Q&A on Condensate Polishers with Res-Kem’s Kevin Preising

While dirty condensate clean-up can be an energy buster in most processing plants, one cost effective solution is to polish contaminated condensate for re-use. Condensate polishers use a simple ion exchange technology that is easy to operate, easy to maintain and economical to use – less make-up water is required which leads to lower chemical and energy consumption.

Here is a brief Q&A video with Res-Kem’s Process Engineer Kevin Preising that addresses some of the most common questions about Condensate Polishers. Kevin touches on the following points:
• The difference between sodium condensate polishers and water softeners
• The life expectancy of a condensate polisher
• What plant utility services are required for condensate polishers
• Why a sub-surface wash is important
• The advantage of using a sample cooler
• The type of instruments on a condensate polisher

Watch it now!

New Two Bed Demineralizer Technical Bulletins

Res-Kem has a complete 2-Bed demineralizer product line designed for industrial water production.  The standard tank sizes range from 18" to 96". 

Two-Bed Demineralizer with
PVC Tank Coating and PVC Face Piping

These two-bed deionizers are designed for fully or semi-automatic production of water with a conductivity of less than 10 micro-ohms and feature:  

• Flow rates from 10 - 220 gpm and capacities from 140,000 - 2,200,000 grains.
• Strong acid 8% crosslinked cation and type 2 strong base anion resins as the standard, with other resins available as an option.
• Microprocessor based control system with conductivity monitor and flow sensor for regeneration initiation.
• Electrical enclosures are NEMA 4XFG corrosion resistant fiberglass, which reduces maintenance costs.
• PVC coated steel vessels depending on size and customer requirements.
• Optional ASME code vessels.
• Factory assembled and skid mounted for quick installation and minimum startup cost.
• Schedule 80 PVC piping package including air operated true union ball valves are standard. Air or electric actuated ball or butterfly valves are available as an option.
• Pressure regulators, rotameters and metering valves supplied for accurate and safe control of regeneration water and chemical introduction.
• Internal distributors are corrosion resistant, designed for optimum efficiency and are fully supported where required.

Technical Bulletins:
The following are the standard system sizes available from Res-Kem:

DI18072	Dual 18-inch diameter demineralizer system
DI24072	Dual 24-inch diameter system
DI30072	Dual 30-inch diameter system
DI36072	Dual 36-inch diameter system
DI42072	Dual 42-inch diameter system
DI48072	Dual 48-inch diameter system
DI54072	Dual 54-inch diameter system
DI60072	Dual 60-inch diameter system
DI66072	Dual 66-inch diameter system
DI72072	Dual 72-inch diameter system
DI78072	Dual 78-inch diameter system
DI84072	Dual 84-inch diameter system
DI90072	Dual 90-inch diameter system
DI96072	Dual 96-inch diameter system

For further information, please contact Res-Kem or call 800-323-1983.

Elliptical Bolt & Yoke Manways

Res-Kem is a leading supplier of elliptical yoke and bolt manways for personnel access to pressure vessels. Res-Kem offers various sizes of these complete manhole assemblies or tank manhole covers, which can be used for industrial and commercial water treatment applications. They are the following:

·         11x15

·         12x16

·         14x18

·         18x24

Most of the manway requests we receive from callers are for replacement cover assemblies, or top assemblies. A top assembly consists of the following:   



·         cover  

·         (2) yokes

·         (2) nuts & bolts 

·         gasket

 

We can also provide complete manway assemblies, which include all of the above, and the tank-welding ring. Tank welding rings, which are known as the tank opening,  are 3/4" or 1" thick, with depths of 3", 4", 5" or 6". Typically, our customers specify the ring dimension. We can offer some assistance on the ring depth if we are given information on the tank shell diameter, and the thickness of either the shell or head.

When it comes to replacing an elliptical manway on an existing tank, the most important aspect is to provide the inside dimensions of the tank opening (which is the welding ring), so Res-Kem can properly quote the correct size cover. Measuring the depth of the opening will help us determine the correct length of the bolts that are needed. For example, if an opening measures 4" in depth, we will offer a bolt length 1" longer than the depth of the opening if the size of the manway is 11x15, 12x16, or 14x18. If the manway is an 18x24 size, we will offer a bolt length 2" longer than the depth.

We offer manways made of:

• Carbon steel
• 304 stainless steel
• 316 stainless steel. 

The manways come standard with a neoprene gasket rated for a max temperature of 170 ° Fahrenheit, or we can provide gaskets rated for temperatures over 500 ° Fahrenheit.

If you are not sure what size manway you require, you can review our product bulletin for assistance, email Mike Polito, or call us at 800-323-1983.

Condensate Polishing & Maintaining Quality Boiler Water

Maintaining proper boiler water quality can be both costly and complicated when faced with navigating ASME boiler water guidelines. One cost effective solution is sodium cycle condensate polishing. Simple to operate and maintain, condensate polishers have been proven to realize real savings relative to chemical and energy consumption and provide the ability to control
corrosion transport and condenser in-leakage.

Not sure if condensate polishing is a good fit for your needs? We’ve developed a Boiler Feedwater checklist to help. Click here to review the list or contact us and we’ll analyze your steam loop together.

Condensate Polisher Ready for Shipment to Chemical Plant in Louisiana



Res-Kem will be shipping a condensate polisher to a chemical plant in Louisiana in a two days.  This system will be used to treat condensate to save water treatment chemical costs, identify process equipment leaks and will likely improve product quality of the chemicals they produce.

What is the problem?
The chemical plant uses steam in heat exchangers and jacketed process reactors.  The steam condensate returns at about 20 ppm hardness 24/7.  Recycling this high hardness condensate back into the boiler makeup water reduces the number of cycles of concentration possible and increases water treatment chemical usage.  Given the number of heat exchangers and reactors, it has been difficult to determine where the leaks are coming from.

What is the system solution?
Working with a Res-Kem subject matter expert, a condensate polisher was selected to reduce the hardness in the steam condensate prior to being returned to the boiler makeup.  A Hach SP-510 hardness analyzer installed on the treated water side of the CP will be used to determine when the polisher needs to be regenerated every two minutes process.  A Hach APA-6000 will be used to measure the incoming value of the hardness during operation.  By measuring and recording the water hardness and which process is operating, the plant engineers should be able to correlate which heat exchanger and/or reactor has the leak.    

 

Single Condensate Polisher with Bray Valves and Sample Cooler

System Operating Parameters:
The new, single tank condensate polisher will treat up to 140 gpm and since the system uses a highly crosslinked cation exchange resin, the system will operate at a maximum of 185 F.  As stated above, the Hach SP510 analyzer will take samples of the treated condensate every two minutes.  When the treated condensate reaches 10 ppm a signal will be sent to the DCS in the control room.  Depending upon the production schedule, regeneration of the condensate polisher start.

System Features:
Res-Kem has a customizable standard design for our condensate polishers from 20 to 66" in diameter with single to multiple tanks in parallel.  All wetted materials of the polisher are manufactured in 304L and 316L stainless steel.  The single mineral tank is an ASME-code vessel with a design pressure of 100 psig and test pressure of 130 psig.  The valves are Bray butterfly valves with 316L wetted parts.  Since we have a customizable standard design we easily accommodated the customer's company-wide standard of HYTORX actuators with position indicators.   

Bray Valve with HYTORX-131 Actuator and Flow Control on Condensate Polisher

Optional Added Features:

• Sample cooler-Required to operate the Hach hardness analyzers.  The maximum operating temperature for these instruments is F.  Also, the sample cooler insure accurate measurement of pH in the condensate.  Without a sample cooler, the pH will be inaccurately high.
• Hach SP510 Go/No Go hardness analyzer-This unit has multiple ranges which need to be selected when ordering
• Hach APA 6000
• Emerson HYTORX actuators

For Additional Help:

• Contact a Res-Kem condensate polisher expert.
• CP Product Bulletin
• Condensate Polisher Checklist PDF
• CP Checklist Webpage
• Value Engineering White Paper

Water Softener Shipped to Food Flavorings Company in New Jersey

Res-Kem recently shipped an industrial water softener to a food flavorings plant in southern New Jersey.  The water treated by the water softener is used to make steam to sterilize the raw plant material prior to extraction and extract the flavoring.   The softener will be a replacement to an existing tank which has failed after 40 years of service.

System Operating Parameters:
Since most of the steam ends up in the plant matter and the extracted flavor ingredient, very little steam condensate is returned.  This make the makeup flow very large.  Each of the three softeners operate at 200 gpm and 80 psig.  Because to the system's age, corrosion of the tanks and piping have become a maintenance nightmare. 

Existing Industrial Water Softener

New System:
The new system is an 84" diameter steel vessel and is finished in an epoxy coated interior and exterior.  The face piping is Schedule 80 PVC.  The valves are Bray valves with Bray air-to-air actuators.  The system is controlled by an Aquamatic 962 controller.  At this point, regeneration will be initiated manually when production will allow.  To handle the existing uneven floor, four jack legs were provided.

New Water Softener prior to Shipment to Food and Flavorings Plant

I Can't Believe It's Not A Water Sample!

Holy Moses! It wasn't 1 week after my last blog on October 28th 2011 about receiving water sample in old pickle jars when I get a water sample in an used margarine container!

Water Sample Container Received by Res-Kem

P-L-E-A-S-E!. My disclaimer: "results not guaranteed for accuracy due to improper sampling container" Ok, the courtesy testing we do is of the non-critical, aesthetics only variety, however, I'm sure the old butter will skew my results. Now that the blue is leaving my face, please help a friend out and read my October 28th 2011 blog. Matter of fact, print it out and keep it in your shirt pocket or maybe tape it to the back door of your work van. Amen.

Validatable Water System for New Jersey Pharmaceutical Company Shipped

We were recently asked to provide a DI water system for a central NJ Pharmaceutical company. They required a small amount of water for a batching operation, 50 – 60 gallons per batch 3 to 5 batches per day. Their requirements were that the water would have to meet USP specifications and that the system would need to be validatable.



Res-Kem Skid-Mounted Water Treatment and Recirculation System
Being Prepared For Delivery

This was a perfect fit for one of our portable skid mounted, pre-plumbed and wired delivery systems. The system fabricated offered 5-micron pre filter cartridge, gallon totalizing meter, SDI exchange tanks, 1-micron resin trap filter cartridge to a 125-gallon storage tank complete with vent filter, spray ball assembly, and 3-way level control. The water would then return to the skid by way of a continuous duty recirculation pump where it would continue through a flow indication meter, bacteria control ultra violet, exchangeable polishing resin tanks and 0.20 micron absolute final filters before returning to the storage tank.

125 Gallon Sterile-Vented Polypropylene Storage Tank
With Spray Ball Assembly Being Prepared for Delivery

The customer also included an optional temperature control dump valve and resistivity monitor with two sensors. All this is controlled by an AB-Micrologx 1200 PLC. The entire skid with storage tank takes up less than 16 square feet of floor space and stands less than 6 feet in height.

To complete the package was all validation documentation to insure a seamless and quick turn over at start-up. This included P&ID, electrical schematics, and data required for IQ (Installation Qualification), and OQ (Operational Qualification).  This package was provided as both a hard copy and on a CD.  

P&ID For Res-Kem Recirculation Skid

Also, as an economical advantage, this system is not only portable but also expandable with very little expense so it will grow as the business grows.

For More Information:
Link to Modular Ultrapure Water Systems
Modular Ultrapure Water Systems Brochure
Service Deionization Information
Need technical help selecting a solution?

Reduce Your Backwash Flow or Lament "Why is my ion exchange resin in the drain?"

It is that time of year.  You must reduce your backwash flow in the Fall or you will find your ion exchange resin in the drain or waste treatment plant.

Why do I need to reduce my backwash flow rate?
If the backwash rate for an ion exchange system is set when the water is warm, the flow rate will be too high when the water temperature is cold.  Anion resins are more susceptible to this problem because their densities are lower than cation resins.  Your ion exchange supplier should have curves of each resin in their literature.

Example of Backwash Flow Rates and Bed Expansion Chart
Purolite C-100

For example, if a water softening system and therefore the tank are designed for a 50% bed expansion at 77F, the backwash flow rate will be about 6.5 gpm/sq ft for Purolite C-100 cation exchange resin.  If the temperature of the water decreases to 41F, the bed will expand 120% at that same 6.5 gpm/sq ft sending most of the resin down the drain.

Please note, each resin will have a different backwash rate, so look in the manufacturer's bulletins for the correct value.

How do I prevent this from happening?

• If you have a backwash valve with a position stop, decrease the flow rate to the correct value at the colder operation temperature. 

• If you have a backwash controller with rubber inserts, remove and plug enough holes to decrease the flow rate to the correct value at the colder operation temperature.



Some of the Numerous Flow Controls and Flow Inserts Offered by Res-Kem

• Install a resin trap in the backwash line of the system.  If there is any media carry-over, it will be trapped, hence the name.



Res-Kem Manufactures Resin Traps for 2", 3" and 4" Piping to Prevent Resin and
Other Media From Contaminating Downstream Equipment

Need Help?:

Contact Res-Kem if you need help determining what needs to be done or to have us service you equipment.

Need Technical Information?

Dow Ion Exchange Resin Information

Purolite Ion Exchange Resin Information

Sybron/Lanxess Ion Exchange Resin Information

Thermax Ion Exchange Resin Information

Flo-Controlet Flow Control Brochure Page 1 and Page 2

Flo-et Flow Control Brochure

Res-Kem Resin Trap Information

3D CAD Drawings for Condensate Polishers for University in Massachusetts

In order to speed installation of the condensate polishers we recently shipped to Massachusetts, Res-Kem was asked to provide 3D CAD files for the condensate polishers.  Here are some screenshots of these drawings.

Solidworks 3D CAD drawing of Triple Condensate Polisher

Why use 3D CAD?
Given the complexity of the installation, tight dimensions and tight timeline, the 3D drawing helps the mechanical contractors understand how the condensate polisher is assembled and needs to be installed.  Also, prior to receiving the system, the contractor can bring piping to the equipment saving on site installation time. 

In addition to the standard AutoCAD and Solidworks files we sent to the customer, we sent an executable file.  This allows anyone, with or without a CAD program, the ability to select any view and take dimensions off of the drawing.

Alternate view of 3D CAD drawing of Stainless Steel Condensate Polishers

Contact us for assistance sizing and selecting a condensate polisher for your plant.