TULSION TROUBLE SHOOTING GUIDE

CONTENTS OF GUIDE :
1) Preface :

2) Typical problems and its causes :

a ) Change of raw water composition.

b ) Incorrect process parameters.
c ) Mechanical failure of equipments.
d ) Poor performance of ion exchange resin.

3) Guide lines for problem free operation :

A ) Preliminary inspection of vessel & equipment.

B ) Resin loading procedure.

a ) Single bed ion exchange bed.

b ) Layered bed ion exchange bed.
c ) Mixed bed ion exchange bed.

C ) Precautions during shutdown of ion exchange unit.

D ) Parameters checkup during service run.

E ) Resin Sampling procedure.

F ) Regenerant quality specifications for ion exchange resin.

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4) Common defouling methods of ion exchange resin.

Calcium defouling for cation resin.

Iron removal from cation resin.
Brine treatment for anion resin.
Calcium defouling for anion resin.
Iron removal from anion resin.
Acid cleaning of mixed bed.
Oil defouling for ion exchange resin.
Disinfection for biofouling.
Silica defouling.

5) Common Symptoms, its possible causes and its remedies.

Insufficient throughput ( OBR )

Poor product water quality
Increase rinse volume following regeneration
High pressure drop across a vessel, which may lead to insufficient flow rate

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1) Preface :

This article was developed to provide the engineer or operating personnel who are responsible for daily
operation and maintenance of industrial ion exchange plants a more complete understanding of the
types of contaminants and agents responsible for the deterioration and fouling of ion exchange
resins. The problems considered in this trouble shooting manual can be easily sorted out after going
through this manual.

Here included various trouble shooting procedures presently being used today to extend the life of
ion-exchange resins, operating under non ideal conditions, and to improve their overall performance.
Ion exchange resins have been used to treat and improve the quality of water throughout the world
for well over 50 years. Not only ion exchange resins are used to improve the quality of potable waters
which affects our daily lives, but their use is also critical in the non water ap plicat ion. Most of the
types of contaminants and agents responsible for the deterioration and fouling of ion exchange resins
are covered in this topic.

New technologies, such as the nuclear power and semiconductor industries, where high purity water
is an essential part of the process and water resistance required is high. During the ion exchange
process, resins may be exposed to a variety of substances that can act as foulants, oxidizing agents or
even catalysts, which can reduce operating efficiency and shorten the useful life of the resin. The
source of these contaminants may be from the water being treated (source dependent), or from p o o r
quality regenerant improperly stored in metal bulk storage containers. Other examples include air-
born contaminates, possibly from a degassifier (Deepak Nitrate: Blower suction was near to acid storage
tank was increasing load on resin due to suction of acid fumes. JCT Phagwara: Blower was choked due
to fibrous particle and leads to under performance of SBA down the line) located in an area
where high levels of dust, microorganisms or other foreign matter can easily contaminate a water
supply, or precipitates formed from poorly executed regeneration procedures (e.g. H2SO4) that can
irreversibly foul an ion exchange resin. All of these contaminants, no matter what the source, can
contribute to poor resin performance.

In most cases, cleaning the ion exchange is much less costly than replacement with new resin,
however, it would be wrong and a waste of resources to try to clean an ion exchange resin which is
irreversibly fouled or chemically and physically impaired. To minimize this type of error, normally, the first
step in any resin cleaning program is to have representative resin samples taken for routine
laboratory analysis (resin sampling techniques will be discussed later in this article.). The resin samples
should be tested for moisture content for both cation and anion resins, total cation capacity and
total/salt-splitting capacity for anion resins. These results will then be compared against values for
new resins to determine the condition of the ion exchange resin. Additional testing for resin foulants
can also be conducted via the laboratory. Normally cation resins are tested for iron and possibly
aluminum fouling, while anion resins are tested for organic fouling and possible iron fouling on re-
quest. Whole bead count is another test which can be conducted to help determine the physical
condition of the resin beads. In most instances, a well developed resin testing laboratory, will suggest the
best possible cleaning procedure and determine its effectiveness.

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2) Typical problems and its causes :

Fig. : Cause and Effect diagram for Short run / Low Output :

Resin Equipment

R L failure
Fouling
Distributor
Lumph formation
Ejector system
Fine formation
DGT malfunction
Calcium precipitation
Short Run

Test procedure Over run

Increased in load Design Vs actual
Change in source Reg.flow
Pretreatment Reg.Qty.

Water Operation

* Change of the Raw water composition

Change in raw water composition has direct impact on plant throughput. It should not affect the water
quality of treated water if we take corresponding throughput considering raw water composition of
present feed water.

A change in ionic composition of the water also affects throughput and water quality, even if the ionic
load remains unchanged. For example, an increase in the sodium to total cation ratio leads to sodium
leakage from cation provided acid regeneration level is not adjusted to compensate. Similarly an
increase in the free mineral acidity (FMA) will shorten the throughput of anion resin after a degassifier.

Feed temperature can have profound effect on the operating capacity of WAC and WBA resins. High
temperature can degrade the resin especially acrylic and Type II anions.

Insufficient or faulty pretreatment can lead to increased suspended solids which cause higher pressure
drop and potential blockage. This results in flow channeling, which reduces the throughput and water
quality. Inadequate pretreatment can also lead to slippage of oxidizing agent and Polyelectrolyte in feed
water thereby damaging the resin and impairing the plant performance.

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* Incorrect process parameters

Typical problem are due to incorrect regeneration condition (amount, concentration, injection time),
incorrect flow rates and improper backwash, which can lead to blockage and flow channeling.
Excessive or too low flow rates can also give operational problem due to channeling.

* Mechanical failure of the equipment

Pumps and measuring equipment such as Flow meters, pressure gauges and cells for measuring pH,
silica and conductivity should be checked and if faulty, restored to good working order or replaced. In
the case of poor water quality, valves should be checked to ensure no leakage of regenerant into the
service water or raw water into the treated water is occurring.
Improper distribution is caused by the improper, blocked or broken distribution systems.

* Poor Ion Exchange resin performance

Changes in the ion exchange resin characteristics, such as degradation or organic fouling, can create
quality, rinse and throughput problems. Whenever resin fouling or bead breakage is suspected, a
representative resin sample should be submitted to the Thermax Technical service and analytical
laboratory. Anion resin sample need to be checked for strong base capacity etc.

3 ) Guidelines for problem free operations in ion exchange unit :

A ) Preliminary inspection of vessel & equipment :

Before loading the resin, make detailed inspection of the empty vessel.

Remove all debris of previous resins or foreign material.

Clean up distributors, and inspect all laterals, splash-plates, and nozzles for damage or
plugging.
Inspect the rubber lining for integrity, if present, and perform a spark test, if possible.
Check all the valves operations and oil & greasing can be carried out.
Whenever possible check the pressure loss of the empty vessel at nominal (normal)
flow rate and observe the flow patterns for uniformity.

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B ) Resin loading procedure :

a ) Single bed ion exchange bed :

Single bed ion exchange vessels are those vessels, which operate with only one type of resin.

Fill vessel with sufficient water (~ 1/3 vessel height) to allow settling and avoid resin
damage.
Load the ion exchange resin by dumping the resin from the top, or by the use of a
vacuum ejector.
Backwash the resins for 30 minutes, according to the design backwash flow.
Initial flow should be 2/3 of the design backwash flows and can be carried for 05
minutes.
Weak base anion resin should be stored in solution overnight in order to wet-out the
resin prior to backwash. If it is not possible then the bed can be operated for one cycle
before backwash.
Close vessel and carry out double regeneration.
If possible soaking can be carried out for 6 8 hours

Fig : Resin charging ejector system

Water flow

Hopper for resin

charging

Power water

To Vessel
Ejector

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b ) Layered bed ion exchange bed :

Fill vessel with sufficient water (~ 1/3 vessel height) to allow settling and avoid resin
damage.
Load strong base anion in chloride form.
With 1 m of water above the strong base anion, load weak base anion resin and soak
overnight to ensure wetting of the resin.
Backwash at 1.5 2 m/hr ( 0.5 0.75 gpm/ft2 ) for 30 minutes.
Close the vessel and carry out double regeneration on both resin components.

c ) Mixed bed ion exchange bed :

Fill vessel with sufficient water ( 25-30% vessel height) to allow settling and avoid resin
damage.
Load cation resin to around 5 cm below final desired level.
Backwash cation at designed flow for 30 minutes.
Settle and drain bed to 5-10 cm above resin surface and fill remaining cation resins up to the

level of the central collector (if in H+ form) or 3-5 cm (1-2 inches) below if in Na+ form.
Carry out a second backwash for 10 minutes and settle.
Ensure that the resin surface is even and at the correct level.
With 1 meter of water above the cation resin, load anion resin.
Backwash at 5-6 m/hr for 5 minutes.
If anion resin is in Cl- form or cation resin is in Na- form, carry out double regeneration on both
resin components.
Rinse resins with flow from top and bottom, with removal of rinse water through the central
collector, for 30 minutes.
Reduce the water level to around 5 cm ( 2 inch ) above the resin bed and air mix for 15 to
20 minutes.
Fill it water and give fast rinse.

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 Start run and monitor rinse down until the specified pH, conductivity and silica are achieved.
If required water quality is not achieved because of resin clumping, the mixed bed should be
run for minimum 5 hrs and then further 15 minutes air mixing should be carried out at the end
of service run before backwashing to optimize resin mixing.

C ) Precautions during shutdown of ion exchange unit :

Used resins should be stored under climate controlled conditions, where feasible, to maximize the life
of the resin. Additionally, care should be taken that the resins are not exposed to air, as they will dry
out and shrink. When re-hydrated, these resins are susceptible to bead breakage due to rapid re-
swelling. The salt can then be removed by successive dilutions, to prevent rapid change in osmotic
pressures and resulting bead breakage.

Biological growth problems can be caused by inactivity of the resin during extended storage. In order
to minimize the potential for biofouling, inactive systems should be stored in a biostatic solution such
as concentrated NaCl. In addition to minimizing biogrowth, the concentrated brine solution will
prevent freezing. The recommended procedure for resins used for water demineralization is as
follows:

After exhaustion and a thorough backwash, the resin is ready for lay-up.
Apply a 15 - 25% NaCl solution to the bed and fill the vessel so that no air is present.
Upon reactivation of the vessel, the resin will need to be re-hydrated by successive washes of
less concentrated salt to minimize osmotic shock.
Prior to service, the beds must undergo a double or triple regeneration.

For mixed bed resins in condensate polishing and other ultrapure water applications, the resins should
be left in a regenerated condition as follows:

Separate the resins and carry out a double regeneration.

Rinse out the regenerants and leave the resins in the rinse water.
Flush the resins periodically down-flow (about once per week) to remove any TOC (Total
Organic Carbon) leachate.
Prior to start-up, rinse and regenerate as normal.

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D ) Parameters checkup during service run :

Check Solution
Measure bed height from window which should be as per
Check the resin level
calculation
It should be as per design and mention the same.
Backwash
Regenerant Name
Concentration of regenerant %
Regenerant consumed Liters --------
Power water flow m3/Hr
. Down flow if CCR m3/Hr------------ Time required --------- (min)
Co-Current
CCR,
Mode of regeneration
. If CCR mention
. Single regenerant ----- Double --------
Injection flow and Time m3/Hr------------ Time required --------- (min)
Slow Rinse flow and Time m3/Hr------------ Time required --------- (min)
Fast Rinse m3/Hr------------ Time required --------- (min)
Check influent water analysis: All Parameters required for
Ionic Load DM plant with form e.g. Cl as ppm Cl or as ppm CaCO3

Type of water used for regeneration DGT outlet or DM water

Parameters
Conductivity required for taking it in service
pH required for taking it in service

For time intervals e.g. say for every four hours till cycle
Silica at the outlet of anion
completed(desired OBR)

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E ) Resin Sampling procedure :

The first step in determining the condition of any ion exchange resin is to collect a sample, or
samples which are representative of the entire resin bed. Generally the larger the exchange unit
the more sampling required.
The methods used to collect resin samples for laboratory analysis can be categorized into three
groups,

1) Grab samples : Grab samples are resin samples taken randomly from the top of the resin bed
and is not the best method of obtaining a representative sample. Ion exchange resin beads
located at the top of the resin bed are generally those in the poorest condition i.e.., (fouled,
oxidative attack, precipitates, suspended solids and resin fines).

2) Core samples: Core samples of resin are much more representative of the cross-sectional area of
the resin bed and for small ion exchange units can safely represent the entire bed. Core samples
are usually taken using a grain thief, thin walled conduit or pipe inserted from top of the bed and
sample collected.

3) Composite sample: Sample collected at 4-5 places and samples then mixed together and
this is composite sample considered to be more representative.This sampling technique is
normally used for relatively large ion exchange systems.

If conduit arrangement is not available then bed will be drained to the level of 50-100mm water
level above the resin bed and air scouring carried for 30 minutes. Air flow should be 100-150
Nm3/m2/hr. Collect sample from 3-4 places top of the bed and mixed together will give composit
sample.

General procedure for taking out resin sample :

Bottle or bag used for sample collection should be labeled with type of resin and
designating the ion exchange unit from which the sample is taken.
Record identification, sampling data, operating data, and statement of problem in the
spaces provided on the data sheet ( Tulsion resin plant format ).
Drain resin bed so that water level is a few inches above the top of the resin bed.
Insert a conduit 3/4" diameter pipe through open manhole. Push the pipe downward until
reaching the bottom or support material below the resin bed and rotate the sampler or cap
the conduit and withdraw slowly.
Care must be exercised not to damage the bottom collection system when taking resin
samples.
Empty the contents of the sampler into a clean container containing water from the
operating unit. If necessary repeat Procedure: in different areas of the resin bed until one
pint of resin has been obtained. If limited overhead space prevents core sampling, obtain
resin sample by method mentioned above.
Sufficient resin sample should be collected for analysis. Quantities required for evaluation
are as follows,

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 Cation/Anion (Separate Beds) ............... 1Litre
Mixed Beds ...........................................1 litre
Transfer the resin sample to a plastic sample bottle (labeled), and completely fill with
water from the operating unit.
Seal bottle tightly and place in suitable container along with Tulsion plant format.

NOTE: Resin samples should be in the regenerated state when laboratory testing for conversion
of foulants is required.This removes foulants that would ordinarily be removed during the
normal regeneration cycle.

F ) Regenerant quality specifications for ion exchange resin : ( IS specifications )

H2SO4 Technical grade :

Specific gravity @ 20 0C : 1.825

H2SO4 as H2SO4 ( % by weight ) : 98.0 min.
Residual on ignition, ( % wt ) : 0.2 max.
Chloride as Cl ( % wt ) : nil.
Iron as Fe ( % wt ) : 0.05
Lead as Pb ( % wt ) : 0.005
Arsenic as AS2O5( % wt ) : 0.01

HCl Technical grade :

Specific gravity : 1.145

HCl as HCl ( % by weight ) : 30.0 min.
Residual on ignition, ( % wt ) : 0.1 max.
Sulphate as H2SO4 ( % wt ) : 0.1 max.
Iron as Fe ( % wt ) : 0.02 max.
Lead as Pb ( % wt ) : nil
Sulphite as SO2 ( % wt ) : 0.05 max.

NaCl grade 2 for softner :

NaCl % by mass : 98.5 min.

Insoluble in water : 0.2 max.
Ca as Ca % : 0.2 max.
Mg as Mg % : 0.1 max.
SO4 as SO4 % : 0.6 max.
Fe as ppm : 20 ppm max.

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NaOH Technical grade :

NaOH as NaOH : 99.5 % min.

Carbonate as Na2CO3 ( % wt ) : 0.4 max.
Chloride as NaCl : 0.1%
Sulphate as Na2SO4 ( % wt ) : 0.1 max.
Silicate as SiO2 : 0.02%
Fe as ppm : 20 ppm
Cu as ppm : 2.0 max.
Mn as ppm : 1.0 max.
Total Hardness : 5.0 ppm.

4) Common defouling methods of ion exchange resin :

* Calcium defouling for cation resin :

Calcium precipitation as CaSO4 into a cation resin bed is potential problem with sulphuric acid
regeneration. Modern high capacity, cation exchange resins can become fouled with calcium sulfate
(CaSO4 ) When using sulfuric acid (H2 SO4 ) as a regenerant. With strong acid resins, the precipitate is
generally found on the surface of the resin bead, which can normally be removed with the proper
cleaning procedure if the resin is not too heavily fouled. On the other hand weak acid resins tend to
foul throughout the resin bead structure, which can make weak acid resin clean up much harder to
accomplish.

The calcium sulfate precipitate is normally caused by contacting the resin with too high acid
concentration or too slow of an injection flow rate in the first step of the acid injection cycle. Although
some super saturation does take place during the regeneration process, the actual solubility of calcium
sulfate is very low at 0.2-0.3%. For co-current regenerated, strong acid systems, the sulfuric acid
concentration is usually limited to 2% in the first step of the acid injection cycle,while
countercurrent, strong acid systems and weak acid systems are limited to 0.5-0.7% concentration and
a minimum flow rate of 8l/l/hr.of resin in the initial stage of sulfuric acid regeneration.

Generally, the effect of calcium sulfate precipitation will be seen as an increase in sodium and calcium
during the service cycle along with loss of throughput capacity. During the regeneration cycle a
white powder like precipitate may be observed in the regenerant effluent.

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The removal techniques in use today involve the following procedures:

Cleaning

Prior to the cleaning procedure the resin should under- go an extended backwash (65%-
70%expansion) using softened or DM water to ensure that all suspended precipitate are
removed.
Prepare approximately 5 bed volumes of HCl solution containing 5%-10% DI water. Always
add the HCl to water and prepare solution in well ventilated area to avoid inhalation of
vapors.
Introduce the HCl solution to the cation unit at a flow rate of ~ 2-4 l/hr of resin.
The reaction between the cleaning solution and calcium sulfate is one of slow dissolution and
repeated cleaning may be required.
After the final bed volume of cleaning solution has passed through the resin bed, the unit is
rinsed with 4-5 bed volumes of softened water and then backwashed for one hour at 65%-
75% expansion.
The cation unit is then double regenerated, rinsed and returned to service.

* Iron removal from cation resin :

Procedure:
Cation exchange resins operating in H form

Cation and anion exchange resins fouled with iron, manganese and aluminum can be cleaned
efficiently with hydrochloric acid.
The treatment should be carried out with around 10 - 15 % hydrochloric acid (100 - 150 g/l).
A quantity of approximately 2 bed volumes (2 m3 solution per m3 resin) should be prepared.
Where possible, the hydrochloric acid should be heated to around 40 C.
After regeneration feed in 2 bed volumes of the hydrochloric acid at a regeneration flow rate.
If possible, stir in the resin in the acid solution with compressed air for about 10 minutes to
remove surface contaminants.
Soak the resin overnight in the acid solution.
Rinse with approx. 5 bed volumes of demineralized water, preferably at a regeneration flow
rate.

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* Cation exchange resins operating in Na form

After exhaustion and backwashing (if co-flow process) , feed in 2 bed volumes of the
hydrochloric acid at a regeneration flow rate.
If possible,stir in the resin in the acid solution with compressed air for about 10 minutes to
remove surface contaminants.
Soak the resin overnight in the acid solution.
Rinse with approx. 5 bed volumes of raw water, preferably at a regeneration flow rate
( if necessary at a service flow rate) until effluent is neutral.
Convert back to the sodium form by means of double/triple regeneration with a solution
comprising
10 % sodium chloride solution (100 g/l).

* Brine treatment for anion resin :

Prior to any chemical treatment, the resin bed should be backwashed with softened or
DMwater for 1-2 hours at a backwash rate that expands the resin bed a minimum of 65%-
70%.
Prepare a solution containing 2% caustic and 10 % NaCl. The volume of each cleaning
solution required will depend on the degree of organic fouling, but will normally range
between 4 and 7 bed volumes of each solution. Some conditions may require repeated
cleanings.
For maximum cleaning efficiency, both cleaning solutions should be heated and contacted
with the resin warmed to (45 50 0C) for Type I strong base resins and ( 90-950C) for
Type II strong base resins).Care must be taken that maximum temperature limits are not
exceeded during the treatment period. Using the existing caustic distributor, pass the NaCl
solution slowly (1.6-0.30 l/l or regeneration flow rate.) through the exhausted resin while
allowing the unit to drain.
The flow rate should not exceed the flow rate used during the normal caustic injection
cycle.Preferably, the resin bed should be preheated to the desired temperature prior to the
passage of the brine through the resin bed.
Using the caustic dilution system, rinse the resin bed with four bed volumes of de-cationised
or demineralized water at a flow of 2-4 l/l of resin. The temperature of the rinse water should
be maintained at the same temperature as the cleaning solutions.Using the caustic distributor
can pass the alkaline brine cleaning solution through the resin bed .
Observe the color of the last two bed volumes of the Alkaline brine exiting the resin bed. If a
light /dark tea color remains, the cleaning solution should be rinsed from the resin bed using
4-5 bed volumes of decationised or demineralised water and a second cleaning performed.
After final cleaning and rinsing have been completed, the resin bed should be
double regenerated with NaOH, rinsed and returned to service.

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* Calcium defouling for anion resin :

The recommended procedure for acid washing is as follows , the acid comcentration should be
increased gradually to avoid osmotic shock to resin.

Exhaust the resin .

Pass 1 BV of 5 % HCl solution through bed with contact time of 30 min.
Pass 1 BV of 10 % HCl solution through bed with contact time of 30 min.
Leave to soak for 2-4 Hrs.
Displace upflow with 2-3 bed volumes of water.
Rinse the bed thoroughly with 3-5 bed volumes of DI water.
Do double regeneration of bed before taking it in service.

* Iron removal from anion resin.

Anion exchange resins (it happens when inlet Fe in raw water is high)

After exhaustion and backwashing (if co-flow process), feed 2 bed volumes of the hydrochloric
acid at a regeneration flow rate.
If possible stir in the resin in the acid solution with compressed air for about 10 minutes to
remove surface contaminants.
Soak the resin overnight in the acid solution.
Rinse with approx. 5 bed volumes of decationised or demineralized water, preferably at a
regeneration flow rate or service flow rate.
Convert into the OH form using dilute sodium hydroxide by means of double or triple
regeneration according to the normal regeneration procedure.

* Acid cleaning of mixed bed :

Acid treatment of a mixed bed is used to remove inorganic contaminants such as metals and also
silica. It can be therefore be applied to bith cation and anion components.

The recommended procedure is as follows, The acid concentration is increased gradually to avoid
osmotic shock.

Exhaust the mixed bed.

Pass 1 BV of 5% HCl solution through resin bed with contact time of 30 minutes.
Pass 1 BV of 10 % HCl solution through bed with contact time of 30 min.
Leave to soak for overnight with occasional air scoring to facilitate contacting of the acid with
the resins.
Displace the acid downflow with min 5 bed volumes DI water.
Rinse the bed thoroughly with 5 bed volumes of DI water.
Backwash the resin to separate and then regenerate with double regenerant quantity.

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Oil defouling for ion exchange resin.

In general, oils, greases and fat can only be removed from ion exchangers by special cleaning
operations, and only in exceptional cases can the adsorbed oil be removed by standard
backwashing and regeneration.
To remove oil, grease or fat from ion exchange resins, the cation exchange resin must be in the
sodium form and the anion exchange resin in the hydroxide form.
The special treatment is carried out with approx. 1.5 bed volumes (1.5 BV) of an aqueous solution of
2 % sodium hydroxide solution and 0.1% non ionic surfactant (1.5 m3 solution per m3 resin). Where
possible, this solution should be heated to around 35 - 40 C.

Approx. 98 % softened or demineralized water

2 % sodium hydroxide (NaOH)
approx. 0.1% nonionic surfactant (approx. 1.5m3 / m3 resin)
The cleaning solution is left to act on the resin bed for several hours (~ overnight). Air agitation
should take place during the contact period for approximately 45 minutes.

The level of non ionic surfactant depends on the degree of contamination of the resin beds. If there is
n o foaming (contamination level is high), the quantity non ionic surfactant should be doubled.

* Disinfection for biofouling :

Softner :

Prior to the cleaning procedure the resin should subjected to extended backwash (65%-
70% expansion) using softened water to ensure that all unwanted debris is removed.
The softening resin is then regenerated using alkaline brine (mentioned in organic de-ouling of
anion). use 6-8 BV. Rinse brine from resin bed using softened water.
Pass sanitizing (alkaline brine) solution through resin bed at the normal regeneration flow rate.
When the last bed volume of sanitizing solution has been passed through the resin bed,
allow the resin bed to soak in the solution for approximately 6-8 hour. After the soaking
period, the last bed volume of cleaning solution is passed through the resin bed.
Rinse out cleaning solution with raw water for 60 minutes at normal displacement flow rate
followed by normal fast rinse for 45 minutes.
Backwash, double regenerate softening unit and return to service.

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Cation, Anion, MB :

Prior to the cleaning procedure the resin should under- go an extended backwash (65%-
70% expansion) using softened water to ensure that all unwanted debris is removed.
The softening resin is then regenerated using alkaline brine (mentioned in organic de-
fouling of anion). use 6-8 BV. Rinse brine from resin bed using softened water.
Pass sanitizing (alkaline brine) solution through resin bed at the normal regeneration flow
rate.When the last bed volume of sanitizing solution has been passed through the resin
bed, allow the resin bed to soak in the solution for approximately 6-8 hour.After the
soaking period, the last bed volume of cleaning solution is passed through the resin bed.
Rinse out cleaning solution with raw water for 60 minutes at normal displacement flow rate
followed by normal fast rinse for 45 minutes.
Backwash, double regenerate unit and return to service.

* Silica defouling :

Silica fouling can occur on anion resins used in the demineralization of water supplies, especially with
water supplies containing high levels of silica. When strong base resins are used to remove soluble
silica from water supplies, silica can accumulate on the resin when proper regeneration techniques
(e.g. progressive regeneration, lower temperature of caustic) are not observed. Overrun of
previous cycle In such cases the plant operator takes the risk that a portion of the silica on the
resin bead can hydrolyze into soluble silicic acid which can polymerize to colloidal silicic acid on the
surface and inside the pores of the resin beads. Strong base type II resins are quite susceptible to
this type of occurrence due to the lower caustic levels normally used to regenerate the resin.
Although the caustic level used may be high enough to obtain the required operating capacity, from
the more efficiently regenerated type II resin it may not be at a sufficient level to solubilize and
remove the silica from the resin bed, which results in unexpected silica leakage during the
demineralization process. Silica fouling is further complicated in the presence of organic fouling. Type
I resin silica fouling also possible due to overrun or increase in ionic load is not considered for
designed OBR.. Silica fouling can also occur in weak base anion units, particularly when they are
part of a three-bed demineralization system operating in thoroughfare regeneration mode (caustic
waste regenerant from a strong base unit is used to regenerate the weak base resin).

Cleaning procedures :

The treatment should be carried out with 4 - 8 % caustic soda (40 - 80 g/l ).A quantity of
approximately 2 bed volumes (2 m3 solution per m3 resin) should be prepared. Where
possible, the caustic soda should be heated to around 40 - 50 C. To ensure safe
handling the instructions in the Safety Data Sheet should be observed.
After regeneration - before rinsing - pass 2 bed volumes of the caustic soda at a regeneration
flow rate
If possible stir in the resin in the alkaline solution with compressed air for about one hour.
Soak the resin overnight in the alkaline solution.
Rinse thoroughly.

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5) Common Symptoms, its possible causes and its remedies.
* Insufficient throughput ( OBR ) :
Possible Causes
Faulty or inaccurate flow meter
High hardness water used for the rinse
Increase in influent hardness
Channelling due to blocked internal distributor
Channelling due to high flow rate
Channelling due to iron and Mg precipitation
Channeling due to compacted bed
Resin loss
Insufficient regenerant amount
Change in water composition
Leaking / bypass of valves
Resin degradation
* Poor product water quality :
Possible Causes
Faulty conductivity meter
High hardness water used for the rinse
Over run
Low flow rates
Silica precipitation in WBA
Calcium sulphate precipitation in cation bed.
Poor regeneration
Resin loss
Insufficient regenerant amount/regenerant
temperature.
Malfunctioning of degasser tower
Leaking / bypass of valves
Remedies
Check the accuracy of product flow meter
against volume delivered, if required replace
the meter.
Use softened water.
Increase the regeneration level.
Repair/clean distributor.
Reduce flow rate.
Air sparge and backwash
Air sparge and backwash
Measure resin bed depth, in the same form that
the resin was supplied.
Check the level in regenerant measuring tank
before starting up of regeneration.
Obtain analysis and reset regeneration
parameters
Check every valve on vessel
Take sample and confim with analysis,clean or
replace the resin as suggested.
Remedies
Check conductivity using an alternative
conductivity meter, if required replace it.
Use softened water.
Double regenerate and correct end point.
Increase the flow rate.
In high silica water regenrant from strong base
anion resin must be initially dumped before
applying to WBA.
Check acid injection concentration
Check regenrant concentration & contact time.
Measure resin bed depth, in the same form that
the resin was supplied.
Check the level in regenerant measuring tank
before starting up of regeneration.
Obtain analysis of CO2 after DGT which should
be less than 5 ppm.
Check every valve on vessel
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Possible Causes
Organic fouling ,loss of strong base capacity
Uneven distribution
Channelling due to no or insufficient backwash
Poor resin quality
Free residual chlorine at Cation inlet
* Increase rinse volume following regeneration :
Possible Causes
Leaking valves
Damaged laterals
Calcium sulphate precipitate in cation resin.
Organic fouling in anion resin.
Cation resin in anion resin
Resin degradation
* High pressure drop across a vessel, which may lead to insufficient flow rate :
Possible Causes
Valves partially closed
Internal distributor blocked
Flow rate above design value.
Low feed water temperature
Increased suspended solids in influent
Calcium sulphate precipitation for cation resin
Iron and manganese fouling of cation
Silica precipiatation on anion
Remedies
Take sample and confirm with analysis, give
brine treatment.
Check bed stability during regeneration and
rinse. Check flow rates and distribution system.
Regenerate again with proper backwash.
Take sample and confirm with analysis, replace
it if required.
Ensure the FRC should be nil in cation inlet
because FRC oxidizes the matrix of strong acid
cation resin. Improve pretreatment procedure
to remove this FRC.
Remedies
Repair or replace as appropriate.
Repair or replace as appropriate.
Clean and check acid injection concentration.
Check the color of effluent during the
regeneration, if it is dark red then give brine
treatment followed by double regeneration.
Investigate the cause and replace anion resin.
Collect sample and carry out its analysis, clean
or replace with fresh resin.
Remedies
Check and adjust all valves.
Repair/clean distributor.
Reduce it up to design.
Reduce flow or change to larger bead resin
Increase backwash time and frequency.
Check the concentration of injection.
Air sparge and backwash,if required change the
resin.
Increase regenerant temperature upto
50 oC.( 120 oF ).
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Possible Causes Remedies
Compacted bed. Extended backwash or air lance during
backwash.
Resin fines Give open backwash carefully to remove all the
fines and replace the that quantity with fresh
resin.
Inappropriate resin chice. Replace resin having specific partical size
distribution for particular application.
Biological growth Clean the resin and improve pretreatment to
control organisms.
Excessive resin volume in vessel Readjust volume according to guidelines.

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