Process Safety Incident Tier 4

R-22 R-134a
WATER CHEMISTRY
AND D M PLANT

Ashok K Prajesh & Khemesh

TCL BABRALA WATER CHEMISTRY
Scaling or corrosive nature of water is ascertained by its pH
and dissolved solids (minerals) concentration in water itself.
On the basis of dissolved minerals concentration, water is
categorised as :

Hard Water
Soft Water

Hard water... is water that contains an appreciable quantity of of

dissolved minerals (like calcium and magnesium).

Soft water... is treated water in which the only ion is sodium &
very less amount of potassium ion (like rain water)
TCL BABRALA WATER CHEMISTRY
Total Hardness
Temporary hardness
Temporary hardness is a type of water hardness caused by the presence of
dissolved bicarbonate minerals (calcium bicarbonate and magnesium
bicarbonate). This hardness can be reduced either by boiling the water, or by the
addition of lime (calcium hydroxide) through the softening process of lime
softening or by passing through weak cation resins. Boiling promotes the
formation of carbonate from the bicarbonate and precipitates calcium carbonate
out of solution, leaving water that is softer upon cooling.

Ca(HCO3)2 + Ca(OH)2 2CaCO3 + 2H2O

Ca(HCO3)2 Heat CaCO3 + H2O + CO2

Ca(HCO3)2 + 2RH R2Ca + 2H2O + 2CO2
TCL BABRALA WATER CHEMISTRY
Total Hardness
Permanent hardness

Permanent hardness is hardness (mineral content) that cannot be removed by

boiling. It is usually caused by the presence of calcium sulphate/chloride and/or
magnesium sulphate/chloride in the water, which do not precipitate out as the
temperature increases. Ions causing permanent hardness of water can be removed
using a water softener, or ion exchange column.

pH of water depends on Total Alkalinity.

Total Alkalinity & Total Hardness ensures the concentration of
minerals in water.
TCL BABRALA WATER CHEMISTRY

Alkalinity in water due to ions : CO3-- , HCO3- , OH-

Caustic Alkalinity : Na2CO3, K2CO3, NaOH, KOH

Alkalinity due to temporary hardness : NaHCO3, KHCO3,

Ca(HCO3)2, Mg(HCO3)2

Alkalinity due to permanent hardness : Cl-, SO4--, NO3-,

CO3- etc.

Palk(> pH 8.3) = OH- + CO3-- , Malk = CO3-- + HCO3- ,

Malk(pH >4.3) = Total alkalinity
TCL BABRALA WATER CHEMISTRY
Water pH vs Alkalinity

Palk
OH-

8.3

CO3-- Malk

HCO3-
pH

4.3
CO2

FMA
TCL BABRALA WATER CHEMISTRY
DESIGNED vs ACTUAL WATER QUALITY
TCL RAW WATER QUALITY
Content Design Unit Actual Unit Actual Unit
Temp. 10 - 40 C - C - C

pH 7.0-8.2 - 7.4 - 7.8 - 7.4 - 7.8 -

Turb. 2.0-5.0 NTU <1 NTU <1 NTU

P-Alk. NIL ppm as CaCO3 NIL ppm as CaCO3 NIL ppm as CaCO3

T-Alk. 290 ppm as CaCO3 270 ppm as CaCO3 270 ppm as CaCO3

Ca 65 ppm as CaCO3 105 ppm as CaCO3 105 ppm as CaCO3

Mg 50 ppm as CaCO3 95 ppm as CaCO3 95 ppm as CaCO3

TH 115 ppm as CaCO3 200 ppm as CaCO3 200 ppm as CaCO3

Na 155 ppm as Na 337 ppm as CaCO3

K 6 ppm as K 8 ppm as CaCO3

Na+K 405 ppm as CaCO3 345 ppm as CaCO3

Cl 70 ppm as CaCO3 70 ppm as Cl 99 ppm as CaCO3

SO4 160 ppm as CaCO3 100 ppm as SO4 105 ppm as CaCO3

NO3 4 ppm as CaCO3 0.11 ppm as NO3 0.1 ppm as CaCO3

SiO2 39.5 ppm as CaCO3 23 ppm as SiO2 20 ppm as CaCO3

Iron 0.54 ppm as CaCO3 0.15 ppm as Fe 0.40 ppm as CaCO3

FRC 0.42 ppm as CaCO3 - - - -

KMnO4 15.625 - - - - -
TCL BABRALA WATER CHEMISTRY
Total Hardness vs Alkalinity
Temporary Hardness Permanent Hardness
TYPES Na Alk
(Carb-H) (Non - Carb-H)
TH=Talk TH Nil Nil
TH>Talk Alk TH-Talk Nil
TH<Talk TH Nil Talk-TH
Bicarbonates of Calcium SO4, Cl, No3 of Ca & Mg are Bicarbonat
(Ca) & Magnesium (Mg) absent only SO4, Cl, No3 of es of
As in TCL Sodium (Na) are there as Sodium
Babrala Permanent Hardness (Na) &
Potassium
(K)

Raw Water main minerals are:

Ca(HCO3)2, Mg(HCO3)2, NaHCO3, Na2SO4, NaCl, NaNO3,
K2SO4, KCl, KNO3 etc
All minerals get removed in D M Plant by Ion Exchange
Columns
DEMINERALISATION WATER PLANT
TWO PRESSURE SAND FILTER

( 2 X 150 M / hr. )

THREE STREAMS OF CATION UNITS

( 3 X 150 M / hr. )

FOUR STREAMS OF ANION UNITS

( 4 X 150 M / hr. )

FOUR STREAMS OF CONDENSATE CATION UNITS

( 4 X 120 M / hr. )
1
DEMINERALISATION WATER PLANT

FIVE STREAMS OF MIXED BED UNITS

( 5 X 225 M / hr. )

INTERMEDIATE STORAGE TANKS :

FWST, SWST, DGWST, DMST, PWST & PCST
INTERMIDIATE PUMPS (P1,P2,P3, P4,P6,P7,P8,P9,
P10,P11, P12, P13 & P5

RESIN USED ARE OF

M/S ION EXCHANGE
M/S THERMAX
M/S DOSHION
M/S AUCHTEL
1
 DEMINERALISATION WATER PLANT
pH 2.5 Cond >1000:,H2SO4, HCl, CO2
Raw Water From Borewells HNO3, H2SIO3, H2CO3 Traces of Na

PSF FWST WAC SAC DGT

P1
pH 7.5 Cond 950:(Ca,MgHCO3)2,: pH 2.5 Cond >1000:,H2SO4,
pH 5.5 Cond >1000; NaHCO3; SO4,Cl,
NaHCO3:SO4,Cl, NO3, HSIO3 of Na,K HCl, HNO3, H2SIO3, Traces
NO3 of Na,K; HSIO3 of Na,K; H2CO3
of H2CO3 Na

P4
MB DMST SBA WBA DGWST
P2
pH >7 Cond 5, traces of pH >6.5 Cond >10:,H2CO3,
pH 7, Cond 0.3:, HSIO3
HSIO3 Cl, Na, SiO2 < 0.2 ppm H2SIO3, Traces HCl
SiO2 < 0.02 ppm,
CL < 0.05 ppm

Turbine ACF PCC

PWST
Condensate Oil, Organic matters,
P5 (Critical Pump) NH3, Urea, K, V, HSIO3 P8
Cations: Fe3+ >Fe2+ >Mg2+ >Ca2+ >Na+ >K+ >NH4+
APC
Ammonia/
PCST UPC
Urea/ CPSGP Anions: SO42- >Cl- >NO3- >HCO3- >HSiO3- USC

1
WAC-SAC Service Operation
pH 7.5 Cond 950:(Ca,MgHCO3)2,:
NaHCO3:SO4,Cl, NO3, HSIO3 of Na,K
TH/TA=0.74, < 1
Fe3+ >Fe2+ >Mg2+ >Ca2+ >Na+ >K+ >NH4+
OEC : 86

Ca&Mg(HCO3)2+2RH = R2Ca&Mg +
2H2O + 2CO2

pH 5.5 Cond >1000; NaHCO3; SO4,Cl,

OEC : 72 (BD,
NO3 of Na,K; HSIO3 of Na,K; H2CO3
Na/TC high), min
Fe3+ >Fe2+ >Mg2+ >Ca2+ >Na+ >K+ >NH4+
66 as per RL

NaCl + RH = RNa + HCl

Na2SO4 + 2RH = 2RNa + H2SO4

pH 2.5 Cond >1000:,H2SO4, HCl,

HNO3, H2SIO3, H2CO3 Traces of Na

1
 WAC-SAC Regeneration

R2Ca&Mg + 2HCl = Ca&MgCl2 + 2RH

Ca&MgCl2, NaCl,
Na2SO4, H2O

RNa + HCl = NaCl + RH

2RNa + H2SO4 = Na2SO4 + 2RH

1
ACF-PCC Service Operation
Oil, Organic matters,
NH3, Urea, K, V, HSIO3

NH3, Urea, K, V, HSIO3

K+ >NH4+

OEC : 45 as per
KOH + RH = RK + H2O RL, max 66
(NH4)OH + RH = RNH4 + H2O

Traces of NH3, SiO2, Urea

1
ACF-PCC Regeneration

RK + HCl = KCl + RH
(RNH4 + HCl = (NH4)Cl + RH

1
WBA-SBA Service Operation
pH 2.5 Cond >1000:,H2SO4,
HCl, HNO3, H2SIO3, Traces of H2CO3 Na OEC : 66 on
RW, 45 on
Cond as
SO42- >Cl- >NO3- >HCO3- >HSiO3-
SO4/FMA low

H2SO4 + 2ROH = R2SO4 + 2H2O

HCl + RH = RCl + H2O
HNO3 + ROH = RNO3 + H2O

pH >6.5 Cond >10:, H2CO3

H2SiO3, Traces HCl

SO42- >Cl- >NO3- >HCO3- >HSiO3- OEC : 20 as per

RL & Silica
slippage
H2CO3 + ROH = RHCO3 + H2O
H2SiO3 + ROH = RHSiO3 + H2O

pH >7 Cond ~ 5, traces of

Cl, Na, SiO2 < 0.2 ppm

1
WBA-SBA Regeneration

R2SO4 + 2NaOH = 2ROH + Na2SO4

RCl + NaOH = ROH + NaCl

RNO3 + NaOH = ROH + NaNO3

RHCO3 + NaOH = ROH + NaHCO3
RHSiO3 + NaOH = ROH + NaHSiO3

1
 MB Service Operation
pH >7 Cond 5, traces of
Cl, Na, SiO2 < 0.2 ppm

Cations: Na+ =K+ >NH4+

Anions: Cl- >HCO3- >HSiO3- Cat OEC : 40 as

per RL &
Na/TC.
(NH4)OH + RH = RNH4 + H2O
Ani OEC : 3 to
NaHSiO3 + RH = RNa + H2SiO3
4 as per RL &
HCl + ROH = RCl + H2O Silica slippage
H2SiO3 + ROH = RHSiO3 + H2O

pH 7, Cond 0.3:, SiO2 < 0.02

ppm, CL < 0.05 ppm

1
 MB Regeneration

RNH4 + HCl = RH + NH4Cl

RNa + HCl = RH + NaCl
RCl + NaOH = ROH + NaCl
RHSiO3 + NaOH = ROH + NaHSiO3

2
Resins

Strong Anion
Resin

R-22 Weak Cation

Resin
Strong Cation
Resin

2
VESSELS INTERNALS

Internals Nos for each vessel Vessel

WAC/SAC/PCC/WBA
LATERAL PIPES SET P.NO.1, 2 & 3 21 (of three sizes)
/SBA/MB
STRAINER NOZZLE FOR LATERAL
210 SAC/PCC/SBA/MB
PIPE,P.NO.1
FLANGE OF STRAINER NOZZLE,
21 SAC/PCC/SBA/MB
LATERAL PIPE
BLIND CAPS FOR EXTERNAL
21 SAC/PCC/SBA/MB
THREADS NOZZLES
PP MOD.HOLDER/STEM WITH WAC/SAC/PCC/WBA
1200
WASHER & LOCK NUT /SBA/MB
PP STRANER WITH DOME WAC/SAC/PCC/WBA
1200
CAP,CONSIST PART 1&2 /SBA/MB
WAC/SAC/PCC/WBA
B/W STRAINER 1
/SBA/MB
WAC/SAC/PCC/WBA
AIR VENT STRAINER 1
/SBA/MB
WAC/SAC/PCC/WBA
RESIN TRAP 2
/SBA/MB

2
VESSELS INTERNALS

thanks

PP STRANER WITH DOME CAP,CONSIST PART 1&2 AND

PP MOD.HOLDER/STEM WITH WASHER & LOCK NUT
2
VESSELS INTERNALS

STRAINER NOZZLE FOR STRAINER WITH FLANGE

LATERAL PIPE,P.NO.1 & BLIND PLUG
2
VESSELS INTERNALS

LATERAL PIPES SET PART NO 1, 2 & 3 (Part 1: 13L+4M+4S)

2
LIMITATIONS IN RESINS
Water supply free from suspended matter
T Iron in the raw water supply can be detrimental to the ion exchange
resin if it exceeds 0.1 ppm.
Water supply free from oxidizing materials such as chlorine
Weak Cation resins function efficiently above pH level 5.0
Weak Cation resins have high regeneration efficiency.
thanks
Weak Cation resins are used primarily for softening and de-
alkalization
Weak Anion resins function efficiently below pH level 5.0
Anion exchange resins more susceptible to organic.
Polymerization of silica may occur in anion resin beds
All resins are susceptible for oil & grease fouling
Standard demineralizer resins cannot remove colloidal or some
organically sequestered materials

2
T

thanks