured using different

methods and expressed as mg/l as dry solids on a
0.44 filter or as Turbidity units using light scattering
without a strict correlation between the two. They can
also be of different nature according to raw water
(source, well, surface, river...) and pre-treatment (sand
filter, lime softening, coagulation, activated carbon...).
The amount of solids tolerated on UPCORE systems is
considered using units of Kg of solids /m2 of vessel. In
the event where the solids filtered out on the resin bed
exceed 0.5kg/m2, it is advisable to use an in-situ air
brush of resins.
It is highly recommended to measure the pressure drop
through the ion exchange vessels and stop at a
maximum value of 2 bars, although UPCORE resins
are strong enough to withstand higher numbers.
For further information, see A comparison of Three
Different Counterflow Regeneration Systems in a 640
m3/h - 2800 gpm - water plant IWC-97-16 presented by
C.Beltle et al.

Q6. What can be done if pressure drop in the resin

bed builds up due to too many suspended solids?
First, understand the reason(s) why such a pressure
drop increase occurred as the reason(s) can be very
different and the solution(s) may well also be different.
The pressure drop can originate from the following
sources, for example:
a malfunctioning of the upstream mechanical filter
a possible failure from upstream pretreatment, which
could result in a post flocculation onto the resin
resin breakage
bio-fouling (on weak acid cation resins)
wrong inert resin / nozzle slot combination
precipitation of calcium sulfate or silica polymerization
on resins
accumulation of silt, colloidal matter, sludge, algae
corrosion, clogged nozzles
The high pressure drop rarely happens all of the
sudden, as a constant pressure build up should be
visible throughout the previous runs and preventive
actions taken. Monitoring pressure drop is advisable,
and if found to increase significantly, then multiple
compaction/settling steps should be exercised, or in
severe cases, perform air brush during compaction. In
extreme cases, a combination of chemical and physical
cleaning should be used.

Q7. What are the minimum flow rates during

operation?
Due to the need to provide a good flow distribution
through the resin bed, the minimum flow rate
recommended is the same as for co-flow regenerated
plants, i.e., 4-5 m/h. Below 2 or 3 m/h, most systems
hydraulically do not allow an even flow distribution of
the water across the resin bed, thus it is better to shut
the plant down for a few hours and resume operation
later at a flow rate higher than 4 -5 m/h.
Start and stop operation is absolutely no problem for
UPCORE systems. After a shutdown, it takes typically
10-15 minutes recirculation to overcome the counter-ion
back diffusion effect, and the plant resumes operation
with the same good water quality it produced before
stopping.

Q8. What are the minimum and maximum bed

depths for the UPCORE System?
Resin bed depths are usually in the range of
1.8-2.5 meters.
The minimum resin bed depth is dictated by water
quality and operating capacity. A shallow bed (1m) will
definitively have a lower operating capacity and
probably a worse water quality than the more typically
usual ones of 2 meters or more. Therefore bed depths
of under 1.2 meters are not recommended and seldom
found in industrial scale UPCORE plants. The
correction factor for operating capacity versus resin bed
depth is provided in the UPCORE System Engineering
Handbook.
The maximum resin bed depth is directly linked to the
pressure drop which the equipment can tolerate. The
resin will typically not be the limiting factor to optimize
the bed depth due to the high physical stability of
DOWEX UPCORE Mono grade resins used.
The largest bed depth in practice used in an UPCORE
water treatment plant is, to date, 4 meters and uses an
anion resin, DOWEX UPCORE Mono A-625.
Q9. What are the recommended minimum and
maximum concentrations of regenerants?
The concentration of regenerant chemicals plays an
important role in obtaining optimum performance from a
water treatment plant using ion exchange resins.
The optimum concentration varies according to
regenerant chemical and water composition:

H2SO4
on weak acid resins should always be
kept to 0.7-0.8%
on strong acid resins, a table in the
UPCORE System Engineering Handbook describes the
recommendation based upon the % calcium in the feed
water
HCl
the higher the better, with a minimum 4%,
but this could be lower with high % sodium ions in the
feed water
NaOH
on single resins, 4% is right in most
cases, warm caustic is recommended for high silica
load when silica exceeds 10 g/liter of resin, then
temperature and velocity should be considered on top
of the concentration
on layered bed anion resins, NaOH
concentration may vary depending upon silica load and
to prevent possible precipitation onto the weak base
resin where the silicate solubility is the lowest. For
example: 15 g SiO2 /l resin then use 2.5% NaOH with a
20-25 minutes contact at 35-50C
The specific conditions are all described in the
UPCORE System Engineering Handbook.

Q10. What is the correct freeboard to use?

The freeboard is a key parameter which directly
impacts plant performance because it will influence the
essential parameters for regeneration. In general it is
true that with a larger freeboard the self-cleaning effect
improves due to the classification in the settling step.
On the other hand when the freeboard is kept small the
water quality is better but the self-cleaning effect is
somewhat less.
The correct freeboard is always the minimal space
considering the most expanded form of the resin.
Strong cation resin A few centimeters with respect
to the delivered ionic form (H).
Strong Base resin Need to consider the resin
swelling to design properly the amount of Cl resin which
is the delivered form.
Weak resins in separate vessels No real constraint
for freeboard, generally large freeboard to compensate
for the resin swelling is acceptable as the regeneration
efficiency does not depend upon the degree of resin
compaction, because regeneration can be still efficient
when made on fluidized resins. It is possible to only use
the compaction for weak acid cation or weak base
anion resins and do regeneration in coflow as practiced
with a weak acid cation vessel in a German water
treatment plant.

Combination WBA+SBA The design for this case

needs to consider the opposite swelling of both resins; it
will always take into account the maximum resin fitting
the vessel under the most swollen form. Typically, a
freeboard of 20-30 cm is used (10%); the tolerance is
less stringent than for cation beds as the compaction is
much easier with the lighter anion resin.
UPCORE resin data sheets provide expected figures for
swelling of current resins.
Dow has developed a computer design program CADIX
which allows the OEM to calculate the right amount of
resin bed depth and thus the right freeboard.

Q11. What is the correct slot width of the nozzles?

The nozzle slot opening design are part of Dows
proprietary know how, and are described in the
UPCORE System Engineering Handbook.
The adequate nozzle slot should be large enough to
allow self-cleaning and let the suspended solids
accumulated over the run and any broken beads to be
removed from the vessel during compaction.
It should be small enough to retain the inert resin, which
in turn prevents the active resin from leaving the vessel.
It should not be too small as to create additional
pressure drop.
It can be different from bottom to top, and on
intermediate nozzle plates when using cation layered
beds.

Q12. Are resin traps needed?

Resin traps are not strictly needed, but in case of
nozzle breakage or similar case, they prevent major
resin loss and should thus be considered to be installed
to ensure plant operation safety.
Most ion exchange plants have resin traps after each
vessel in the production line to prevent a potential
disaster from a breakage in distributor/collector
systems. Some plants also have them also at the
regeneration effluent pipes. The choice should be made
independent of the ion exchange system being
designed.

Q13. Is the inert resin soft so that it would

compress during compaction?
No, the inert resin is not compressible under normal
operating condition at any moment of the service or
regeneration phase.

Q14. Why is cross contamination of the anion

resin with strong acid cation resin very unlikely
with the UPCORE system?
This is mainly due to the UPCORE system's selfcleaning effect, which provides resin classification
during each regeneration cycle.
The cross contamination of anion resin with cation resin
is commonly encountered with a certain percentage of
Amberpack and Schwebebett plants and is perceived
as a serious problem which might lead to expensive
resin replacement cost or long rinse times.
The cases where the cation resin can contaminate the
anion can be listed as follows:
Whole beads of cation resin contaminate anion resin
Can happen during vessel loading when mixing a cation
resin bag with anion by mistake; the cation resin will
then be on the bottom of the anion resin in the vessel.
This will typically cause very long rinse times at the end
of the regeneration cycle.
Also during bottom distributor breakage from cation
resin vessel a similar situation to the above happens.
Cation resin fines contaminate the anion resin
With upflow service / down flow regeneration systems
such as Amberpack or Schwebebett, the finer resins
and resin pieces accumulate on the top of the cation
vessel which is the closest to the anion resin vessel through possibly a degasifier - thus creating the highest
opportunity for anion vessel contamination.
This is the reason why the inert floating material is
much smaller size with these systems, in order to
prevent any resin to pass with the service water to
the next vessel.
These systems generally need resin traps to prevent all
cross contamination.
For downflow service / upflow regeneration - Dows
UPCORE system, the finer resins and resin pieces may
accumulate at the top of the cation vessel as well, but
all eventual resin fines and debris are eliminated at
each regeneration cycle during the compaction step.
They are also at the furthest point of the bed from the
following anion vessel. This is the reason why the
floating inert material is much coarser with the
UPCORE system to enhance the resin cleaning.
The only way out for the fines is into the regenerant
waste stream as they are highly unlikely to cross the
entire bed and lead to contact with the anion vessel.

Q15. Does the layered bed concept work well?

This question usually stems from poor experience with
traditional air hold down systems and other counter flow
(and even co-flow) regenerated systems.
We do not have such problems with UPCORE systems
mainly due to the classification step during each
regeneration cycle. Todays uniform size resins also
allow to tailor the particle size - which is important for
good separation of the layers in a layered bed - in such
a way that the necessary separability of the weak and
strong base layer from each other is obtained and good
product water quality results. In practical operation,
there is always a small degree of mixing between WBA
and SBA resins in a LB which, however, is already
accounted for in UPCORE system designs so that it is
ensured that the product water quality required by the
customers is met. In any case, it is much better to run
without an intermediate nozzle plate, as this would not
only increase the capital cost but also raise the need for
an additional layer of inactive inert resin.
A wealth of positive experience with UPCORE layered
beds exist as these are involved in around 90% of the
large scale plants operating today.
Layered beds using weak and strong resins in one
vessel allow better efficiency and significant cost
savings compared to using the resins in two vessels.
This assumes the layered bed is properly designed and
the correct regeneration parameters are utilized.
An intermediate plate for cation resins is often
recommended, especially with dirty feed waters.
Layered bed anion resins keep separated without the
need for an intermediate plate due to difference in
density and bead size, giving excellent regeneration
efficiencies and low silica levels in the treated water.

Q16. You do not recommend an intermediate plate

in UPCORE layered bed anion vessels - why is
this?
We have found that using the UPCORE system, layered
bed anion resins keep separated without the need for
an intermediate plate due to difference in density and
bead size. The uniform size resins we supply are
tailored to aid separation.
To the right are listed the pros and the cons when
designing an intermediate plate in a layered bed anion
vessel.

Advantages of an intermediate plate:

prevents weak to strong resin mixing
allows a better pressure drop management, each
resin chamber can tolerate 1-1.2 bar, allows higher
flow rate, which is useful when treating the very low
TDS (<1 meq/l) water from a single pass reverse
osmosis unit
prevents down time for re-separation if for some
reason the resins are completely mixed
makes selective resin loading, unloading or chemical
treatment in separate room possible
Disadvantages of an intermediate plate:
additional cost
double nozzle are sensitive to clogging
with a nozzle plate, the strong base anion resin bed
depth is usually set at 1.2 m; without it, it is at 0.8m
(minimum)
no flexibility to change the weak base/strong base
resin ratio. It is likely that within a lifetime of the
equipment of 20-30 years, the water composition is
not going to remain constant. Wrong weak
base/strong base resin ratio will compromise
optimized chemical efficiency, which drives running
cost for resin operation. (Cost for chemicals will
undoubtedly increase in the future.)
last, but not least, is the fact that an intermediate plate
will strongly minimize the self-cleaning effect within
the layered bed, even if the strong base resin is the
less exposed to contamination, and even considering
DOWEX UPCORE Mono resins to be highly
mechanically resistant, one must always consider the
resin to give some physical degradation and thus
resin fines with time.

Q17. What do you do when resin mixing occurs in

an UPCORE system's layered bed?
Resin mixing in layered bed can be accepted at no
expense of treated water quality nor chemical efficiency,
provided a reasonable zone of 25% mixed resin is kept
within intermediate line. A completely mixed resin bed is
to be avoided.
A method to separate a mixed layered bed is described
in the UPCORE System Engineering Handbook and
has been found to be successful in practice in the few
cases when needed.

Q18. Is a mixed bed necessary after an UPCORE

plant for boiler feedwater production?

Q20. Does DOW only use uniform size resins in

the UPCORE system?

The necessity of having a mixed bed after UPCORE

demineralization line is dictated from specification on
the pressure the boiler operates. Typical specification
for boiler feed water call for conductivity and silica
figures.
Over 60 bars pressure, we recommend the use of a
polishing step. Even if UPCORE plants deliver typically
waters of <1 S/cm and <20 ppb silica, we would favor
in these cases to have polishers. Polishers are usually
mixed beds, but similar quality can be achieved with
correctly designed, separate strong acid cation and
strong base anion vessels.
The lower the sodium in the feedwater, the better the
treated will be:
10% sodium in the feedwater should provide a treated
water <0.2 S/cm
50% sodium will result in 1-2 S/cm
Overrunning the ion exchange units will not allow such
numbers, however.
Depending on the feedwater quality and regenerants
used, it is possible to operate two UPCORE plants in
series and achieve near mixed bed quality this way.
Especially when the UPCORE plant is never run to a
conductivity or silica breakthrough and always stopped
at 90 percent or less of its design throughput, the water
quality will be near MB quality. This concept has
operating cost and flexibility advantages.

The UPCORE system works better with uniform size

resins. 5-25% chemical savings can be anticipated,
especially where raw water contains significant high
sodium percentage. In this case, the uniform size
DOWEX UPCORE Mono resins show a better
exhaustion profile and provide a definitive better quality.
The same is true with silica, and all weak acids, which
will have a sharper breakthrough front.
high chemical efficiency is requested, because of
sharper exhaustion front for ions, the operating
capacity is higher and so is the chemical efficiency.
high treated water quality is needed, because of
uniform size, the resin beads which are in the
polishing zone, are significantly better regenerated
than conventional resin and provide a better treated
water quality.
higher flow rates are needed, as uniform size resins
allow higher flow rates than conventional resins, being
more mechanically strong and having less resin fines.
As a result of these advantages, Dow now only offers
uniform size resins - DOWEX UPCORE Mono resins for use in the UPCORE system.

Q19. Can I use the UPCORE system for

condensate polishing?
Yes, several major plants are currently treating
condensate return.
The advantages of the UPCORE system are as follows:
no cross contamination between chemicals - single
vessels
no cross contamination between resins - single
vessels
high operating capacity for volatile treatment
layout easily tuned to needs:
One layout which has treated 350 m3/h for many
years is:
Sacrificial strong acid co-flow for efficient crud removal
+ UPCORE strong acid cation + UPCORE strong base
anion (+ optional small trail cation unit).

Q21. Can I use other resins than DOWEX resins

for the UPCORE system?
Dows UPCORE system has been developed over the
years on the basis of DOWEX UPCORE Mono resins.
These resins are designed to give trouble-free,
optimized performance and chemical consumption
together with an outstanding resin lifetime.
Using other resins may lead to average or erratic
results due to many possible reasons:
unsuitable resin particle size, leading to bad
compaction efficiency
mechanically unstable resins could potentially damage
the plant operation and impair water quality
non-optimized regeneration parameters for the resin in
the UPCORE system
unsuitable inert / resin combination, leading to loss of
self-cleaning effect
Dow cannot design using resins from other suppliers,
will not check designs from other parties using such
resins and will not service or in any way support a plant
not using UPCORE resins. The plant may also not be
referred to as an UPCORE plant nor offered as such.

Q22. What resin losses can be expected?

For DOWEX UPCORE Mono resins, it is considered
normal that about 0.5-3% per year of the installed resin
volume breaks down mechanically depending on
operation and resin type. In the UPCORE system, these
broken beads are removed by the self-cleaning
mechanism every cycle. Whole unbroken beads are
retained in the vessel due to the inert resin layer, and
hence little physical resin loss is to be expected during
normal operation. Resin loss may happen, however, if
there is damage to the distribution system; in this case,
the resin trap normally installed will enable the lost resin
to be recovered.

Q23. What are the resin lifetimes in the UPCORE

system?
The useful resin lifetime depends upon the environment
in which the resins operate. Generally 10 years for
cation resins and 4-6 years for anion resins is a good
rule of thumb.
Experience shows typical values below for total,
mechanical and chemical losses:
UPCORE resin:

Year 1 Years 2+
TOTAL

Mechanical

Chemical

MAC-3

(5)

3 (3)

2 (2)

Mono C-600

(5)

2 (3)

3 (2)

Mono WBA-500

10

(8)

3 (3)

7 (2)

Mono A-625

10

(6)

3 (3)

7 (5)

Mono A-500

10

(6)

4 (3)

7 (5)

As all operating conditions are different from plant to

plant, the above numbers are only indicative and are
not to be taken as guarantees.
The presence of certain organic substances, oxidants
and metals (such as Fe, Mn, Cr and others) may
dramatically increase the degradation rate of some
resins as may high temperature and extreme hydraulic
conditions.

Q 24. Who can design and build UPCORE

systems?
Dow has a number of licensed OEMs worldwide able to
design and supply UPCORE systems. In addition, a
number of consultants/architect-engineers have
licenses to design such systems. The licensees have
access to the UPCORE System Engineering Handbook
and CADIX design program with an UPCORE system

design option. In addition, they are able to call on the

global technical experience of more than 500 plants
currently in operation and enjoy the support of Dows
technical ion exchange specialists.
For the case where an end user wishes to retrofit their
existing plant to UPCORE and is able and willing to do
the engineering work themselves, an end user license
is also possible.

Q25. You claim that UPCORE system is better for

revamping existing water treatment plants than
other systems - why is this?
There is rarely any need to consider any major
equipment to be added. In most cases, co-flow lines
have already the main piping for the operational flow in
the same configuration as for an UPCORE system.
There is no need to build a separation plate between
weak and strong base resins to get optimized chemical
efficiency from a layered bed.
A co-flow plant retrofit using the UPCORE system
requires essentially to reconsider top distribution /
collection system, reverse the regeneration flow from
top to bottom into upflow using demineralized water as
service water. About 25 to 30% of all UPCORE plants
worldwide are retrofitted co-flow plants!

Q 26. In a rebuild, how can I find the right

freeboard if I cant look into the vessel?
The correct freeboard will be initially calculated based
on the internal inspection and measurement of the
available volume inside the vessel. The design is made
according to resin swelling properties.
Loading the strong acid resin in the fully swollen H form
shouldnt give any problem.
Some safety will be taken with the anion resin.
Observing the treated water quality and pressure drop
will give an indication of any errors in filling levels. A
poor water quality is indicating an excessive freeboard then re-fill step by step to acceptable figures.

Q27. What materials can be used for constructing

the distribution system?
The material could be from the less expensive PVC
piping with nozzles to the most expensive, Johnsontype stainless steel. It is important that the system
evenly distributes and collects the chemicals and
service water using the correct pressure drop and is
adequately fixed within the vessel. (Since in the

UPCORE system the distributor is embedded in inert

resin the mechanical problems typically associated with
distributors in air-hold down and water hold down plants
are not common.)

Q28. How much will I save when converting my

existing co-flow plant to the UPCORE system?
The saving derives mainly from reduced regenerant
consumption although other savings in service water,
elimination of lime pretreatment, etc., can also
contribute. Savings on chemicals compared with co-flow
operation ranges from 35-50%.
Our experience shows payback times for an
UPCORE retrofit are typically 6-18 months. Due to the
longer run length, the plant availability increases and if
the plant is manually operated, additional savings due
to fewer manpower needed for regenerations can be a
major benefit, too. Waste water is also typically reduced
by 40%.

Q29. Who can make an economical comparison

for me?
You can - with the help of Dow Liquid Separations
technical staff and the available tools such as the
CADIX design program and a special software which
takes into consideration depreciation factors.
Alternatively, any licensed UPCORE OEM or design
office.
The key data for input are the costs for chemicals,
feedwater and major works to be done to rehabilitate
the plant. See the input sheet for economical
comparison of UPCORE system retrofitting.

it is a packed bed system

operating service is downflow and regeneration upflow
The UFD system is different because:
the system operates with a plate for layered beds
it is not a self-cleaning system
it uses different inert resins and upper distribution
system characteristics
it operates with external backwash tanks
As the UPCORE system has had continued success,
other resin suppliers have offered what look like very
similar systems in addition to their own preferred
offerings. They have very limited experience in
designing such plants and even less experience in plant
performance. Dows experience over 17 years with the
UPCORE system has led to an optimization and
knowledge of the crucial things that can go wrong in
designing such systems.
TAKE THE RISK OUT by using the UPCORE system
with DOWEX UPCORE resins.

Q32. How do overall counter current systems

compare?
The different water treatment systems can be
summarized as follows:
Co-flow
Counter flow
packed beds
non-packed beds
Continuous systems
Counter flow systems are preferred due to better
treated water quality and less regenerant usage. These
are as follows:

Q30. What are the disadvantages of the UPCORE

system?
There are few disadvantages to what is a very simple
but highly performing system.
The compaction is the only noticeable difference to any
other systems, which means a possible need for an
additional pump of a large size for compaction step although normally the feed pump is of adequate size.

Q31. Which look-a-like system(s) to the UPCORE

system is (are) on the market?
One look-alike system is UFD from Degremont.
The UFD system is look-a-like to the UPCORE system
because:

Packed beds

Non-packed beds

DownFlow Service

UpFlow Service

Dow UPCORE System

Bayer SCHWEBEBETT

Degremont UFD

R+H AMBERPACK

Air or Water Hold down

Bayer RINSEBETT

Permutit SplitFlow

Bayer LIFTBETT

Davy Bamag ECONEX

Bayer MULTISTEP

Salcon SALMIN

Of these, today the use of packed bed systems is

increasingly popular, and a very detailed comparison
between the UPCORE system and upflow service
systems is available from Dow. Ask your sales
representative if interested.

Q33. How do you compare economics of UPCORE

systems to those of reverse osmosis?
Informative published papers comparing economics of
IER to RO process are available; these publications list
the parameters and cost factors that need to be
considered for such a comparison. Since chemical and
water and labor costs, among others, can be very
different from case to case, no general answer can be
given.
Refer to the comparison of UPCORE packed bed
system to RO using Western Europe Figures (see P.A.
Newell et al., presented at IX 96 in Cambridge UK).
In Western Europe, the break-even point where RO and
IER are of comparable cost is 6.5 to 7 meq/l against a
optimistic 1.5 meq/l in the US environment (ion
exchange resins conservatively operated in co-flow
mode).

Q34. Where do you have UPCORE system plants

running and can I visit them?
There is a global reference list available for more than
400 UPCORE plants.
The list shows the type of industry, flow rate and
startup date.
You are welcome to visit UPCORE system plants
(naturally with the consent of the end user); your local
Dow representative will help you identify installations in
your vicinity and help you select the ones that are as
technically similar as possible to your planned new or
rebuild UPCORE unit.

*Trademark of The Dow Chemical Company