DEMINERALIZATION PLANT

TABLE OF CONTENTS

1. INTRODUCTION
a. System Function
b. System Overview
2. FLOW PATH DESCRIPTION
3. COMPONENTS ANDDESCRIPTION
4. OPERATION
a. Start-up
b. Normal Operation
c. Shutdown
d. Emergency Procedure
5. CONTROL AND INSTRUMENTATION
6. REFERENCES

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DEMINERALIZATION PLANT
1. INTRODUCTION

a. System Function
A demineralization plant is a process of removing mineral composition of water
by using the Ion exchange process to produce a higher Quality of water. The function of
demineralization plant is to supply demineralized water to be used for plant cycle. This
water is used for cycle make-up to condenser hotwell and meeting other requirements
including boiler filling, closed circuit cooling water, chemical dosing and etc.
The system comprises of storage and transfer facilities of demineralized water to
various consumption points covering the following equipment.

Demineralized water tank

Demineralized water pump

Interconnecting pipe and instrumentation

b. System Overview
The demineralization plant takes filtered water and removes the mineral
composition of water to be used for plant cycle water. The filtered water is first pumped
to mixed bed exchanger by mixed bed transfer pump to obtain high purity of water.
When the desired output is obtained, the demineralized water will be stored in DM water
storage tank.
The distribution of demineralized water will be distributed from storage tank to
cycle make-up,make-up water required for CCCW system and chemical dosing system,
hotwell by DM water transfer pumps. Boiler initial fill will be done boiler fill pumps.

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DEMINERALIZATION PLANT
2. FLOW PATH DESCRIPTION

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DEMINERALIZATION PLANT
The water from the BWRO product water tank is pumped to Mixed Bed
Exchanger. The Mixed Bed Exchanger contains both strong acid cations and strong
Base anions resins. Any slip of cations and anions is exchanged and removed in mixed
bed exchanger, which act as a polisher. Hydrochloric acid (HCI) and Sodium Hydroxide
(NaOH) are used for regenerating cations and anions resins respectively. The DM water
thus produced will be stored in DM water storage tank.
Bulk Acid/Alkali unloading pumps are provided for unloading acid/alkali received
from the tankers to respective bulk storage tanks. Required quantity of HCl/NaOH
solution will be transferred from bulk storage tanks into respective dilution tanks by
gravity and injected into the respective units through ejectors.
Regeneration waste from demineralization plant reject will be led to Neutralizing
pit for further disposal/reuse. The regeneration waste from demineralization plant will be
self-neutralized. The neutralized effluent will be pumped by means of effluent transfer
pumps to the guard pond for further use in CHP and AHP dust suppression.
The Neutralizing pit will be in two compartments with acid and alkali froof/poly
propylene glass. Once a compartment of neutralizing pit gets filled, the neutralized
effluent disposal pumps are started and kept in recirculation mode. pH of the effluent is
measured at the pump discharge and acid or alkali is added as required from the acid or
alkali measuring tanks provided at the neutralizing pit by Manual Operation. The blower
is allowed to run to mix the dosed chemicals. One the pH value comes within the
acceptable range, the neutralized effluent is disposed to guard pond by closing the
recirculation valve opening the disposal valve. The entire operation of neutralization is
automatic. Necessary interlocks will be provided.
The Distribution of DM Plant will be distributed from DM water storage tank to
cycle make-up, make-up water required for CCCW system and chemical dosing
systems, hotwell by DM water transfer pumps. Boiler initial fill will be done boiler fill
pumps.

5. COMPONENTS AND DESCRIPTION

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DEMINERALIZATION PLANT
The demineralization plant will consist of the following components:

Three (3) Nos. (2W+1S) MB Feed Pumps.

Three (3) Nos. (2W+1S) of Mixed Bed Exchanger Unit.

Two (2) Nos. (1w+1S) of Mixed Bed Blower.

Two (2) Nos. of DM water storage tank of capacity 400 m3 in each tank.

Three (3) Nos. (2W+1S) of DM water transfer pump. Common for both
units.

One (1) No. of Boiler Fill Pumps.

One (1) No. of pH correction system comprising of Two (2) Nos. (1W+1S)
of Morpholine Dosing Tank, and Two (2) Nos. (1W+1S) Dosing Pumps.

Two (2) Nos. (1w+1S) of Hydrochloric Acid unloading pumps.

Mixed Bed exchanger (10GCF10BB001/10GCF20BB001/10GCF30BB001)

A Mixed Bed Exchanger is designed to produce high purity treated water. They can
be use as polishing units to obtain high purity water. The Mixed Bed Exchanger contains
both strong acid cations and strong Base anions resins. Any slip of cations and anions
is exchange and removed in mixed bed exchanger, which act as a polisher.
Hydrochloric acid (HCI) and Sodium Hydroxide (NaOH) are used for regenerating
cations and anions resins respectively. The DM water thus produced will be stored in
DM water storage tank.
Mixed bed Air Blower (10GCC03ANOO1/10GCC4AN001)
The MB air blower will be used to mix the MB resins during the regeneration. The
blower are provided with the discharge valves, pressure indicator to check pressure and
monitor blower operation, if operating or stopped.
DM Regeneration Pump (10GCHIOAPPOI/10GHCIAP001)

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DEMINERALIZATION PLANT
Two numbers of pumps are provided to transfer DM water to MB units regeneration.
The pumps are provided with suction and outlet discharge valves and common pressure
switch to monitor the pumps if operating or stopped.
Bulk Alkali Storage Tank (10GCNC1OBB001/10GCN1OBB002)
Bulk alkali storage tank are provided for storage of alkali. The tank is provided with
inlet, outlet and drain valves, level indicator and transmitter.
Alkali Transfer pump (10GCN1OAP001/100CN1OAPOO2)
Two number of alkali transfer pump are provided to transfer the alkali from acid
unloading hose to the bulk alkali storage tank. The pumps are provided with Inlet, outlet
and drain valves, and individual pressure indicator to check the pressure and monitor
pump operation.

Alkali measuring tank (10GCN20BB001/10GCN30BB001)

Alkali measuring tank are used for measuring the required quantity of alkali for
regeneration The tank are vertical cylindrical tank provided with inlet, outlet and drain
valve, level indicator and level transmitter. The ejector is provided to inject alkali to mix
bed units.
The pumps are provided with sanction and discharge valves, outlet pressure
indicator and common pressure switch to monitor the pumps if operating or stopped.
Bulk acid storage tank (10GCN50BB001/10GCN50BB002)
The bulk and storage tank are provided to stored Hydrochloric acid and discharge it
to the acid measuring tank by gravity. The tank is provided with inlet and outlet drain
valves, level indicator and level transmitter.
Neutralization Pit (10GNRIOBB001/10GNRIOAPOO2)
The neutralization Pit provided to receive the regeneration waste from the DM plant
and other waste
Effluent transfer Pump (10GNRIODAPOOI/10RIOAPOO2)

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DEMINERALIZATION PLANT
Two Pumps are provided to transfer the DM Plant regeneration wastewater collected
in the neutralization pit to discharge.
Acid unloading pump (10GNCN20AP001/10GCN20APOO1)
Two acid unloading pump are provided to transfer acid from acid unloading hose to
the Bulk acid storage tank. The pumps are provided with the suction and discharge
valves individual pressure indicator to check pressure and monitor pump operation
Acid Measuring tanks (10GN60BB001/1OGCN70BB00I/10GCNBOBBOO1)
For measuring the required quantity of acid for the regeneration of the MB units acid
measuring tanks with outlet inlet and drain valves, level indicator and level transmitters.
Ejector system is provided with power water flow measurements. Ejector will inject acid
to the MB units.
Air Blower for N Pit
Two numbers of air blower for N PIT for angulations. The Blower are provided
with the suction filter, discharge valves, pressure indicator to monitor the blower, if
operating

5. CONTROL AND INSTRUMENTATION

Butterfly Valve
A Butterfly valve is a valve which can be used for isolating or regulating flow. The
closing mechanism takes the form of a disc. Operation is similar to that of ball valve,
which allows for quick shut off.
The disc is position in the center of the pipe, passing through the disc is a road
connected to an actuator on the outside of the valve. Rotating the actuator turns the
disc either parallel or perpendicular to the flow.
A Butterfly valve is from the family of valve called Quarter turn Valves. In
operation, the valve is fully open or closed when the disc is rotated a quarter turn
when the valve is closed, the disc is turned so that it completely block off the
passageway. When the valve is fully open, the disc is rotated a quarter turn so that it
allows an almost unrestricted passage of that fluid.
Pressure Transmitters

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DEMINERALIZATION PLANT
Pressure transmitters are in a wide variety of application. They are used in the
system to warn the operations of high pressure levels before a disaster takes place.
Pressure transmitters also ensure that the machine do not apply too much or too little
pressure during production. Pressure transmitters can be used in conjunction with other
devices to measure depth, attitude, water flow and even pressure loss in order to
prevent leaks in a system. A pressure transmitters or pressure sensor is advice that
measures pressure in liquid, fluid or gas.
Flow Transmitters
A flow transmitter has a sensor with an electrical transmission output for remote
indication of flow rate.
Pressure Indicator
A pressure indicator is an instrument for measuring and recording pressure changes.
Pressure Indicators usually have a sensing element (sensor) and transmitting and
recording devices.
Pressure Switch
A pressure switch is a form of switch that closes an electrical contact when a certain
set pressure has been reached. The switch may be designed to make contact other on
pressure rise or on pressure fall.
Level Transmitters
A level transmitter has a sensor with an electrical transmission output for remote
indication of liquid or bulk level.
Level Indicator
Sensor that Indicate level
Ball valve
A ball valve is a device with a spherical closure unit that provides on/off control of
flow. The sphere has a port, also known as a bore, through the center. When the valve
is positioned such that the bore is aligned in the same direction as the pipeline, it is in
open position and fluid can flow through it. When rotated 90 degrees, the bore becomes
perpendicular to the flow path, meaning the valve is closed and the fluid cannot pass
through.

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DEMINERALIZATION PLANT

6. REFERENCES

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