Parts for Solo, Solomatic, Bruner, Brunermatic, Permutit, Aquamatic, Culligan HiFlow Multiport Valves & Others

Routinely, Res-Kem receives requests for quotes for water treatment systems and their replacement parts. One area that frequently needs explanation is replacement parts for multi-port valves including Solo^®, Solomatic^®, Bruner^®, Brunermatic^®, Permutit^®, and Aquamatic^®.

We get questions like:

Please quote the following.:

AQUAMATIC valves with 6 ports total. 5 ports are 3". One in the rear and 4 in cross form. The 6th port is 2", which is the regenerant inlet port.

The fluid flowing through the valves is composed as follows:

1) Hydrochloric acid (HCL) 32% at ambient temp.
2) Sodium Hydroxide NaOH (caustic soda) 50% at ambient temp.
3) Water at ambient temp.
4) Picture of valve attached.



Another Question:
I have a Kisco water softener system with Aquamatic Solomatic Valves. The model number of the system is TWSKOM-300. I need replacement valves. What can I do?

Res-Kem Solution:
As a service company, Res-Kem frequently comes across many different water treatment systems, which have Solo, Solomatic, Bruner, Brunermatic, Permutit and Aquamatic Multiport Valves as well as other manufacturers. Unfortunately, many of these valves and controls for the valves have been discontinued or parts are extremely difficult to find, (which may be due to industry consolidation), and those parts which are available are very expensive. The Res-Kem solution is to replace the multi-port valves with a "valve nest" and an appropriate control system.

A valve nest performs all the functions of a multiport valve using Aquamatic diaphragm, Keystone butterfly, or other valves as specified by the customer. Using a standard layout with flexibility to account for various tank sizes, a valve nest is a very cost-effective alternative to a multi-port valve.

Valve nests can be supplied in a wide variety of materials: Cast iron valves with steel piping, Bronze valves with copper piping, plastic valves with PVC piping, stainless steel valves with stainless steel piping. They can be adapted to filters, softeners, dealkalizers, demineralizers and deionizers.

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.

Water Neutralization Saves $23,000 Annually

Res-Kem has published another white paper on water treatment. This next one is entitled "Bucking the Industry Trend… Simple Change to Water System Saves New Jersey Manufacturer $23,000 Annually"by Kevin Preising.

This paper details how the addition of an acid water neutralizer (5.5-6 pH) as a pre-treatment step to the Reverse Osmosis system saved over $23,000/year in downstream operation expenses at a New Jersey manufacturing plant. The acid water neutralizer, with an investment of less than $7,000 and operational and labor costs of only $700/year, has a Return on Investment of less than three months. While not a solution for all systems with reverse osmosis and high acidity, discussing neutralization with a qualified vendor can save Electrodeionization and/or Service DI operational expenses.

What is really interesting about this paper is it shows how a simple acid water neutralizer, properly applied, can save a considerable amount of money on operating expenses.

Having been in the water treatment industry for two decades, I have seen the trend in the water treatment industry towards more and more complex water treatment technologies and discounting past knowledge as old-fashioned. Often lost is a true understanding of water chemistry by some current "industry experts" and the simple, economic solutions to water treatment problems.

Please take a look and tell us what you think!

Activated Carbon: Mesh Size

We are often questioned about the differences between 1240 (12 by 40) mesh activated carbon and 830 (8 by 30) mesh activated carbon. The 1240 mesh activated carbon is smaller than the 830 activated carbon.

The screens or the mesh sizes are different. The 12 mesh screen has 12 openings per square inch 12 across and 12 down. The 40 mesh screen has 40 openings per square inch, 40 across and 40 down. Obviously the "holes" of the 12 mesh screen are larger than the "holes" of the 40 mesh screen. It follows that the holes on an 8 mesh screen are larger than 12 and 30 mesh holes are larger than 40 mesh holes.

If you would like a laminated card with this guide, contact Res-Kem.

As part of the manufacturing process the activated carbon companies pass the carbon through various screens to meet the specification.


So if you look at 1240 mesh activated carbon, it shouldn't have particles larger than 12 mesh or smaller than 40 mesh. The 830 mesh activated carbon shouldn't have particles larger than 8 mesh or smaller than 30 mesh.

What difference does this make to the user of the activated carbon? The most commonly used activated carbons for residential POE (point of entry) systems, commercial and industrial systems are 830 and 1240 mesh. We use 1240 mesh activated carbon because it has greater surface area and provides excellent chlorine and organics removal. Because the activated carbon filter acts as a mechanical filter in addition to removing chlorine and adsorbing organics, it will accumulate particles of dirt or crud at the top of the bed. An activated carbon filter is backwashed on a regular basis to remove this and prevent pressure loss across the bed.

In instances where the water contains more turbidity or crud, an 830 mesh activated carbon may be used. Having larger particle size than the 1240 activated carbon, the filter containing 830 mesh activated carbon won't need to be backwashed as often. However, as the particle size increases from a 1240 mesh activated carbon to an 830 mesh carbon, thereby decreasing the backwash flow rate, adsorption capacity will generally decrease.

When we specify an activated carbon it's important to know the water source. If it's city water or well water from a potable source, we can assume there is little if any turbidity and use of a 1240 mesh activated carbon will work well. If an industrial plant is taking water directly from a river or lake there may be disruptions to the clarification system that may cause excess crud or turbidity. In these cases we see the use of 830 mesh activated carbon.

Here is a full glossary of activated carbon definitions.

FILMTECTM BW30LE-440 and BW30LE-4040 RO Elements to be Discontinued

The Dow Chemical Company recently sent a discontinuation notice for the FILMTEC BW30LE-440 and BW30LE-4040 which have been an industry standard for many years. Dow will not take orders for the current LE elements after May 30, but will honor any orders on the books even if shipment is not until the end of the year.

The good news is FilmTec Corporation has developed a new Low Energy, LE, membrane. FILMTEC elements rolled from this LE membrane have the highest active membrane areas, and operate at lower pressure reducing operating costs.

FILMTEC LE-440i:
This RO membrane element replaces the FILMTEC BW30LE-4040 RO Element. The FILMTEC LE-440i has 440 square feet of RO membrane which is the highest active membrane area in the industry.

The FILMTEC LE-440i element:

Has 10% higher productivity than the FILMTEC BW30LE-4040

Operates at lower pressure

Maintains High Rejection

Minimizes operating expense

Reduces total cost to produce industrial, commercial, or municipal water

Incorporates iLEC^TM interlocking endcaps minimizes O-ring leaks which improves permeate quality

FILMTEC< LE-400 element:
This RO membrane element replaces the FILMTEC BW30LE-440 RO Element. The FILMTEC LE-400 has 400 square feet of RO membrane.

The FILMTEC LE-400i element:

Has higher salt rejection for better permeate quality

Operates at lower pressure

Minimizes operating expense

Reduces energy cost to produce industrial, commercial, or municipal water

Water Softener Is Not Producing Soft Water

Problem:
Your customer's water softener is not producing soft water. The brine tank may be filling with water.

Symptoms:
A water softener is used to protect clothes from iron and manganese staining, plumbing fixtures and appliances from mineral deposit damage, and reduce household chemical usage. Your customer has spotting on their glassware, cloudiness on shower stalls, and dingy clothes. Also, they may be getting iron and manganese staining on their clothes, appliances, and bathroom fixtures.

Possible Solution:
The most common problem is the brine used to regenerate the softener is not getting into the unit. The first place to look for a problem is in the "brine injector". Just like the water aspirator you used in elementary chemistry class to make a vacuum, the water softener valve uses water flow through venturi across an orifice to pull brine from the brine tank into the water softener. If anything plugs the orifice, the brine will not get into the water softener. In the following video, Michael Urbans, Technical Manager for Res-Kem's Residential Segment, shows how to clean or repair the brine injector on a Pentair^® Fleck^® 7000 multiport softener valve.

Harmsco Cartridge Filter and Filter Housings

The Harmsco^® industrial cartridge filter and filter housing product line is now available from Res-Kem Corp. Res-Kem is proud to be a master distributor of the entire Harmsco^® industrial cartridge filter and filter housing product line including:

Harmsco^® HIF Series Up-Flow Cartridge Filter and Filter Housings

Harmsco^® Hurricane^® Combination Cyclone Separator and Cartridge Filter

ASME Code Harmsco^® HUR-Series Hurricane^® Filter Housings with Swing Bolt Closures

Harmsco^® WB-Series WaterBetter^® Single Cartridge Filter Housings


Standard features of the Harmsco product lines are:

NSF Certifications

FDA Grade Materials of Construction

Electropolished 304 Stainless Steel

Failsafe Top Lid Closure Utilizing Multiple Fasteners

Top Lid Design / Safest Closure On The Market

Patented Up-Flow Filter Housing Design

Vent free

No cross-contamination of "contaminated" and "clean" fluids

Here is the link to the complete Harmsco industrial product line.

Save $91,000 Annually In Low Pressure Boiler Water Treatment Chemical And Fuel Costs Using a Dealkalizer

A white paper entitled "Save $91,000 Annually In Low Pressure Boiler Water Treatment Chemical And Fuel Costs Using a Dealkalizer" was written by Kevin Preising a Sales Engineer at Res-Kem Corp.

This white paper explains how dealkalization of boiler feedwater improves boiler steam/condensate systems reliability, fuel savings, and chemical savings. The Return on Investment, ROI, is substantially less than one year when a dealkalizer is added to an existing boiler feedwater plant with a conventional sodium cycle water softener - deaerator pretreatment.

Annual chemical savings are over $76,000 and "cycle-up" energy savings are over $15,000 savings using a dealkalizer with chloride form anion ion exchange resin. Reductions in condensate piping replacements can add further cost savings and will make the ROI even more attractive. In applications where neutralizing amine concentrations are limited by FDA regulations, the dealkalizer can be used in conjunction with reduced feed of neutralizing amines, achieving an optimized solution of reduced chemical feed with improved return condensate pH numbers.

The goal of this discussion is confined to the addition of a dealkalizer post water softener.
The results of adding a dealkalizer are:
- Minimized waterside scale formation
- Minimized boiler-carryover
- Minimized boiler blow down through increased boiler cycles
- Increased return condensate pH values - thereby reducing the need for neutralizing amine chemical feed to control corrosion in the condensate.

Ion Exchange Resin Disposal

Recently a customer asked us what to do about getting rid of the old resin after replacing it with new. This is a common question we get all the time.

In general we can assume the following:

Municipal or City Treated water contains little or no contaminants that are harmful to drink; therefore, it is unlikely the used resin has any contaminants on it to prevent it from being land filled as ordinary trash.

Well water and untreated surface water supplies may contain contaminants that can remain on the resin after regeneration. These contaminants are usually metals and are found on the cation resin. They may include but are not limited to lead, copper, and arsenic. For more specific information about contaminants we recommend this site. http://www.epa.gov/safewater/contaminants/index.html#mcls

How to dispose of used ion exchange resin is determined first and foremost by state and local government agencies. Regulations do vary from state to state. To satisfy local regulations it is recommended that you or your environmental manager call your regular waste removal company and ask them what to do. Most likely you will be asked to provide a TCLP test (Toxicity Leachate Characteristic Procedure) for your particular ion exchange resin, see attached pdf file for more specific information about this test.

Most likely the waste removal company will ask for an MSDS on the ion exchange resin you want to throw away. MSDS for most ion exchange resins can be found on the Res-Kem website using these links: http://www.reskem.com/pages/resin-pdfs.php

As part of our rebed service (service to change out spent ion exchange resin or activated carbon) Res-Kem will arrange for proper disposal of spent ion exchange resin or activated carbon on your behalf. This assumes we are providing turnkey removal and installation and the ion exchange resin or activated carbon is purchased from Res-Kem Corp. Sorry, we don't handle hazardous rebed applications.

TCLP Fact Sheet from EHSO

How to Correctly Size a Sodium Cycle IX Condensate Polisher

Problem: Customer Can't Get Enough Flow through Condensate Polisher => How to Correctly Size a Condensate Polisher

Customer called to state they couldn't get enough flow through their new condensate polisher. During the service visit, it was determined that the Deaerator and Condensate system was not being operated in accordance with Best Practices Procedures presented by the US Department of Energy's Office of Industrial Technologies, Energy Efficiency and Renewable Energy.

In this case the customer was feeding softened make up water into the Condensate tank along with the returned condensate, directing this water through the condensate polisher, then sending to the Deaerator. A Sodium Cycle Ion Exchange Condensate Polisher is typically sized and designed to treat only returned condensate, not to heat up make up water. In this case the polisher needed to handle both the make up and returns. It was never sized for this.



Normally, the softened make up water goes to the inlet of the deaerator, is heated by steam to remove the dissolved gasses, stored in the deaerator storage tank and sent to the boiler. The low-pressure condensate goes to a condensate receiver, through a condensate polisher and sent to the deaerator storage tank.

Most likely, the customer was thinking the condensate return, which is hot, would heat up the make up water before going to the deaerator, thus saving energy and steam. Conventionally, deaerators are designed to take cold softened make up water and heat it up in the steam chamber to remove oxygen and CO2 before sending it to the boiler.

The best way to save energy would be to install a Boiler Blowdown Heat Recovery System. This consists of a Blowdown Flash Tank and Heat Exchanger. Simply put, with this system the boiler blowdown water goes to a Flash Tank, where the pressure is reduced from the boiler operating pressure to the Deaerator operating pressure; typically 5 psig (228 deg F). When this blowdown water pressure is reduced, most of the water flashes to steam. The steam is directed to the deaerator steam inlet. The remaining blowdown water goes to a shell and tube or coil type heat exchanger, which is used to heat the softened make up water prior to going to the deaerator. The heat exchanger also reduces the blowdown water to safe and acceptable temperature levels for drains.

Separate from this, the condensate return water, having traveled through the myriad of piping, contains iron (crud) and some hardness and needs to be "polished" before being recycled back to the boiler. The condensate polishers are designed to handle only the returned condensate, which is a percentage of original make up water. When sizing up a condensate polisher we need to know the percentage of make up water that is "returned". It is only that percentage we are concerned about when we size up the condensate polisher.

Thus, a basic system would look like this:


The better energy saving system (as described above) would look like this:


A condensate polisher is used in addition to this Boiler Blowdown configuration.

Use of a condensate polisher and a good chemical treatment program enables the customer to use less make up water and energy. When considering use of a condensate polisher it's important to size it for treatment of the condensate only.

For more information about energy savings and Boiler Blowdown Systems see attached pdf files that the government has made available via the Internet.

US Department of Energy Steam Tip Sheet - Minimize Boiler Blowdown

US Department of Energy "Boiler Blowdown Heat Recovery Project Reduces Steam System Energy Losses at Augusta Newsprint" - Best Practices Technical Case Study