INDUSTRIAL VISIT/

TRAINING
(CHC-4910)
Study of De-Mineralization
Water Plant

Presented by – Arohi Shandilya

B.Tech. 4th year Chemical Engineering
Faculty No. – 19CHB081
Enrollment No. – GK1255
Serial No. - 02
CONTENTS:
• Introduction
• De-Mineralization Water Plant (DM Plant)
• Purpose of DM Plant
• Major Equipments
• Process of DM Plant
• Ion-Exchange Mechanism
• Calculations of Ionic load and Throughput
INTRODUCTION
There are ten divisions under Offsite and
Utilities – 7. Effluent Treatment Plant
1.Fire and Safety
8. Ammonia Storage
2.Captive Power Steam Generation Plant
9. Main Flare Stack
3.De-Mineralisation Plant
10. Distributed Control System
4.Cooling Water System

5.Instrument Air Plant

6.Inert Gas Generation Plant

DE-MINERALIZATION WATER PLANT
• The Fresh Water contains various impurities such as
• SUSPENDED SOLIDS: Debris, Dust & Dirt, Organic matter, Turbidity.
• DISSOLVED SOLIDS: Cations, Anions, Colloids.
• GASES: CO2, O2, NH3, H2S.
• These impurities results in corrosive and scaling nature of water, which is harmful for
any process equipment in plant.
• DM Water Plant ensure removal of total suspended solids, total dissolved solids, gases
and other materials (as oil and organic matters) from water and produces pure water
(polished water) through ion exchange process.
DM Plant
PURPOSE OF DM PLANT
• To Produce Polished Water For The Entire Complex @ 500 M³/hr, used as Boiler
Feed Water for Steam Generation as well as for Quenching and Process Flushing.
• DM water is supplied to steam generating units and process plants. The boiler feed
water’s total dissolved solids must be less than 0.02ppm.
• Low pH or dissolved oxygen in the water attacks the steel. This causes pitting or
lowering the thickness of the steel tubes, leading to rupture of the boiler tubes.
• Impurities carried over in the steam, causing deposits on turbine blades leading to
reduced turbine efficiency, high vibrations, and blade failure.
MAJOR EQUIPMENTS
• Two Pressure Sand Filters ( 2 X 150 m^3/Hr)

• Three Cation Units ( 3 X 150 m^3 /Hr)

• Four Anion Units ( 4 X 150 m^3 /Hr)

• Four Condensate Cation Units ( 4 X 120 m^3 /Hr)

• Five Mixed Bed Units ( 5 X 200 m^3 /Hr)

• Two Degassed Towers

MAJOR EQUIPMENTS
Intermediate Storage Tanks :

• FWST Filter water storage tank

• SWST Service water storage tank

• DGST Degassed water storage tank

• PCST Process condensate water storage tank

• DMST Demineralized water storage tank

• PWST Polish water storage tank

PROCESS OF DM PLANT
PROCESS OF DM PLANT
• Raw water, from raw water ring header, passes through the pressure sand filters
where total suspended solids (as debris, dust & dirt, silt, sand, mud) get removed.
• . Filtered raw water get stored in Filtered Raw Water Storage Tank & Service Water
Storage Tank. Service Water Storage Tank supplies water as drinking water in plant
& as plant cleaning water i.e., service water.
• Filtered Water Storage Tank supplies water to Cation units (WAC and SAC) where
Calcium ions, Magnesium ions, Sodium ions, Potassium ions & other cation traces
are removed from water.
• The outlet water, then passes through Degassed Tower where carbon dioxide gets
removed from water and processed water gets stored in Degassed Water Storage
Tank.
• Degassed Water Storage Tank supplies water to Anion units (WBA and SBA), where
Sulphate ions, Chloride ions, Nitrate ions, Bi-carbonate ions, reactive silica ions are
removed. The outlet water gets stored in De-Mineralised Storage Tank.
PROCESS OF DM PLANT
• In Demineralised storage tank, turbine condensate from process plants also
gets stored. De-Mineralised Storage tank supplies water to Mixed Bed for
further purifying and Mixed Bed’s outlet water gets stored in Polished Water
Storage Tank as polished water.
• Process condensate water and Steam condensate water get stored in Process
Condensate Storage Tank and this water after passing through Activated
carbon filters & Process Condensate Cation Units gets stored in Degassed
Water Storage Tank
 ION-EXCHANGE MECHANISM
• As water passes through Weak Acid Cation unit, Ca, Mg and Fe ions are trapped in the
resin bed and H ions are released. The reaction is given below:
Ca&Mg(HCO3)2 + 2RH R2Ca&Mg + 2H2O + 2CO2
• In Strong Acid Cation unit, Na and K ions are trapped in resin bed along with bivalent
cations (Ca, Mg etc.) and H ions are released. The reactions are as follows:
NaCl + RH RNa + HCl
Na2SO4 + 2RH 2RNa + H2SO4
 ION-EXCHANGE MECHANISM
• In Weak Base Anion Unit, SO4, Cl and NO3 ions replace the resin’s OH functional group. The
reactions are follows:
H2SO4 + 2ROH R2SO4 + 2H2O
HCl + ROH RCl + H2O
HNO3 + ROH RNO3 + H2O
• In Strong Base Anion Unit, HCO3 and HSiO3 ions are caught in resin bed along with other
anions. The reactions are given below:
H2CO3 + ROH RHCO3 + H2O
H2SiO3 + ROH RHSiO3 + H2O
• The reactions involved in Process Condensate Cation unit are as follows:
KOH + RH RK + H2O
(NH4)OH + RH RNH4 + H2O
CALCULATIONS
For Weak Acid Cation Unit (WAC) :
Raw water analysis gives the following result:
Calcium hardness as CaCO3 = 105 ppm
Magnesium hardness as CaCO3 = 95 ppm
Sodium hardness as Na = 155 ppm
Potassium as K = 6 ppm
Total iron as Fe = 0.15 ppm
Now, all parameters are calculated in ppm as CaCO3.
Sodium as CaCO3 = ppm of Na*equivalent weight of CaCO3/ Eq. wt. of Na
= 155*50/ 23
= 336.96 ppm
CALCULATIONS
Similarly, Potassium as CaCO3 = 6*50/39 = 7.69 ppm
Iron as CaCO3 = 0.15*50/28 = 0.268 ppm
Ionic load on WAC = Ca + Mg + Fe
= 105 + 95 + 0.268 ppm
= 200.268 ppm as CaCO3

Resin volume in WAC = 8 m3

Exchange Capacity of resin = 200 kg as CaCO3/ m3 of resin volume
Regeneration Efficiency = 70%
CALCULATIONS
Throughput of WAC = Resin volume*Exchange Capacity* Reg. eff.* 1000
Total ionic load (ppm as CaCO3)

= 8*200*0.7*1000
200.268
= 5592.5 m3