WASTE NEUTRALIZATION

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Contents
11.1 Fundamentals ......................................................................................................... 2

11.2 Process and Operation Overview ....................................................................... 3

11.2.1 Wastewater Collection ................................................................................ 3
11.2.2 Wastewater Mixing ...................................................................................... 3
11.2.3 pH Measurement ......................................................................................... 5
11.2.4 Wastewater pH Adjustment ....................................................................... 6

11.3 Equipment Design and Options ......................................................................... 7

11.3.1 Batch Tank ..................................................................................................... 7
11.3.2 Tank Mixing Eductor ................................................................................... 7
11.3.3 Centrifugal Pumps ...................................................................................... 8
11.3.4 pH Sensor ...................................................................................................... 9
11.3.5 Valves and Piping ........................................................................................ 9

11.4 Application and Design ..................................................................................... 10

11.4.1 Application.................................................................................................. 10
11.4.2 Design Calculations .................................................................................. 10
11.4.3 Expected Results ......................................................................................... 13

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 Acceptable
pH for
Alkaline Discharge
Wastewater Neutralization to Drain

Acidic
Wastewater

Figure 11.1-1: Acidic and Alkaline Wastewaters Neutralize Each Other

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 Module 11
WASTE NEUTRALIZATION

11.1 Fundamentals

Neutralization involves adjusting the pH of a liquid to approach the neutral pH of

7.0 (neither acid nor base). The concept of pH is discussed in detail in Module 2,
Section 7. Generally, neutralization involves the use of an acid (pH less than 7) to
lower the pH of a tank of basic (or alkaline) liquid (pH greater than 7), or the use of a
base (or alkali) to raise the pH of a tank of acidic liquid.

In the water treatment industry, wastewater is generated from the regeneration of

the resins used in cation, anion, and mixed bed ion exchange systems. The chemicals
used to regenerate the resins have extreme pH levels. For example, sulfuric acid,
with a pH of 1-2, is used for regeneration of cation resin and sodium hydroxide, with
a pH of 13-14, is used for regeneration of the anion resin. After the regeneration
process, the water containing these chemicals must be disposed of. Due to its ex-
treme pH, the wastewater cannot be sent directly to drain, as this will typically vio-
late local regulations regarding the pH of wastewater discharge. For example, the
NPDES (National Pollutant Discharge Elimination System) standard for stream
discharge pH is 6-9. The acceptable pH of the discharge varies by location and the
destination of the discharge (such as a stream, a well or a sewer leading to a
municipal waste treatment plant).

To neutralize the highly acidic wastewater from a cation resin regeneration, a supply
of alkaline liquid is needed. An anion resin regeneration is usually performed at the
same time, and its wastewater is alkaline. When these two wastewater streams are
combined, the pH is neutralized and approaches 7. If the resulting pH of the
combined liquids is not within the acceptable range for discharge, an additional
amount of either acid or base must be added to shift the pH into the acceptable
range. Figure 11.1-1 on the opposite page shows this concept. Generally, the
chemicals used to adjust the wastewater are the same chemicals used to regenerate
the resins in the ion exchange systems.

The regeneration of resin from a mixed bed ion exchange system generates both
highly acidic wastewater and highly basic wastewater. The total amount of
wastewater generated is generally a lower volume than the combined wastewater
streams from a pair of cation and anion ion exchange systems. Regardless of the
volume, the two wastewater streams resulting from the regeneration of a mixed bed
system can be combined to nearly neutralize each other.

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 Batch
Neutralization
Tank

Figure 11.2-1: Batch Neutralization Tank

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 11.2 Process and Operation Overview

The process of neutralization involves the following:

Collection of wastewater resulting from the regeneration of various ion

exchange systems

Combining and mixing wastewater streams

Measuring the pH of the combined wastewater streams

Adjusting the pH of the wastewater so it is within acceptable limits for

discharge to drain

11.2.1 Wastewater Collection

The wastewater remaining at the conclusion of an ion exchange resin regeneration

cycle generally has an extreme pH and cannot simply be sent to drain. Instead the
wastewater is directed to a batch neutralization tank. Figure 11.2-1 on the
opposite page shows a typical batch neutralization tank. The purpose of the tank is
to hold the wastewater streams in one location. Once collected, the goal is to use the
wide variations in pH of the streams and cause them to neutralize each other.

11.2.2 Wastewater Mixing

For complete neutralization to occur in a reasonable amount of time, the acidic and
alkaline waste volumes in the batch tank must be thoroughly mixed. There are
several mixing approaches that can be considered.

A motor-driven mixer on a shaft can be used to mix the contents of the tank. The
tall tanks often used in this application necessitate the use of long shafts that require
careful balancing with submerged bearings to keep the shafts in place. Mounting
the mixer assembly on the side of the tank removes these requirements but adds an
underwater seal. The maintenance for either of these approaches can be difficult.

Mixing can also be achieved by blowing air into the bottom of the neutralization
tank. This method avoids the use of moving parts and the associated maintenance
concerns, but requires a suitable supply of air. This procedure usually requires a
large set of blowers to produce the volume and pressure of air required to mix a full
tank of water.

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 Another mixing method lets centrifugal pumps recycle the wastewater in the tank.
This approach provides a fast and efficient mix with a relatively low-maintenance
piece of equipment. Only one pump operates, and any additional pumps are for
redundancy. Figure 11.2-2 below shows a pair of recycle pumps.

Recycle/Discharge Pumps

Figure 11.2-2: Recycle / Discharge Pumps

In a recycle mixing design, water flows from the bottom of the neutralization tank
and proceeds to the suction of the operating recycle pump. After being discharged
from the pump, the water is directed back into the batch tank. The time required to
pump the entire contents of the tank one time is the turnover rate. This can be
measured in turns per hour, with one turn being equal to the volume of the batch
tank flowing through the pump one time.

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 Suction Parallel
Section

..Five gallons
One gallon circulated
pumped

Suction
Nozzle

Figure 11.2-4: Principle of Tank Mixing Eductor

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 As it enters the tank, the water passes through an eductor that mixes water from
the pump (the motive fluid) and water from another part of the tank (the entrained
fluid). The batch tank contains a series of eductors, equally spaced on laterals, to
thoroughly mix the tanks contents. Figure 11.2-3 below shows the arrangement of
eductors inside the batch tank.

Tank Mixing Eductors

Figure 11.2-3: Tank Mixing Eductors

The flow of water from the recycle pump through an eductor creates suction that
pulls in approximately four times the amount of water being pumped. For every
gallon pumped into a single tank mixing eductor, five gallons are discharged, which
significantly reduces the turnover rate. Figure 11.2-4 on the opposite page shows a
schematic of how an individual eductor functions. The agitation caused by the
discharge stream also encourages mixing of the tank contents, especially when using
a series of eductors arrayed through the batch tank.

11.2.3 pH Measurement

While the wastewater is being recycled, an inline sensor continuously monitors its
pH. As the wastewater in the tank is being mixed, the pH is checked to verify that it
is within acceptable limits for discharge. If the pH of the batch is acceptable, the
water is sent to drain. If the pH of the batch is outside the acceptable range, addi-
tional chemicals are added to bring the pH to a desirable level before it is discharged.

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 11.2.4 Wastewater pH Adjustment

If the batch of mixed wastewater from a cation resin regeneration and an anion resin
regeneration does not yield an acceptable pH for discharge, then the batch must be
adjusted. Based on the pH measurement, an algorithm in the control system
determines the amount of acid or caustic that must be added to the batch tank.
Figure 11.2-5 below shows where the chemicals are added. If the pH of the batch is
too high, acid is added. If the pH of the batch is too low, caustic is added. The
amount added should be sufficient to bring the pH of the batch tank contents into
the acceptable range. The chemicals used are commonly the same chemicals used
for cation or anion resin regeneration.

Acid Caustic

Figure 11.2-5: Location of Chemical Additions

After the adjustment chemical is added and the contents of the tank are thoroughly
mixed, the pH of the wastewater batch is measured again to confirm that it is within
the acceptable range. If the pH is acceptable, the contents of the batch neutralization
tank are sent to drain. If the pH is not acceptable, another adjustment cycle is
executed until the pH of the batch is acceptable.

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 Batch
Neutralization
Tank

Figure 11.3-1: Batch Neutralization Tank

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 11.3 Equipment Design and Options

The equipment for a waste neutralization system is relatively straightforward. Due

to the extreme pH of the wastewater and the adjustment chemicals, the choice of
construction materials is critical.

11.3.1 Batch Tank

The batch tank is an atmospheric tank designed to withstand the extreme pH of the
cation and anion resin wastewater. Figure 11.3-1 on the opposite page shows the
batch tank. The tank itself is made of either fiberglass (FRP) or carbon steel. Due to
the extreme pH of the wastewater streams, a carbon steel tank is lined with an epoxy
polyamide sprayed lining or natural rubber sheet lining. For more information on
atmospheric tanks, see Section 9.1.

11.3.2 Tank Mixing Eductor

A series of eductors are used to mix the contents of the batch tank in a shorter
amount of time than required by a traditional agitator. By using the flow of water
through the eductors to create suction, water is drawn into the eductor from other
parts of the tank and combined with the water from the recycle pump. Typically, for
every gallon of water pumped into an individual eductor, four additional gallons are
drawn in to be mixed. This creates a circulation ratio of 5:1; five gallons leave the
eductor for every one that is pumped in. Figure 11.3-2 below shows a single tank
mixing eductor.
For good mixing, the discharge plume
of the eductor should cover most of
the height of the tank. An eductor
typically provides a discharge plume
(in feet) of about half the driving
pressure (in psi). Since tanks are
usually taller than they are wide, and
eductors are mounted at an angle, a 60
psig driving pressure is typically used.

Figure 11.3-2: Tank Mixing Eductor

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 11.3.3 Centrifugal Pumps

The centrifugal pumps supply the mixing energy for the system. They can also be
used to send the neutralized tank contents to drain. Figure 11.3-3 below shows a
typical centrifugal pump arrangement.

Motor
Pump

Figure 11.3-3: Centrifugal Pumps

The pump materials of construction must be able to withstand the pH extremes of

the wastewater and the chemicals present. For more information on centrifugal
pumps, see Section 9.2.

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 11.3.4 pH Sensor

The inline pH sensor monitors the pH of the wastewater. The sensor measures the
electrical potential between a reference material and the wastewater flowing past an
inline probe. The signal is
converted to electrical
current and transmitted to
the control system. The
results are used to
determine whether the
Reference wastewater batch is
Material Display
within an acceptable
range for discharge. It
also monitors the batch as
it is being discharged. If
the pH is not acceptable,
the control system
determines what type of
adjustment chemical
should be added to bring
the batch into the
In-line acceptable range.
Probes Figure 11.3-4 shows pH
probes and associated
electronics.
Figure 11.3-4: Inline pH Monitor

11.3.5 Valves and Piping

Like other components of the waste neutralization system, the valves and piping
must be able to withstand the extremes in pH of the incoming wastewater streams.
Stainless steel is a typical choice as the material of construction due to its corrosion
resistance. However, if hydrochloric acid (HCl) is used as an adjustment chemical,
components that come in contact with the concentrated acid must be protected
(due to the corrosive effects of high chloride levels). If carbon steel is used, it must
be lined with polypropylene (PPL) or a Teflon-type material (TFE). PVC pipe is often
a good choice in sizes smaller than 8 inches. Larger size PVC fittings tend to be
fragile. Similarly, piping just downstream of a sulfuric acid injection point must be
protected from the heat generated by the dilution reaction. Plastic pipe is not a wise
choice in this application.

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 Batch Tank
Volume

Pump
Size
Eductor
Quantity
and Size

Figure 11.4-1: Waste Neutralization System Calculated Attributes

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 11.4 Application and Design

11.4.1 Application

A waste neutralization system is generally used when wastewaters with extreme pH

values are generated by the regeneration of resins in ion exchange systems. If the
facility or municipal waste treatment systems cannot handle the wide variations in
pH along with the peak flows, a neutralization system is required.

11.4.2 Design Calculations

Figure 11.4-1 on the opposite page shows the components of a waste neutralization
system for which key attributes must be calculated. The following input data are
assumed:

The amount of wastewater (in resin volumes) generated by each resin

regeneration step:

ANION Volumes CATION Volumes

Backwash 2 Backwash 2
Pre-Heat 1 - -
Caustic 2 Acid 2
Displace 1 Displace 1
Rinse 10 Rinse 6
Total volumes 16 Total volumes 11

Volumes could be lower depending on the ion exchange vessel and

whether rinse water is recycled. Actual volumes of waste produced are
normally calculated with detailed ion exchange process calculations.

The desired turnover rate. (Assume 4 turnovers to thoroughly mix the batch
and 10 minutes per turnover to quickly process the batch.)

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 Batch Tank Volume

To use the wastewater from an anion resin regeneration to neutralize the wastewater
from a cation resin regeneration, the batch tank must be able to hold all of the
wastewater from the regeneration of both systems. A safety factor of 50% is added
to this total to account for conditions (for example, regeneration cycle alarms) that
might increase the amount of wastewater generated. The batch tank must also
include extra volume for the low level cut-off alarm (5% of total), high level alarm
(5% of total) and overflow alarm (5% of total).
The total volume of the batch tank is calculated as follows:

VTotal = (Vcation waste + Vanion waste ) x 1.5 [safety factors] x 1.15 [total alarm factors}

Where:
Vcation waste = cation resin volume x waste volume generated per cation resin volume
Vanion waste = anion resin volume x waste volume generated per anion resin volume

The calculations must be done in consistent units, usually cubic feet (as resin vol-
umes are mostly expressed in cubic feet) then converted to U.S. gallons using the
conversion factor 7.5 U.S. gallons/cubic foot.

For a system with 170 cubic feet of cation resin and 226 cubic feet of anion resin per
vessel:

Vcation waste = 170 ft3 x 11 ft3 waste per ft3 resin = 1,870 ft3 waste
Vanion waste = 226 ft3 x 16 ft3 waste per ft3 resin = 3,616 ft3 waste

VTotal= (1,870 ft3 + 3,616 ft3) x 1.5 x 1.15 = 9,463.35 ft3

Converting to US gallons:

VTotal= 9,463.35 ft3 x 7.5 USgal/ft3= 70,975 US gallons (or 71,000 gallons)

The height and diameter of the tank can be adjusted to accommodate this volume
and the location of the waste neutralization system.

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 Eductor Quantity and Size

Eductors are available in a range of sizes, however, larger sizes tend to be machined
and thus quite expensive. If small units are selected, the installation cost tends to be
high because of the large quantity required. Currently, a 1 unit appears to be the
largest standard size available at a cost-effective price. Table 11.4-1 below provides
the operating characteristics of this unit as a function of operating pressure. Note
that, at all pressures, the circulation ratio is very close to 5 gpm of circulation per gpm
of motive flow.

Eductor Model ME4OP (1.5 inch)

Pump Pressure
10 15 20 25 30 35 40 50 60
(psi)

Motive Flow
33 40 47 52 57 62 66 74 81
(gpm)

Circulating Flow
165 202 233 261 286 309 330 369 404
(gpm)

Table 11.4-1: Elmridge 1 inch Eductor Capacities

The mixing flow, or total eductor capacity, is calculated by dividing the tank volume
by the desired turnover time:

Mixing flow (gpm) = VTotal (gal) / turnover time (minutes)

The mixing flow is divided by the eductor circulation ratio to determine the actual
flow to the eductors, called the motive flow:

Motive flow (gpm) = mixing flow (gpm) / circulation ratio

The circulation ratio depends on the eductor selected but usually varies only slightly
across a specific eductor product line.

The minimum number of eductors required is calculated by dividing the total motive
flow by the motive flow per eductor at the operating pressure selected, and rounding
up to the next integer. Mechanical layout considerations may increase this number
slightly but do not need to be considered during process calculations with standard
eductors.

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 Continuing with the sample system and using the 10-minute turnover time initially
selected, the values for mixing flow and motive flow can be calculated as follows:

Mixing flow = 71,000 gallons / 10 minutes = 7,100 gpm

Motive flow = 7,100 gpm / 5 = 1,420 gpm

At 60 psi driving pressure, each 1 eductor uses 81 gpm of water, yielding a total
eductor count of 18:

Eductor count = 1,420 / 81 = 17.53, or 18

Pump Size

The pump size is fixed by the number of eductors selected (above). The pump flow
equals the number of eductors times the motive flow per eductor. The pump pres-
sure is the operating pressure (normally 60 psig) selected to get a reasonable plume
height.

For the example above:

Pump flow = 18 eductors x 81 gpm per eductor = 1,458 gpm

Pump head = 60 psig x 2.3 ft TDH per psig = 138 ft TDH.

11.4.3 Expected Results

After mixing and potential adjustments, the contents of the batch neutralization tank
will have a pH within local acceptable limits for discharge to the wastewaters final
destination (stream, well, or sewer leading to a municipal waste treatment plant).

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