MIXED BED

Operational manual


1
Chapter 1


Description

1.0 Introduction
Mixed bed demineralizer plant embodies a single column unit in which strong cation &
strong anion resins are intimately mixed together . Water passing through the column
comes repeatedly in contact with these resins and is thus in effect subjected almost
infinite number of demineralizing stages . Demineral water of extreme purity is produced
- Purity that can not be produced by any other commercial method.

Mixed bed resins are regenerated with acid and alkali but the ion exchange resin must be
separated before this can be done . Bed seperation is done by backwashing . This carries
the lighter anion resin to top and the cation resin sinks to bottom.

1.1 Quality of water
Conductivity is proportional to the residual ionized solids in the water. Most mixed bed
effluent water will have conductivity less than 1 micro mhos . Where ultra pure water is
required two mixed beds are provided . The first mixed bed is known as primary mixed
bed and the second as secondary mixed bed.
A typical quality of mixed bed treated water is as follows

Conductivity at 25
O
C --------- < 1 micro siemens /cm
Silica --------- max 0.05 ppm as CaCO3
Total electrolyte --------- < 0.5 mg/ litre
Total hardness Nil
pH 6.8 ---7.2

1.2 Feed water Quality
Raw water or feed water to Mixed bed must be free from turbidity & organic matter,
Heavy metals , free chlorine and oil. The minimum inlet pressure required is 2 kg /cm2 .
If Raw water is being directly fed as feed water to mixed bed then the raw water TDS
should not be more than 50 ppm.
















2
Technical Data sheet

Type down flow

Parameters units CATION ANION

Unit dia mm

Unit dia Meters

Area Sq. meters

Bed depth mm

Unit HOS Meters

Type of Resin

Resin volume Cu .Meters

Chemical required as 100%
ACID Kgs
ALKALI Kgs

OBR M
3


Min. treatment
flow M
3
/hr

Max. treatment
flow M
3
/hr

Period between
regeneration hours

Normal Flow M
3
/hr

Regn flow M
3
/hr

Back Wash Flow M
3
/hr

Slow rinse flow M
3
/hr

Fast rinse flow M
3
/hr

Minimum pressure kg/cm
2


Maximum pressure kg/cm
2


3
Chapter 2

Operating the Plant


2.1 Starting
1. Open inlet Valve V1 & Air release valve V7 to remove trapped air
2. Close air release valve
3. Open inlet Valve V1 Final rinse (acid Rinse ) outlet valve V5 and maintain
the level in the drain sump at the final rinse level marker if orifice or V notch
board is provided .
4. Open valve v13 so that sufficient water flows through conductivity cell
5. Switch on the conductivity indicator
6. When the conductivity of the rinse effluent is satisfactory , close rinse outlet
valve and open outlet valve V2 and the unit is in service
7. The rate of flow to service is controlled by outlet valve V2.

2.2 Stopping the plant
1. Switch of the feed pump
2. Close the inlet valve , conductivity cell valve and outlet valve .
3. Open air release valve and release pressure
4. Close all valves







V1 V4

V17
V7 V9
V6 V16
V6 V16

V2
V2
V3 V5 V8
V11


V13
V12

V10


BLOWER


4

3.3 Nomenclature of Valves
V1 Inlet Valve
V2 Outlet Valve
V3 BW inlet Valve
V4 BW outlet Valve
V5 Acid Rinse & Final Rinse outlet Valve
V6 Acid Inlet Valve
V7 Air release
V8 Power water valve to caustic ejector
V9 Caustic suction valve
V10 Power water valve to acid ejector
V11 Acid suction Valve
V12 Blower air inlet Valve for Air mixing
V13 Isolation valve for conductivity cell
V14 Pressure guage isolation Valve ( Not shown)
V15 Isolation Valve for Rotameter

3.4 Regeneration
Preparation of regenerants :
Hydrochloric Acid
Take specified amount of hydrochloric acid in the acid measuring tank . Some call
this tank as acid dilution tank . Add demineralized water to make 10 % acid solution.
Caustic Solution
Fill the caustic dilution tank with demineralized water and gradually add the
Specified amount of 99 % rayon grade caustic . Stir the mixture, with the hand
stirrer , while pouring caustic soda and dissolve it thoroughly .
Note
1. When filling an empty tank , the depth of undrawn solution between the bottom of
tank and the caustic solution pipe must be allowed for and sufficient caustic soda must
be added to compensate for the additional amount of water used.
2. The concentration of diluted regenerant may be confirmed either by checking the
specific gravity.

3.4.1 Steps of regeneration
Step 1
Backwash
With wash outlet valve V4 open , open and adjust wash inlet valve V3 to maintain the
flow up to wash level marker in the sump . This is possible if Orifice or V notch board is
provided in the drain sump. If not the flow can be adjusted with the help of Rotameter .
After 10 minutes close V3 & V4 .
Step2
Settling
Open inlet valve V1 . Open and adjust final rinse outlet valve V5 to maintain the flow in
the drain sump up to final rinse marker .After two minutes close both the valves . After 1
minute check through the resin separation window ,two distinct layer are formed . If
distinct layer of the two ion exchange resin is not formed than backwashing step is to be
repeated .


5

Step 3
Caustic injection
Open wash inlet valve and caustic rinse outlet valve . Maintain the level upto up flow
mark in the drain sump . Open the caustic ejector power water valve V16 . The flow
should be adjusted upto caustic rinse marker Now slowly open caustic suction valve in
such a way that the caustic regenerant gets emptied in the time specified . After all the
caustic has been injected caustic suction valve V9 is closed.

Step 4
Caustic Rinse
Open inlet valveV1 and adjust caustic rinse outlet valve V16 to maintain the flow level
in the drain sump at the caustic rinse level marker . After twenty minutes of rinsing close
Valve V1 & V16.

Step 5
Acid injection
Open acid rinse outlet valve V7 , Acid ejector power water valve V10. and acid suction
valve V11 and acid inlet valve 6. Slowly adjust ejector power water valve V10 , to
maintain the flow level in the drain sump at the acid level marker. When the level falls to
the bottom of the acid suction pipe , close ejector power water valve V10 and acid
suction valve .

Step 6
Acid Rinse
Open flushing valve V17 and acid rinse outlet valve V5 . Adjust Valve V5 to maintain
the flow level in the drain sump at acid rinse level marker .After ten to 15 minutes of
rinsing close flushing valve V17 and acid rinse valve V5

Step 7
Drain down
Open wash inlet valve V4 and air release valve V10 and air drain valve. When water
level is seen from the top[ inspection window close valves V17 & V 18 Air Drain Valve.

Step 8
Air Mixing
Open air inlet Valve V12 air blower delivery valve and air drain valve .Start the air
blower and gradually open air delivery valve and simultaneously close air drain valve ..
This is done for 20 minutes to ensure that complete mixing has taken place.

Step 9
Refill & final Rinse
After 10 minutes of air mixing , quickly close air blower delivery valve and air inlet valve
V12 and open air drain valve V . Then open acid Rinse outlet valve V5 ( the same valve
is also called Final Rinse valve) and close wash outlet valve V4 . open inlet Valve V1 .
Close air release Valve V7 and stop the air blower . Valve V5 ( acid/final Rinse ) outlet
Valve V5 is so regulated that flow level in the sump is maintained at final rinse mark . If
no orifice Board or V notch is provided the flow is maintained with the help of instrument.


6
After 5 minutes of rinsing open air release Valve V7 and release the trapped air and close
the air release valve again . Open the valve to conductivity cell and switch on the
conductivity meter. If the conductivity is satisfactory open Valve V2 and the plant is in
service.

Note
1. During Acid injection , a down flow is generally maintained through the anion
exchanger bed , to prevent the diffusion of acid on the anion exchanger. This is done
by slightly opening inlet valve V1 and to prevent caustic diffusion on cation exchanger
, upflow is maintained by slightly opening backwash inlet valve V3 .
2. If the unit is new then run the mixed bed to its rated capacity even though it may give
quality water for more quantity than specified .



7
Chapter 3

Quality of Water from Mixed bed


The effluent from a mixed bed is extremely pure demineralized water . The pH of water is
around 7 (between 6.8 to 7.2) . A conductivity less than 1 micro seimens is obtained ,silica
value of 0.02 ppm is normal .Total electrolyte is less than 0.5 ppm. The silica in MB
effluent is dependent on the regeneration level ,the temperature of regeneration and silica
loading . The water produced by MB is ultrapure and hence an excellent solvent . Utmost
care in sampling & estimation must be taken must be taken to avoid errors .Necessary
blank test must also be carried out side by side . For conductivity & pH measurement
online meters are suitable . Atmospheric CO
2
may contaminate and vitiate the result if
suitable precaution is not taken .




8
Chapter 4


Troubleshooting of Mixed Bed


Problem Cause Action
Loss of capacity Organic fouling of anion
loss of resin.
Check and rectify. Give
Brine wash
Excessive Rinsing Organically fouled, clean.
Improper regeneration Channeling poor
distribution. Check laterals
and strainers Use correct
quantity of regenerant.
Exhaustion of preceding
cation / anion unit
MB need not be considered
to be exhausted. Most
MBs are designed for 3-4
runs of Anion and cation
Pressure drop Valve not opened fully.
Broken or blocked internals.
High flow rate or Resin fine
etc.
Bacterial growth Unit idle. Check, Recycle
water.
Poor Treated Water quality Low pH Anion resin organically
fouled Clean, Check
Blower, Air Mixing not
proper, See note on acid
leakage from MB.
High pH Cation/Anion not working,
check, Regeneration not
proper, check Increase in
ionic load.
Silica leakage Organic fouling clean.
Improper regeneration.
Over exhaustion.
Clumping Happens with new resin,
Give Brine treatment.
High conductivity Air mix not proper,
Insufficient air, Fouled
resin, Back wash not proper,
Improper regeneration,
Channeling / poor
distribution.
General poor quality Loss of inert resin, Loss of
cation resin if no inert resin,
Middle collector not in


9
proper position, Backwash
not proper. Air mixing not
proper