Report

Brine Purification Plant

Submitted to:
Mr. Muhammad Khurshid Sheikh
[Head of Planning Department]
Training In-charge:
Mr. Malik Mansoob [Planning Specialist]
Copy to:
Mr. Ashraf Naaz [Head of Production]
Submitted by:
Mr. H Muhammad Zia ul Noor

Ittehad Chemicals Ltd, KSK

 BRINE PURIFICATION PLANT 9035 DATED: 8-3-2017

Contents

Introduction ......................................................................................................................... 2

Brine Purification ................................................................................................................ 2

Saturator .......................................................................................................................... 3

Purifier ............................................................................................................................ 5

Mass Balance on Purifiers .............................................................................................. 7

Settler .............................................................................................................................. 9

Primary Filters: ............................................................................................................. 11

Secondary filters ........................................................................................................... 13

Ion Exchange Feed Tank .............................................................................................. 16

Ion exchange unit .............................................................................................................. 17

Regeneration steps ........................................................................................................ 21

Troubleshooting ................................................................................................................ 24

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 BRINE PURIFICATION PLANT 9035 DATED: 8-3-2017

INTRODUCTION

The caustic soda (a chlor-alkali) industry has vital importance because its per capita

consumption is normally considered as an indicator of normal growth of a country, especially in

the sector of derived chemicals, textiles, thermoplastics, polymeric products etc. The caustics chain

begins with sodium chloride (NaCl) and forms the basis for what is often referred to as the chlor-

alkali industry. Brine is the life blood for chlor-alkali industries. A passable supply of high quality

brine on a continuous basis is important for plants operation. Sodium chloride (brine) is the main

input and caustic soda, chlorine and hydrogen gas are simultaneously produced in the membrane

cell electrolytic process.

BRINE PURIFICATION

For membrane process, essentially high purity brine is required as the unwanted impurities

(Ca+2, Mg+2 and SO4-2) deteriorate ion exchange membrane (IEM) performance, therefore,

purification of brine, settling, filtration, acidification, de-chlorination are auxiliary processes for

the quality and efficient production of such alkalis.

Figure 1 - Block Diagram of Primary Filtration

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Table 1 describes the required quality specifications of brine. The main sections of brine

purification process are:

 Saturator
 Purifiers
 Settler (Clarifier)
 Primary filters
 Secondary (Candle) filters
 Ion exchange (tanks) units

No. Sample Test Unit Limit

1 Settler’s overflow T. S. S. NTU <10
2 After Primary filters pH - 9.5-11
Free Cl2 mg/L Nil
Ca+2, Mg+2 mg/L <5 mg/l
T. S. S. NTU <10
3 After Secondary Filters Free Cl2 mg/L Nil
T. S. S. NTU <1
4 After Deionizer Ca+2, Mg2+ µg/L I.E.M 1 I.E.M 2
<50 µg/L <50 µg/L
5 After Polisher Ca+2, Mg2+ µg/L <25 µg/L <25 µg/L
6 Feed Brine Ca+2, Mg2+ µg/L <25 µg/L <25 µg/L

Table 1 - Brine Specifications after different purification processes

SATURATOR

Brine is a solution of NaCl (sodium chloride) salt in water. Brine is generally produced by

the dissolving of fresh (rock) salt in water or depleted brine from mercury and membrane

processes. The low concentrated sodium chloride solution (brine) i.e. 220 g/l, which is coming

from the cell room where it lost its sodium ions concentration due to electrolysis to form caustic

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soda, so it is recycled back to saturator to gain its concentration level up to 300 g/l. Saturator of

275 m3 is used to saturate the brine by showering de-chlorinated brine (having pH of 9-11) on

northern and southern bed of NaCl rock salt with temperature 65-70 0C and flow rate 160 m3/hr.

Industrial water pipe of 2 inches is also used to shower water on salt bed for brine make up

purposes. Low concentration of sodium ion de-chlorinated brine passes through 13 ft. height of

rock salt bed and then it enters into primary pits through channel lines. Rock salt composition is

given below as:

Rock salt Components Weight percentages

NaCl 93%

Na2SO4 2.2%

Ca++ 0.3%

Mg++ 0.3%

Insoluble 3-4%

Table 2 - NaCl Rock Salt Specifications

Saturated brine is collected in pits. There are three primary pits and two secondary pits.

Primary Pits

Three primary pits of 400 m3 each are used to sediment the 4% remaining impurities like

mud, silicate, granules and other settle down impurities, it takes 4 hour of retention time to settle

down impurities. And it takes almost four hours to fill one pit. Out of three pits, second pit is used

as standby pit. When one pit become full of sludge then it is cut off from the circuit and the other

pit ready for use is put into circuit. Pits are made inclined for the removal of sludge.

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Secondary Pits

Two secondary pits of 35 m3 each are used to remove the further impurities which are not

removed by primary pits. One pit is used as standby for removal of remaining settle down

impurities. Other purpose for formation of secondary pits is the addition of chemicals such as

sodium sulfite of 5 m3 tank is used when chlorine present in primary pits.

Figure 2 - Brine Pits Section

A titanium coated or fiber pipe with number of holes of half centimeter size is used as filter
media attached at end side of secondary pit from where pump suction start. At the end two
centrifugal pump of 60 HP (one as standby) are used to transfer brine to purifier 1.

PURIFIER

Purifier is a reactor or vessel in which chemical reaction occur. Two open tank CSTR
(continuous stirred tank reactor) purifier of 70 m3 each are used to produce adequate particles size

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that can be easily agglomerate with flocculent in settler. Paddle agitator is used to provide mixing
energy in such way that particles do not disintegrate. Three reactant chemicals are added in purifier
to achieve large particle size of the impurities so that they are bound by flocculants and are easily
settled down and hence removed.

 Barium carbonate
 Sodium carbonate
 Accofloc

These reactant chemicals maintain excess carbonate and hydroxyl ions in two purifiers.

Purifier 1

Saturated brine from secondary pits enters into purifier#1 from bottom side and emit from
top side after retention time of 45 minute. A bypass line is attached with inlet of brine to purifier
which is used for distribution of additive chemical either from top or bottom of purifier. Two type
of reactant chemicals are used to remove sulfate and calcium ions from brine as fellow:

1. Barium carbonate
2. Sodium carbonate

Solution tank of barium carbonate

Barium carbonate has ability to remove sulfate ions present in brine in form of barium

sulfate. Amount of BaCo3 required removing impurities depend on sulfate ions. Barium carbonate

solution of 8 % w/w is prepared in 7 m3 of fiber or mild steel with rubber lining tank. Brine from

primary filter is used as solvent for BaCo3 solution to maintain sodium ions in purifier 1. A motor

driven mixer of 70 rpm (revolution per minute) is used to provide mixing energy for solution

formation. A batch for two hours of BaCo3 is prepared and then it transferred to purifier from top

side position with the help of two centrifugal pumps (one as standby) to purifier.

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Solution tank of sodium carbonate

Sodium carbonate solution of 8% w/w is prepared in 7 m3 of fiber or mild steel with rubber
lining tank. Brine is used as solvent for solution formation. A peddle type motor driven mixer with
30 rpm is used to provide mixing energy. One batch of 2 hours is added to purifier in bypass line
of brine to distribute the solution partially from top and bottom.

MASS BALANCE ON PURIFIERS

𝐵𝑎𝐶𝑂3 + 𝑁𝑎2 𝑆𝑂4 = 𝐵𝑎𝑆𝑂4 + 𝑁𝑎2 𝐶𝑂3

𝐶𝑎𝐶𝑙2 + 𝑁𝑎2 𝐶𝑂3 = 𝐶𝑎𝐶𝑂3 + 2𝑁𝑎𝐶𝑙

Rock salt 93 % NaCl

De-chlorinated brine
NaCl = 220 g/l
Flow rate = 150 m3/hr Saturator
NaCl =300 g/l
Density = 1170 kg/m3

Impurities 4 % (mud, silicate and granules)

Basis: 1-hour Operation

NaCl consumed from rock salt = 300 - 220 g/l

NaCl consumed = 80 g/l

Mass flow = 80 kg/m3x 150 m3/hr

Mass flow = 12000 kg/hr

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93 kg NaCl in rock salt = 100 kg

1 kg NaCl in rock salt = 100/93 kg

12000 kg NaCl in rock salt = (100/93) x12000 kg

Rock salt required /hour = 12903 kg

Mass flow of Na2SO4 = 12903x 0.022

= 284 kg/hr

Moles of Na2SO4 = mass/M.W. = 284/142

=2 moles

BaCO3 Required:

Reaction: 1BaCO3 + 1Na2SO4 1BaSO4 + 1Na2CO3

Mole of Na2SO4 = 2 mole

BaCO3 (mole) : Na2SO4 (mole)

1 : 1

Amount of BaCO3 required = 2 moles x 197 (Mol. Weight of BaCO3)

BaCO3 Required = 394 kg

With 1 g/l excess of BaCO3 = 1 kg/m3 x 150 m3/hr = 150 kg/hr

Total mass of BaCO3 required = 394 + 150 = 544 kg/hr

Bags of BaCO3 required = 544 / 25 = 22 bags

For 2 hours No. of Bags of BaCO3 required = 44

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Na2CO3 produced in this reaction react with CaCl2 to form CaCO3 and NaCl.

𝐶𝑎𝐶𝑙2 + 𝑁𝑎2 𝐶𝑂3 = 𝐶𝑎𝐶𝑂3 + 2𝑁𝑎𝐶𝑙

Purifier 2

Brine enters from bottom side into purifier 2 after emitting from top side of purifier 1. In

this purifier caustic soda 31% solution is added by gravity from overhead tank and its flow can be

adjusted through rotameter. A stand by tank can also be used in case of NaOH solution shortage.

Sodium hydroxide is used to precipitate the magnesium ion impurity in form of magnesium

hydroxide. NaOH is added into purifier 2 because reaction of caustic soda with magnesium is fast

as compared to reaction of barium and sodium carbonate with sulfate or calcium ions.

Reaction: 2NaOH + MgCl2 Mg (OH) 2 + 2NaCl

Solution Tank of Accofloc

Accofloc solution of 1% (w/w) is prepared in 7 m3 of fiber or mild steel with rubber lining

tank. First of all, 700-gram cationic polymer Accofloc is added into 1/2 m3 tank with de-ionized

water as solvent mixed by using tee mixer at 42 rpm. Then this solution is transferred into 7 m3

tank filled with industrial water as solvent for further dilution. Sodium sulfite tank is also present

for addition into Accofloc tank if chlorine present in settler. When all these additives are mixed

with peddle mixer at 50 rpm to form uniform mixture then it is transferred to small tank place

between purifier and settler by using two centrifugal pumps (one as standby).

SETTLER

Settler is a clarifier used to remove solid particulates or suspended solids from brine by

sedimentation process.

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Construction

The brine settler is a solid contact type clarifier like a huge bowl which is broad from the

top and narrows at the bottom. A big high efficiency marine propeller type agitator is fitted at the

center of the settler which completes its one revolution in 9 minute and 6.6 revolutions per hour

keeps on fluid in slight motion. It is made up from mild steel material with titanium coating from

interior side and has capacity of 1000 m3 which takes 10 hours of retention time for settling.

Working

First of all, brine enters into settler from the center with Accofloc into primary mixing zone

of settler, here flocculation, with suspended particles present in brine, occur. After this it enters

into secondary mixing zone of settler, here charge reduction and agitation increase the particles

collision and then particles move down (or settle) by gravity due to its weight and size increased

by flocculating medium. The impurity particles bound with each other to form bigger size particles

called as Sludge which settles down at the bottom of the settler and send to sludge pits. Brine
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recovered from sludge pits send to purifier 1 and sludge dumped to drain well. An automatic

instrument air control pneumatic valve is attached with bottom end for de-slugging which open

after every 45 minutes for 30 second valve opening. At the top section clarified brine overflow and

move toward clarifier tank by gravity and overflow from tank again move toward settler top side.

After every two hours, down take sample analyze the excess carbonate and hydroxyl ions. Test

result tells us how much amount of reactant chemicals are needed in purifiers. Brine is send

towards primary filter from clarifier by using two centrifugal pumps (one as stand by) of 60hp.

PRIMARY FILTERS:

Brine primary filters are required to remove the suspended solids overflowing with the

brine from the settler/clarifier. There are five number of flowing gravity sand filters operated in

parallel

Construction

Primary filters are made up of mild steel of total volume of 13 m3 consists of a multilayered

pebbles and stone filtering bed and one upper layer of anthracite coal. The bed of these

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multilayered pebbles and stones are formed according to their size increase from top bed to bottom

and anthracite coal at upper most bed of filter. Designing of bed according to size of pebbles and

stones as fellow:

Pebbles Size Bed Volume

40-50 mm 2.7 m3

16-30 mm 1.3 m3

11-15 mm 0.55 m3

5-10 mm 0.55 m3

3-4 mm 0.55 m3

0.8-2 mm 4.3 m3

Total 10 m3

Working

Brine enters into primary filter from top side and out from bottom. After passes through

bed of anthracite coal and multilayered bed of pebbles, impurities like excess carbonate and

hydroxide ions stuck with porous part of pebbles and brine out with impurities reduce up to 10

ppm (parts per million). Pressure gauge (not in working at present) is attached with top of filter

which tells us about backwashing indication. If pressure increases from 1 bar, then it means

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filtering media become full of suspended particles. By using backwashing, we can reuse our

filtering media again.

Backwashing steps

To backwash a primary filter for 45 minutes the following steps should be followed:

 Close inlet and outlet valves of brine simultaneously

 Open the vent valve for air removal
 Open the drain valve for 5-10min and let the drain into recovery pit
 Close the drain and recovery pit valve after draining all brine
 Open the industrial water valve for backwashing
 Backwashing water enter from bottom and coming out of the backwash pipe at the top

 When water becomes clear then close the water inlet valve and open the drain valve to
drain the water into drain channel
 Now close the drain valve and backwash valve
 Open the inlet and outlet valve of brine and at the end close the vent valve

SECONDARY FILTERS

The brine from the primary filter is stored in the storage tanks, from it is pumped to the

four secondary filters, arranged in parallel operation to remove the further impurities that are not

removed from primary filters. The secondary brine filters reduce the concentration of suspended

solids (mostly CaCO3 and Mg (OH) 2) to < 1 ppm with particle size < 0.5 micron.

A vertical shell and tube heat exchanger with counter current flow is installed before the

secondary filter to maintain the temperature around 60 0C. Steam is on the shell side, while brine

flow in tube from bottom to top.

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Principle

The Secondary brine polishing filters are vertical tubular backwash filters that utilize a

cellulose fiber pre-coat to achieve such level of filtration that protect the ion exchange system from

suspended solids which would otherwise plug the column.

Construction

The secondary brine filters contain 142 tubes suspended vertically from a tube sheet. The

filter tubes are constructed of C-PVC (chlorinated polyvinyl chloride) with a polypropylene sleeve

and are covered with a seamless polypropylene sock type covering. The conical shaped bottom

facilitates the backwash by directing the filtered solids cake to the dump (drain) connection during

the backwash. All other internal hardware (fasteners etc.) is constructed of titanium or plastic and

gaskets are constructed of EPDM (ethylene propylene diene monomer) to minimize metals

contamination of the brine.

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Working

Brine enters the filter through the bottom conical section and is evenly distributed

throughout the filter chamber. Brine cross exchanger is located upstream of the secondary filter.

The brine cross exchanger is designed to exchange thermal energy between the brine primary

storage tank to the secondary filters. Filtration is from the outside of the tubes to the inside. As the

brine passes through the cake and tubes, suspended solids are deposited on the outside diameter of

the tubes. The collection of these suspended solids forms a cake layer on the tubes. The formation

of this cake layer results in increased pressure drop from 2.5 kg/cm2 to above and eventually

necessitates backwashing of the filtered brine. Filtered brine flows up through the inside diameter

of the tubes and enters the top head of the filter through the openings in the tube sheet. Filtered

brine is then discharged from the top head through the main filtered brine outlet and stored in 70

m3 storage tanks.

Pre-coat Solution Tank

The pre-coating solution tank is used for mixing pre-coat material and brine. The 7 m3 tank

is an open top FRP vessel with peddle type agitator 32 rpm provided to ensure a homogenous

mixture. Industrial and DI water can be use as solvent but mostly brine is used as solvent to form

20 % w/w of Alfa cellulose by adding pre coating material i.e. Arbocel of 17.5 kg (one bag) in the

tank.

Backwashing and pre-coating steps

To backwash a primary filter for 35 minutes the following steps should be followed:

 Close the inlet and outlet valves of brine simultaneously

 Open the drain pneumatic valve and drain all the filter cake solution into the pit

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 Brine will drain at a high rate because of the compressed air entrap inside the filter doom

 Close the drain valve after complete draining of brine and filter cake

 Turn on the Arbocel pump for circulation

 Open the inlet and outlet pre-coat valve to circulate a brine solution containing the pre-coat
material through the filter until a uniform layer of pre-coat is applied

 Watch glass will show milky liquid coming out of the filter when it becomes clear (coating
will complete) then close the Arbocel coating

 Close the inlet pre-coat valve

 Open the inlet and outlet valve of brine

 At the end close the outlet of pre-coat valve and turn off the pump of Arbocel

If the brine feed stream contains a large percentage of fines (small) or slimy solids, then

the pressure drop across the filter may rise rapidly, giving short cycle times. This is often the case

when the brine has a poor Ca to Mg ratio (less than 2:1).

ION EXCHANGE FEED TANK

Filtered brine from the secondary brine filters flows into the FRP made Ion Exchange Feed

Tank. Brine exiting the ion exchange feed tank is pumped through the brine cross exchanger which

is located upstream of the ion exchange system. The brine cross exchanger is designed to exchange

thermal energy between the brine feed stream to the ion exchange system. The brine cross

exchanger is a shell and tube heat exchanger constructed of titanium plates, where steam is used

to heat the brine feed to the brine ion exchange system as required to maintain the temperature in

the range of 60 to 65ºC.

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 BRINE PURIFICATION PLANT 9035 DATED: 8-3-2017

ION EXCHANGE UNIT

Brine passes through secondary filter still has enough particles of size less the 0.5 microns

may damage the membrane of electrolysis cell. So the special unit called ion exchange resin

applied to remove unwanted impurities of calcium and magnesium ions.

There are two ion exchange units

1. Ion Exchange unit 1

2. Ion Exchange unit 2

Ion exchange unit 1 provides feed to IEM 1 and the ion exchange unit 2 provides feed to

IEM 2. Working of both units is same.

Principle

Ion Exchange resins are insoluble granular substances which have in their molecular

structure acidic radicals that can be exchanged. The positive ions fixed on these radicals are

replaced by ions of the same sign in brine solution in contact with them.

Construction

The ion exchange vessels are typically constructed of rubber lined steel to minimize

impurities pick up by the passing brine. Internal piping is typically constructed of Titanium,

Hastelloy C-276, or C-PVC (plastic only for the top inlet distributor). External piping is typically

constructed of C-PVC or FRP. The vessel under-drain system must be constructed of metal

(Titanium and/or Hastelloy C-276), and must be spiral wound wedge (well screen) design. Plastic

is not allowed to be used for the bottom under-drain system, and cloth wrapped laterals are

forbidden. An ion-exchange resin or ion-exchange polymer is an insoluble matrix normally in the

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form of small (0.5-1 mm diameter) beads, usually white or yellowish, fabricated from an organic

polymer substrate. The beads are typically porous, providing a high surface area. Ion exchange

Ion Exchange Unit 1

resin type is a chelating resin of micro porous structure with polystyrene matrix cross-linked with

di-vinyl benzene substituted with weakly acidic amino-phosphonic active groups.

The characteristics reactions are shown below:

2RCH2NHCH2PO3Na2 + Ca+2 ------> (RCH2NHCH2PO3)2CaNa2 + 2Na+

Regeneration to Hydrogen Form:

(RCH2NHCH2PO3)2CaNa2+4HCl--->2RCH2NHCH2PO3H2+CaCl2+2NaCl

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Conversion to Sodium Form:

RCH2NHCH2PO3H2 + 2NaOH ---------> RCH2NHCH2PO3Na2 + 2H2O

The chemical structure of this resin facilitates the formation of complexes with metallic

ions such as calcium and magnesium. The relative affinities for metals in an alkaline brine

environment are as follows; Mg+2 > Ca+2 > Sr+2 > Ba+2.

Working

There are three ion exchange resin units operate in series, one unit use as ionizer (primary

column), second as polisher (secondary column) and the third one as standby for regeneration.

Alkaline brine enters the top of the column and flows downward through the resin bed. As the

brine contacts the resin, calcium ions in solution are “exchanged” for sodium ions in the resin.

Two sodium ions are exchanged for each calcium ion. The resin bed becomes “exhausted” where

there is too few sodium ions left to exchange with the calcium ions, resulting in the “break-

through” of calcium ions in concentrations exceeding 20 ppb in the exiting brine. Lab analysis of

the brine downstream of the ionizer (primary calcium) every 8 hours is used to determine when

break-through has occurred indicating the need to regenerate the ionizer (primary column).

Merry-go-round Fashion

After regeneration, the regenerated column is placed in stand-by mode. When the primary

column (ionizer) is taken offline for regeneration, the stand-by column is put into service as the

secondary (polishing) column and the secondary column becomes the primary column (ionizer).

This cyclic operation has been described as “merry-go-round” fashion.

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Safety Precaution for Resin

Four important safety precautions for resin are as given below:

1. The brine ion exchanges system must be free from mercury because it is not stripped from
the resin during regeneration and it will permanently reduce the capacity of the resin,
thereby shortening cycle time (i.e. shortening the length of time between regenerations)

2. Brine feed to the ion exchange system must not have any free chlorine present. Free
chlorine will oxidize the resin which destroys the resin’s ion exchange capacity
3. The feed brine temperature should be maintained in the range of 55 to 60ºC and the pH
should be maintained in the range of 9-10.
4. The brine flow rate is typically controlled in the range of 10 to 30 BV per hour

Regeneration of resin

An exhausted column that has been taken off line must have the resin converted from the

calcium form back to the sodium form. This conversion procedure is called regeneration. It is not

possible to go directly from the calcium to the sodium form as with a classical water softener resin.

Sodium chloride is not used to place the resin in sodium form since the chelated functionality of

the cation resin is not able to split a neutral salt.

Auxiliary equipment required for the ion exchange system regeneration includes;

 HCl Measuring Tank (for 31% HCl)

 NaOH Measuring Tank (for 32% NaOH)
 HCl Metering Pump
 NaOH Metering Pump

Weak acid and weak caustic are made by diluting strong acid and strong caustic with de-

ionized water for regeneration of the ion exchange resin. The metering pumps are designed to

provide the proper flow rates of strong chemicals so that the final (diluted) concentrations are 4-5

wt.% HCl/NaOH. Sodium sulfite must be added into the HCl Measuring Tank as required to

eliminating the chlorine otherwise free chlorine will damage the ion exchange resin permanently,

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causing reduced capacity. Free chlorine can also be generated by the reaction of HCl with sodium

chlorate. It is therefore important to completely rinse the column of brine prior to the start of acid

regeneration. Lastly, the de-ionized water used for regeneration also must be free of chlorates and

free chlorine.

A general outline of the sequence for this chemical addition is as follows;

BV/hr Time BV Flow

No. Description (Bed (min) (Bed Direction Concentration
volume) volume)
1 DI water rinse 3.0 60 3.0 Down flow Chlorine = Nil
2 DI water backwash 8.8 30 4.4 Up flow Chlorine = Nil

3 Acid regent(HCl) 4.0 60 4.0 Down flow 4-5 wt. % HCl

4 DI water rinse 3.0 60 3.0 Down flow
5 Caustic conversion 4.0 60 4.0 Down flow 4-5 wt. % NaOH

6 DI water rinse 3.0 60 3.0 Down flow Chlorine = Nil

7 Brine rinse 3.0 60 3.0 Down flow

REGENERATION STEPS

There are nine steps needed to regenerate an exhausted primary column (ionizer) as given

below:

1. Brine drain
2. Brine displacement
3. Backwashing
4. Water drain
5. Acid injection
6. Acid displacement
7. Caustic injection
8. Caustic displacement
9. Brine rinse

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Brine Drain

First step is to drain all the brine before regeneration. Close inlet and outlet of brine then

open manual and automatic drain valve with opening air vent valve that brine could drain easily.

Brine displacement

After the brine is completely drained, open DI water inlet valve as the drain valve is already

open. When brine is completely drain then close the water inlet valve and drain valve.

Back Washing

Backwashing is done from bottom to top. Open the backwash DI water inlet and outlet

valve. Adjust the water manual valve so that resin does come out of the vessel. Air vent valve

should close during backwash.

Water Drain

To drain water after backwash, open drain valve and vent valve so that water can be drained

easily and early.

HCl Injection

After the removal of free chlorine from HCL tank by suing sodium sulfite, open acid tank

valve and adjust the water manual valve to reduce 32% acid to 4%. Open the suction and delivery

valves of acid metering pump. Adjust the pump stroke to 78% and Check the concentration of acid

from sample point, it should be 4%. The concentration of acid 4% is used because it provides

roughly the same molarity as the brine solution which reduces the likelihood that the resin will

experience osmotic shock. After 1 hour, check the acid concentration from the drain valve and if

this concentration is equal to the inlet concentration, acid injection is complete. If this

concentration is not equal to 4% then continue acid injection.

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Acid Displacement

After acid injection remove the excess acid from ion exchanger, open the DI water inlet

valve and check the pH of water coming out of drain valve. Continue this process until pH is

normal (7.0) and when the excess acid is completely removed then close the DI water inlet valve.

Caustic Injection

After complete water drain, start caustic injection. Open caustic tank valve and adjust the

water manual valve so that the concentration of caustic is 4%. Start the caustic injection pump and

open its suction and delivery valves by keeping the pump strokes to 66%. After 1 hour, check the

caustic concentration from the drain valve and if this concentration is equal to the inlet

concentration, caustic injection is complete. If this concentration is not equal to 4% then continue

acid injection.

Brine rinse

After caustic injection the primary column is regenerated with sodium ions and can be uses

again after rinsing the bed with brine at the end to continue to process. Now this regenerated

column becomes secondary column (polisher).

Acid concentration conversion from 31% to 4%:

Formula: C1 x V1 = C2 x V2

C1 (concentration of given acid) = 0.31

C2 (required concentration of acid) = 0.40

V1 (Volume of given acid) = 1000 liter

V2 (Volume of required water) =?

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 BRINE PURIFICATION PLANT 9035 DATED: 8-3-2017

V2 = 0.31 x 1000/0.04 = 7750 liter

For 60 % stroke

Dosing pump flow rate = 3.6 liter/hr

1000-liter acid = 7750 liter of water

1-liter acid = 7750/1000 liter of water

3.6 liter acid = (7.75) x 3.6 liter of water = 28 l

At 60% doze = 28 liter/hr DI water flow required to convert 31% acid to 4%.

TROUBLESHOOTING

Problem Cause Solution

1. Carbonates, sulfates  Lower conversion in  Increase BaCO3,

and chlorides in purifier Na2CO3 or NaOH
sample injection

2. Precipitates after  Low coagulation in  Increase Accofloc rate

primary filters settler  Increase residence
time in settler

3. Primary filter storage  Pressure builds in  Release pressure by

is not filling filter opening vent valve

4. Brine starts to solidify  Low temperature  Increase steam flow in

HE
 Check for possible
leakages

5. Ca++, Mg++ etc. are  Cationic resin is  Regeneration of ion

present after ion exhausted exchange unit
exchange unit

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 BRINE PURIFICATION PLANT 9035 DATED: 8-3-2017

6. Resin in output or  Damage to the strainer  Check for blockage

backwash stream  Change the filter

7.  

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