Showing posts with label Ion Exchange Resin Analysis. Show all posts
Showing posts with label Ion Exchange Resin Analysis. Show all posts

Friday, September 09, 2011

Common Anion Resin Foulants

In a previous blog, we discussed common cation resin foulants. Here are some typical issues that we see with anion resin.

Organics:
Surface waters, such as rivers, streams, reservoirs, lakes, etc, can contain hundreds of PPM of natural and man-made organic matter. Natural organics are commonly formed from decaying vegetation. This decaying vegetation includes tannins, tannic acid, humic acid, and fulvic acid. Organics block strong base sites, which reduces the resin’s Salt Splitting Capacity (SSC). SSC is a major component of the resin capacity. It is a measure of the number of sites acting as a strong base on the anion resin, which acts together with strong acid sites to perform mix-bed polishing. As these sites become blocked, this reduces the anion resin’s capacity. Organic fouling of anion resin is noticed by the tea-colored to dark brown color of the water flowing from the outlet of an anion unit during regeneration.

Iron:
Precipitated iron, also known as ferric iron, or clear water iron (ferrous iron) that becomes oxidized into small solid iron particles can coat ion exchange resin, both Anion and Cation resin, reducing the resin’s ion exchange capacity. Not only does iron coat the surface of the resin, but it can also penetrate within the resin bead. Clear water iron (ferrous iron) can be removed from strong acid cation resin through a softener; however, if clear water iron comes in contact with oxidizing agents, such as air/oxygen or chlorine, ferrous iron turns to ferric iron and this will clog resin beads, decreasing their capacity and prevent ion exchange.

Aluminum:
Aluminum Sulfate, also known as alum, is used in water treatment to remove turbidity and suspended solids, causing these smaller particles to stick together to form larger particles, so they can be removed by filtration. Typically, Aluminum can be found in water due to the carryover of using Alum. Aluminum can precipitate into a jelly-like substance and coat resin, which will make the exchange sites inaccessible and reduce the capacity.

Silica:
Silica Fouling is commonly caused by improper regeneration in which the regenerate temperature is too low, or if the caustic used to regenerate contains too much silica. At low pH levels, silica can turn into colloidal silicic acid, which causes shorter runs and poor quality on anion resin beds.

Oil/Grease:
These substances can coat the resin causing short service cycles and poor product water quality. Dirt particles and broken resin beds will stick to oil and grease which also causes channeling of the resin bed. Oil fouling typically occurs from leaks in oil-lubricated pumps.

If you notice a loss in capacity of your anion vessel, it would be best to take a sample of the resin and have it tested to investigate any potential problems. To learn the best way to sample your resin, please check out this previous blog post.

Friday, August 26, 2011

Ion Exchange Resin Testing & Analysis Services

Test your ion exchange resin to monitor and maintain your water treatment systems such as softeners, dealkalizers, condensate polishers, deionizers or demineralizer systems. You should have the resin analyzed on a yearly basis to check the quality and performance of the resin. Samples can be taken from the resin bed and sent to Res-Kem to have the resin analyzed.

Res-Kem partners with Purolite Company to perform the resin analysis. The three most common tests we see performed are:


  • Total Capacity
  • Moisture Content
  • Resin Bead Integrity

    Other tests that can be performed are:
  • Iron Fouling
  • Organic Fouling
  • Ash Content of the resin

    but we will explain the latter in the detail.

    First, a sample of the resin bed is required, so it can be analyzed. Taking a good sample is very important to get proper results on the analysis performed. We recommend a sample be taken from various levels of the resin bed and within different areas of the bed. We suggest using a piece of PVC pipe, ½” or 1” in diameter and long enough to get down into the resin. Stick the pvc pipe all the way down the resin bed to pull up a sample. Think of a soda straw, when you place your finger on the top of the straw in soda, and pull up the straw with soda inside it. Now that we have our sample, lets look at the resin tests.

    Total Capacity Test:
    The total capacity of an ion exchange resin is defined as the total number of sites available for exchange per some unit weight or unit volume of resin. The capacity is expressed in terms of millequivalents per milliliter MEQ/ML for wet resin. For example, new strong acid cation resin, typically, has a total capacity spec of 2.2 MEQ/ML. A resin sample will get compared to new virgin resin for the test. Based on our experiences with Purolite, if a total capacity analysis shows more than a 20% difference compared to new resin, one should consider a resin change out. In the case of the SAC resin, a change out would be suggested if the total capacity test of the sampled resin shows a spec of 1.75 MEQ/ML or less compared to a new spec of 2.2 MEQ/ML.

    Moisture Capacity Test:
    The moisture content of a resin is a measure of its water holding capacity or swelling. New Cation Softening resin will usually have a water retention spec of 45-48%. Type I Strong Base Anion resin the Chloride form has a spec of about 48-54% moisture. If a resin analysis is to be done, it is important to test the moisture content of the resin sample to see if it’s within spec. An increase of the moisture content in resin is a clear indication of oxidation occurring on the resin. The resin tends to become soft, which leads to pressure drop and channeling, and will eventually affect the capacity of the resin. Going back to the softening resin spec, if we see an increase of more than 6% on the higher spec of 48%, we will throw up a red flag.

    Bead Integrity Test:
    Our bead integrity test is a percentage measurement of whole, cracked, & broken resin beads. Whole, cracked, and broken beadsFor example, test results will show the following: 94-4-2. 94% would be whole, 4% would be cracked, and 2% would be broken. Broken beads usually occur over time and are a normal part of wear and tear on the resin. Usually, a thorough backwashing of the resin bed will remove broken beads and fines. If broken beads accumulate over time because they are not flushed from backwashing, and the percentage test results of broken beads are shown to be in double digits, their presence will result in channeling of the resin bed and pressure drop.

    For further information:
    On our resin analysis, please visit our website.

    Please contact me, Mike Polito, when you have completed the Resin Analysis Request Form.

    Here are the resin analyses charges.
  • Wednesday, August 17, 2011

    Common Cation Ion Exchange Resin Foulants

    We are often asked to help with an ion exchange system that no longer has the same run length as when it was new. Typically, this is the result of either reversible or non-reversible fouling of the cation and/or anion ion exchange resin. These are some of the common foulants:

    Iron:
    Clear Water Iron (ferrous iron) can be removed through a softener. As long as iron stays in the ferrous form, regenerating a softener with a salt brine solution will remove the iron off the resin. When ferrous iron becomes oxidized into ferric iron (small solid iron particles), this type of iron will coat the surface of the resin, as well as, penetrate the internal matrix of the resin bead. Two common oxidizing agents, which can be present in water during the service cycle, are chlorine and oxygen that can cause the ferrous iron to form into ferric iron.

    Aluminum:
    Aluminum can be found in water due to the carryover of using Alum or Aluminum Sulfate in water treatment to remove suspended solids and turbidity. Aluminum will coat the resin and penetrate inside the resin bead causing poor exchange sites and reduce capacity.

    Barium:
    Barium is a metal that can be removed by softening resin. If Barium precipitates into Barium Sulfate where the Sulfate is greater than two ppm and the Barium is less than one ppm, this will foul the cation resin and reduce it’s capacity.

    Oil/Grease:
    Oil fouling typically occurs from leaks in oil-lubricated pumps. This will coat the resin causing short service cycles and poor product water quality. Dirt particles and broken resin beds will stick to oil and grease which also causes channeling of the resin bed.

    Hardness Salts (Calcium & Magnesium):
    This type of fouling occurs from improper resin regeneration. In a demineralizer or deionizer using sulfuric acid regeneration, calcium sulfate can form when the sulfuric acid regenerant is at too high a concentration or at too low a flow rate. This will lead to a gradual build up of hardness ions on the surface of the resin beads and within their structure. Once this occurs, regenerating the resin becomes more difficult which causes shorter service runs and reduces the resin life.

    How Do I Figure out what the problem is?
    The best way is to take a representative resin sample and have it tested. Please note, this may not be cost effective on small softeners because the labor cost of taking the sample and the resin analyses cost may be more than simply replacing with new resin. If you decide to have your resin tested, please fill out our Resin Analysis Submittal Form so we can start to figure out what the problem is. After that Mike Polito will have an RMA # issued so the resin sample can be received at Res-Kem.

    Monday, August 17, 2009

    Short Ion Exchange Resin Life-What's Happening?

    Lately I've been hearing our sales people commenting that customers don't think their cation softening resin is lasting as long as it used to. This is a general comment, not something we're surveying. Here is some food for thought:

    Has the manufacturing process changed?
    Yes. One of the relatively recent changes to the process came with the non-solvent resins. The greatest motivating factor behind the non-solvent resin came from the EPA. Simply put, the resin manufacturers had to stop manufacturing the resin using solvents because they couldn't put the by-products down the drain. So the resin we used to clean up the water had a manufacturing process that potentially contaminated the water. Makes sense!

    Are the non-solvent cation resins lasting as long as the solvent based resins?
    According to a major manufacturer non-solvent ion exchange resins are manufactured to meet the same standards of the solvent type. That is, both the solvent and non-solvent resins are 8% crosslink and will react similarly under the same set of circumstances. For instance, both resins, in the presence of 2 ppm chlorine, will react and break down.

    Should the solvent free ion exchange resins be used in industrial applications?
    According to the data sheets for Sybron C-249 NS and Purolite C-100, the answer to this is yes.

    So what are some of the reasons we are seeing shortened life/capacity?
    Is there chlorine in the feed water?
    In the presence of chlorine or any oxidant, cation ion exchange resins will breakdown prematurely. You say - yes, but the chlorine has always been there. I agree. However, as our water infrastructure has aged have the municipalities been forced in some instances to add more chlorine to compensate?

    Are there higher levels of iron in the water?
    As we know cation resin will remove ferrous iron but regenerating the iron off of the resin is challenging. Over time there is a loss of capacity as a result of the iron being embedded into the cation bead.

    Is the cation resin seeing higher temperatures?
    Gel cation resin can tolerate high temperatures but the combination of higher temperatures and an oxidant such as chlorine will dramatically lessen the life of the resin.

    We've been supplying ion exchange resins for over 25 years now. We have customers who call every three years, most commonly replacement of anion resin in a demineralizer application and other customers we hear from every 5 or even 7 years - softener applications. I can't say as I've seen a trend that points to bad manufacturing practices by manufacturers.

    In my opinion, the overwhelmingly majority of the problems result from oxidants such as chlorine and chloramine and my favorite - Operator Error - Oops ... we just backwashed all the resin out!

    Thursday, May 28, 2009

    Industrial Water Softener Maintenance

    Res-Kem Corp. and our sister company General Water Services offer preventative maintenance contracts for customers here in the Mid-Atlantic region. I thought it might be helpful to go over our Preventative Maintenance procedures for a commercial or industrial water softener for those of you who maintain your own water softening equipment.

    Dual tank industrial water softener using multiport valves assembled by Res-kem Corp. of Aston, PA.
    For an industrial water softener we suggest our customers have bi-annual visits by our technicians. It's a very simple inspection that can prevent unscheduled downtime and the associated problems. How often our customer tests the water hardness is largely determined by how critical the application is and the availability of staff. We strongly suggest testing the water hardness on a daily basis if possible.

    Res-Kem service technicians do a mechanical inspection that includes the following:
    Inlet and Outlet Water Hardness - When we specify a commercial or industrial water softener we are given a water analysis, the average, high and low flow rates, hours of operation, and desired end-point. It's important to note changes against the design specification. If all things are equal, seeing hard water at the outlet points to a mechanical problem with the water softener (or no salt in the brine tank). If something else has changed - flow rate is lower or higher than specified or the inlet water hardness has increased - our technician will review the data with our engineering department and discuss the problem in greater depth with the customer.


    Inlet and Outlet Pressures - Pressure testing is done when the water softener is running at the design specification. If there is a high differential the water softener might be running at too high a rate. If the water softener is running at a typical flow rate, (10 – 15 gpm/ft2) and there is a high differential pressure, the resin bed could be plugging up and preventing the water from flowing through the softener correctly. The differential pressure across a softener resin bed should generally run less than 15 psig. Of course there are many factors, which can result in higher differential pressures, i.e. depth of the resin bed, design of the internal distribution, age of resin, etc.


    Inlet Chlorine (in absence of carbon filter or bi-sulfite feed) - Chlorine will break down cation ion exchange resin. Exposure to significant amounts of free chlorine, "hypochlorite" ions, or other strong oxidizing agents over long periods of time will eventually break down the crosslinking. Over time the cation resin turns to mush and will plug up the bed or eventually be flushed out so there remains much less resin than required.


    Check salt level in brine tank, add if necessary

    Make Note of Leaks - Our technicians are trained to look carefully for that small drip. We'll fix it if possible while we're there, otherwise we will make an appointment to come back to service the problem. You should have gaskets in on hand for both the manway and handhole openings.

    Make Adjustments to the Control Valve - You should have received an operating manual with the water softener which includes information about the system settings.

  • If outlet water is out of hardness specification adjustments may be necessary.

  • Verify water softener timer is set to correct time and day.

  • Recalculate how often the water softener should be regenerating based on hardness and gallons and adjust control as necessary.

  • Optional Annual Maintenance

    Valve Maintenance - There are many different types of controls and valves used on a commercial industrial water softener. In general you will need the following parts on hand to perform this service:

  • Aquamatic Valve Nest Systems - Diaphragm & Seal Kits, Internal Parts Kits, Seat Tools and Shaft Tools.
    Valve nest using Aquamatic valves for a industrial water softener

  • Fleck Top Mounted Control Systems - Upper and Lower Seal & Spacer Kits, Top Piston Kit, Lower Piston Kit.


  • Autotrol Top Mounted Control Systems - Internal parts kits. Specific kits depend on valve type.

  • Ion Exchange Resin Test - Although softener resin will last significantly longer than deionizer resin, in the presence of chlorine or other oxidants it will break down. If your water is highly chlorinated or has other contaminants such as iron, you should test the resin within 18 to 24 months of start up and every year thereafter. Otherwise, test the resin after the third year and then every year thereafter. By doing so you will know when to budget softener resin replacement as it is often a major expense.

    Thursday, August 07, 2008

    Type II Anion vs Type I Anion: Ion Exchange Resin Analysis Yields Regeneration Savings

    Res-Kem is a supplier of ion exchange resins from several vendors including Purolite. Res-Kem is often asked to diagnose a potential ion exchange resin problem. Depending upon the resin type, cation, anion, or mixed bed, cost and length in service, it may make sense to sample the resin and test for parameters that can identify what has caused the resin not to perform and a potential remedy.

    Problem
    :
    One recent example of the value of an ion exchange resin analysis are the results of two anion samples sent to Res-Kem. The customer was noticing:


  • More frequent regenerations
  • Increased chemical usage
  • Longer rinse times This resulted in a much higher cost to produce water for use.

    They needed a solution.

    Ion Exchange Resin Analysis Reports:

  • Ion Exchange Resin Analysis Report for Train A
    Ion Exchange Resin Analysis Report for Train B

    Discussion of Resin Analysis (Written by Ted Begg of Purolite):

    Train A & B strong base anion resin analysis concluded the samples are Type II Strong Base Anions, equivalent to Purolite A300. Both samples exhibited dramatic loss in strong base capacity and severe organic fouling. Typical Type II anions will have 90% strong base capacity when new, however, it is not uncommon to see severe reduction to the levels observed, ~ 60%, when the resin is continually subjected to temperatures well in excess of 95 degrees F. Strong base capacity is responsible for silica removal. As this capacity is lost, throughput to silica break gets lower and lower with cost of caustic for regeneration steadily increasing. Given caustic is approaching $1000/ dry ton, lost throughput due to resin degradation comes at a very high cost.

    The organic fouling noted is severe and is likely contributing to lost throughput and increased rinse volume (fast rinse). The organics on the resin pick up sodium during caustic regeneration, which slowly elutes off during the fast rinse. Therefore the increased rinse volume.

    The Demineralization System:

    This plant was designed to mix returned hot condensate to the finished water make up storage tank. This water is used for boiler feedwater and as well as for regeneration. While the heated water is beneficial for boiler feedwater, it is not good for regeneration of the anion resins. This water can approach and possibly exceed 130 degrees F. The Type II strong base anion resin temperature limit is stated by manufacturers at 105 degrees F, however, it is more prudent to maintain the limit to a maximum of 95 degrees F. Given the plant operating conditions and the condition of the anion resin, we recommended that the anion be replaced with a more temperature stable product. A Type I porous anion resin with uniform particle size distribution is recommended as a replacement. The product, PFA400, is stable up to 140 degrees F and is more resistant to organic fouling than the incumbent resin. In this case longevity of the resin will improve. The throughput capacity of PFA400 will approach the incumbent resin as well. Thanks Ted for the detailed discussion above of the analyses.

    Our Conclusions and Observations:

    The conclusion is using a Type II anion in place of a Type I, where low silica water is required and the system can run above 95 degrees F, is a misapplication for the reasons stated above which are:


  • Less stable at higher temperatures
  • Strong base sites break down more easily breakdown to weak base sites
  • Lower capacity for silica

    So how does this misapplication happen? The selection of the ion exchange resins for a demineralization system generally occurs many years before a system is started up. Depending upon the perceived complexity of the water treatment system which includes the demineralization system, an engineering company may be specifying the demineralization system components including the resins as well as a whole host of other pieces of equipment. Then these specifications will be bid on by a short or long list of OEM's each of whom wants to get the job. Most will bid to the specs, but others may suggest a cheaper alternative.

    One common area to shave money from the whole job is to skimp on the demineralization system in particlar the anion system. When lowest installed cost is the driver, sometimes Res-Kem sees equipment companies selling deionization systems using a Type II anion resin. The reason they promote the use of a Type II anion is the anion portion of the system is smaller. Because the Type II anion resin has about a 10% higher initial capacity than a Type I, the equipment needs 10% less of the expensive anion resin and the size of the anion tank is smaller. The end result is several months after commissioning and transfer of the equipment from the OEM to the user, the problems begin. By then, the low budget OEM will be on to their next project and will often walk away from your problem.

    Res-Kem believes the moral of the story is work work with a knowledgeable OEM with experienced personnel who will recommend the best equipment for your application and will stand behind their equipment when installed.