1 Samyang Layered Bed System (Water Treatment)

Technical Report

Samyang Layered Bed System

(Water Treatment)

Samyang Corporation
Ion Exchange Resin Team
31, Jongno 33-gil, Jongno-gu, Seoul, Korea
TEL) 82-2-740-7732∼7, FAX) 82-2-740-7709
http://samyangtrilite.com
2 Samyang Layered Bed System (Water Treatment)
C
3 Samyang Layered Bed System (Water Treatment)
C

■ Classification by IER layer

■ Various combinations by Raw water and treated water quality

4 Samyang Layered Bed System (Water Treatment)
C

1. Overview
A Layered Bed water treatment system allows economical production of pure water
through simultaneous employment of Strongly Acidic Ion Exchange Resin (SAC IER)
and Weakly Acidic Ion Exchange Resin (WAC IER) for a cation exchanger; and of
Strongly Basic Ion Exchange Resin (SBA IER) and Weakly Basic Ion Exchange Resins
(WBA IER) for an anion exchanger. Successive regeneration of WAC or WBA ion
exchange resin with regeneration waste water of SAC or SBA ion exchange resin
enables high regeneration efficiency and ability to cope with the change of raw water
due to a good resistance to organic fouling of resins.
Generally, a cation exchanger is chemically stable and is strong against organic
pollutants of raw water, so it is rarely constructed in layered bed; thus, it is preferable
to construct a layered bed with anion exchangers only. The following figure is a
diagram of Samyang Packed Bed System Process (Layered bed) that does not use
intermediate plate; there are two types of resin layer in one resin tower. The
separation of resin layers is performed according to the difference in the particle size
and the specific gravity.
2. Understanding the layered bed pure water system (Ⅰ)

The 2B3T+MBP system, a typical demineralizer using SAC and SBA ion exchange resin, is
shown in the figure above. The layered bed system employs two types of anion
exchange resins in the anion exchanger.
5 Samyang Layered Bed System (Water Treatment)
C
6 Samyang Layered Bed System (Water Treatment)
C

■ Advantage of Samyang Layered bed System

1. Simple structure of the resin tower

(No intermediate plate is needed owing to the separation of resins by the difference
in particle size and specific gravity)
2. Very high regeneration efficiency (85~95%) due to the regeneration of WBA with
regeneration waste water of SBA IER
3. Very high operating capacity of the WBA IER
4. Smooth desorption of silica due to the use of Type1 SBA IER
5. Longer life time of resins; WBA IER prevents organic contamination of SBA IER
6. Easy retrofit of existing resin tower; adjusting ratio of 2 types of IER (SBA, WBA)

■ Disadvantage of Samyang Layered Bed System

1. Possible SiO2 leakage for treating water with high SiO2%

- Not recommended to use when SiO2% is above 30%
2. Intermediate sight glass is needed to check the separation of two types of resins
(SBA, WBA)
3. Rather high initial investment cost due to higher price of WBA IER than SBA IER

3. Specification for SBA and WBA IER for Layered bed

Grade TRILITE KA18LB (SBA) TRILITE AW90LB (WBA)

Strongly Basic Anion Exchange

Weakly Basic Anion Exchange
Type Resin
Resin (Porous type)
(Gel type)
Matrix Styrene-Divinylbenzene Copolymer
Functional group Trimethylammonium (Type1) Dimethylammonium
Ionic form Cl OH
Beige translucent Ivory opaque
Physical form
spherical beads spherical beads

Specific gravity 1.11g/㎖ 1.04g/㎖

Moisture retention(%) 43∼47% 40∼50%

Total capacity 1.3meq/㎖ 1.5meq/㎖
Swelling rate OH / Cl＝1.24 Cl / OH＝1.30
Uniformity coefficient 1.4 ↓ 1.1↓
0.6∼1.2mm 0.5∼0.6mm
Particle size

Operating temperature 60℃(OH form) 80℃(Cl form) 100℃ ↓

Operating pH range 0∼14 0∼9
7 Samyang Layered Bed System (Water Treatment)
C

4. Regeneration efficiency comparison between SBA, WBA Exchange

resins

1.2

TRILITE AW90
1.0
Base Capacity (eq/ℓ-R )

0.8

TRILITE KA18LB
0.6

0.4

0.2

0 40 80 120 160
Regeneration Level (g-NaOH/ℓ-R)

5. Understanding the layered bed pure water system (Ⅱ)

WBA exchange resin (TRILITE AW90LB) has excellent regeneration efficiency, as shown
above, and exchange capacity for multivalent ions; SBA exchange resin type 1 (TRILITE
KA18LB) has low regeneration efficiency but strong basicity, allowing low ion and silica
leakage.
Grade TRILITE KA18LB TRILITE AW90LB
Regeneration
Low High
efficiency
Ion leakage Low High
Silica removal High Low
Organic
fouling Low High
resistance

As shown in the above table, two types of ion exchange resin with different
characteristics are filled in one resin tower, exerting excellent performance during
service. These resins are separated without an intermediate plate due to difference in
specific gravity and particle size.

Type TRILITE KA18LB TRILITE AW90LB

Specific gravity 1.11g/㎖ > 1.04g/㎖
Particle size 0.6∼1.2mm > 0.5∼0.6mm
8 Samyang Layered Bed System (Water Treatment)
C

While backwashing the resin tower, the resin layer is initially expanded (Bed Expansion)
and settles down, the TRILITE KA18LH is located at the bottom part of the resin layer
because of its high shipping density and average diameter, and the TRILITE AW90LB is
located at the top, forming the layers.
At this time, the conventional products were mixed in the middle layer by separation
depending on the apparent density without adjusting the particle size, but TRILITE
KA18LB and TRILITE AW90LB are able to separate completely owing to their
differentiation in terminal settling velocity with adjusting the particle size as shown in
the figure below.

Sedimentation rate of TRILITE KA18LB

is much faster than that of AW90LB.
Uniformity of TRILITE AW90LB results
sharp rate of differentiation for
sedimentation. Hence, there is no
mixture of 2 types of IERs.
→ Excellent separation efficiency

TRILITE AW90LB, a weakly basic anion-exchange resin, has high exchange capacity for
free mineral acids (FMA), thus is highly economical if FMA concentration in raw water
is high. Its usage is not recommended, however, if FMA concentration is relatively low
and SiO2% is high (over 30%).
※) Free mineral acid(FMA): Chloride(Cl－), Nitrate(NO3－), Sulfate(SO42－)

For reference, the selection of the SBA exchange resin for the anion tower according to
the quality of the raw water is as follows:
Raw water condition
Recommended IER Grade
TDS SiO2% COD

Low TOC in SBA exchange resin Gaussian TRILITE SAR20

raw water Gel Type2 UPS TRILITE MA-20
30%↓ High TOC
WBA exchange resin + SBA TRILITE AW90LB + TRILITE
Total ionic in raw
exchange resin Gel Type1 KA18LB
contents water
in raw Gaussian TRILITE SAR10, 12
water Low TOC in SBA exchange resin
raw water Gel Type1 TRILITE MA-12, MA-
(50ppm↓) UPS
10
30%↑
High TOC
SBA exchange resin
in raw TRILITE AMP18
Porous Type2
water
9 Samyang Layered Bed System (Water Treatment)
C

Low TOC in SBA exchange resin Gaussian TRILITE SAR20

raw water Gel Type2 UPS TRILITE MA-20
30%↓ High TOC
Total ionic WBA exchange resin + SBA TRILITE AW90LB + TRILITE
in raw
contents exchange resin Gel Type1 KA18LB
water
in raw
water Low TOC in SBA exchange resin Gaussian TRILITE SAR20

(50ppm↓) raw water Gel Type2 UPS TRILITE MA-20

30%↑ High TOC
SBA exchange resin
in raw TRILITE AMP28
Porous Type2
water
※ 1g KMnO4/ℓ-Resin ↓, ※※ 5g KMnO4/ℓ-Resin ↓

Regene
Heat Chemic
ration Organic
Type resistan al Economic efficiency
efficien fouling
ce stability
cy

SBA Gaussian TRILITE SAR20 Increases with low

Better Good Good Good
Gel type2 UPS TRILITE MA-20 TOC and low TDS

SBA Gaussian TRILITE SAR10, 12 Increases with low

Good Good Better Better
Gel type1 UPS TRILITE MA-10, 12 TOC and low TDS

WBA + Increases with high

Layered TRILITE AW90LB +
SBA Excellent Excellent Better Better TOC, high TDS and
bed TRILITE KA18LB
Gel type1 low SiO2%

Increases with high

SBA Porous type1 TRILITE AMP18 Good Excellent Better Good TOC, less TDS and
high SiO2%

Increases with high

SBA Porous type2 TRILITE AMP28 Better Excellent Better Good TOC, high TDS and
high SiO2%

6. Layered Bed Water Treatment System: Operating condition

6.1 Summary
Type Data
Service flow rate
Maximum 50m/hr
Normal 20∼40m/hr
Minimum 5m/hr
Regenerant
2%↑
concentration
Injection flow rate LV 8 m/hr↑
Injection period 20min↑
Slow rinse 3BV
Fast rinse 3∼5BV
Outlet condition 2 ㎲/㎝↓
SiO2 leakage 100∼150ppb ↓
10 Samyang Layered Bed System (Water Treatment)
C

6.2 Vessel sizing Summary

Classification TRILITE AW90LB TRILITE KA18LB
Bed depth
Maximum 2,000mm 1,500mm
Normal 800∼1,500mm 800∼1,300mm
Minimum 500mm 800mm
Regeneration level
Maximum 90g/ℓ-Resin 120g/ℓ-Resin
Normal 50g/ℓ-Resin 80g/ℓ-Resin
Minimum 30g/ℓ-Resin 40g/ℓ-Resin
Swelling 20% 12%

6.3 Ratio of Anion Exchange Resins for Layered bed

TRILITE AW90LB
TRILITE AW90LB 30%
65%
∼ TRILITE KA18LB
TRILITE KA18LB 70%
35%

① SiO2 Concentration Low ① SiO2 Concentration High

② Regeneration efficiency High ② Regeneration efficiency Low
6.4 Regeneration condition and Operating condition for Layered bed
6.4.1 When SiO2 input is low
NaOH
NaOH Injection period NaOH Injection flow rate
Concentration
2% 20∼30min LV 8
No limit for Overrun operation (approximately, up to 50%)
6.4.2 When SiO2 input is high
NaOH
NaOH Injection period NaOH Injection flow rate
Concentration
2% 25∼40min LV 8 ↑
Overrun operation is limited. It is desirable to control over NaOH concentration to less than
2%. When highly concentrated NaOH is put, Silica contamination may occur to WBA
exchange resin while regenerating operation. Also, it is suggested to manage the
temperature of regenerant lower than 35℃, to protect silica contamination of WBA.
11 Samyang Layered Bed System (Water Treatment)
C

7. Operating condition of layered bed water treatment system

The WBA exchange resin at the front of the SBA exchange resin may have an increased
operating exchange capacity than the theoretical end point, which is because the SBA in the
rear end polishes the ions leaking from WBA. This phenomenon is called overrun operation.
The degree of overrun operation can be expressed by the following equation.

Overrun% = 100×(overrun amount of treated water / theoretical amount of attainable water)

The higher the overrun % is, the higher the concentration of FMA leak to the SBA at the end
point is, which should be considered when operating. The calculation of WBA resin amount is
as follows:

WBA Volume = FMA total ion load per cycle (g/cycle) / WBA operating exchange capacity
(g/L-Resin)

In the absence of overrun, only the SiO2 and HCO3- ions should be treated by the SBA;
however, when overrun operation occurs, small amount of FMA leaks and the load increases. In
this case, the ion loading of SBA is as follows:

SBA ion loading = SiO2 + HCO3- + FMA leakage from WBA

In conclusion, it can be seen that the resin amount of SBA increases when the overrun
operation is performed a lot. Generally, when calculating the amount of ion exchange resin in
a layered bed pure water system, it is common to consider a certain overrun % after
calculation assuming no overrun operation.

Free mineral acid (FMA) : Chloride(Cl-), Nitrate(NO3-), Sulfate(SO42-)

Overrun Operating Capacity : Operating capacity more than total capacity of anion exchange
resin, when there is a SBA exchanger behind a WBA exchange resin. It is due to SBA acts as
polisher at the rear end of WBA.

Inlet FMA

End point of service

Operating capacity Overrun operating Capacity

12 Samyang Layered Bed System (Water Treatment)
C

8. IER Charging Method for Layered Bed Water Treatment System

TRILITE KA18LB is most swelled when ionic type is OH type, and TRILITE AW90LB is most
swelled when it is in exhausted form. Therefore, it should be considered that the volume is
increased about 5% when charging ion exchange resin.
8.1 General counter-current regeneration Water Blocking System
① Fill resin tower with water about 50% to prevent physical crush of resins.
② Put in TRILITE KA18LB (Cl type) into tower
③ Perform backwash (LV 6-8m/hr, 30min)
④ Fill water up to approximately 1m above the charged TRILITE KA18LB, and then put in
AW90LB. (It is preferable, at this time, to leave TRILITE AW90LB in water for about 8 hours,
or to supply water to resins by carrying out 1 cycle operating before back wash (step ⑤) if
there is no time to do so. If water supply operation is omitted, resin loss may occur during
backwash because TRILITE AW90LB is porous resin and air might remain among pores.)
⑤ Conduct backwash (LV 1.5-2 m/hr, 30min).
⑥ Close the manhole and perform double regeneration.
⑦ After displacement, carry out service from the point below the specified electric conductivity.

8.2 Packed Bed System

① Calculate the freeboard above the resin layer based on the case when the resin layer is most
swelled.
② Add TRILITE KA18LB followed by Inert Resin in accordance with the provision of 8.1.
③ Add TRILITE AW90LB in accordance with section 8.1.
④ The following procedures are the same as section 8.1.

9. IER Separation Method for Layered Bed Water Treatment

System
Since the layered bed pure water system has 2 types of ion exchange resin charged in the tower,
the separation must be smooth, which is essential for proper operation. If the separation is not
satisfactory due to inadequate operating conditions or if pollutants are accumulated excessively
in WBA exchange resins on upper side, follow the procedures below to induce the ion exchange
separation and pollutant discharge.

① If the ion exchange resin is contaminated, perform cleaning process of the ion exchange resin.
After cleaning is completed, perform double regeneration and settle the resin layer.

② Perform backwash at a flow rate of LV 1-2 m/hr for 2-4 hours (At this time, the WBA
exchange resin is backwashed upward, and the SBA exchange resin is located at the bottom.)

③ Rest the resins for settlement.

④ Perform backwash at a backwash flow rate of LV 2-3 m/hr for 4 hours (At this time, the WBA
exchange resin mixed in the SBA exchange resin moves upward.)

⑤ Rest the resins for settlement and perform double regeneration again.
13 Samyang Layered Bed System (Water Treatment)
C

■ Case Study1 (Co-current System → Samyang Packed Bed System)

- Operating Cost Evaluation
This is a retrofit example of co-current system to Samyang Packed Bed System.
Ⅰ) Feed water analysis
2+ -
Ca 0.46 meq/ℓ Cl 0.60 meq/ℓ
2+ 2-
Mg 0.30 meq/ℓ SO4 , etc 0.32 meq/ℓ
+ + -
Na ＋ K 0.59 meq/ℓ HCO3 0.43 meq/ℓ
Total Cations 1.35 meq/ℓ SiO2 0.12 meq/ℓ
※Total cations = TC Total Anions 1.47 meq/ℓ
Ⅱ) After Degasfier Anion
-
Cl 0.60 meq/ℓ ※FMA＝0.60＋0.32＝0.92meq/ℓ, Cl / FMA%=65.2%
2-
SO4 , etc 0.32 meq/ℓ ※Cl%＝0.60 / 1.24＝48.4%
-
HCO3 0.20 meq/ℓ ※Weak Acid＝TEA – FMA = 1.24–0.92 = 0.32
SiO2 0.12 meq/ℓ ※SiO2%＝0.12 / 1.24＝9.7%
TEA 1.24 meq/ℓ ※FMA / Weak Acids = 2.88
※TEA(Total Exchangeable Anions)
- 2- - - 3-
※FMA(Free Mineral Acids) = Total sum of ions; Cl , SO4 , NO3 ,F ,PO4 , etc from organic
contents
-
※Weak Acids = Total sum of ions; HCO3 , acetic acid, citric acid, silica, etc mostly resulted from
organic contents. It is generally calculated by TEA – FMA.
Ⅲ) Requirements
2B3T(2Bed 3Tower) system(Cation exchanger → degasfier → anion exchanger)
Flow Rate＝450 ㎥/hr, Running Time＝20hr
Operating Temperature＝15℃, Regeneration Temperature＝35℃
Required SiO2 Leakage＝150ppb as SiO2
Ⅳ) Cationic load(eq/cycle)＝TC×450 ㎥/hr×20hrs＝12,150eq/cycle
Anionic load(eq/cycle)＝TEA×450 ㎥/hr×20hrs＝11,160eq/cycle
Ⅴ) Cation exchange resin regeneration level ＝100.0g as 100% HCl/ℓ-R ,
Anion exchange resin regeneration level ＝100.0g as 100% NaOH/ℓ-R

Cation Anion
12,500ℓ SBA Type2
15,000ℓ
WBA
Retrofit Cation 10,060ℓ
12,500ℓ
SBA
6,720ℓ

Per unit production cost :

457 Won/Ton 424 Won/Ton

Annual save on Operating Cost : 100,355,623 WON / Year

14 Samyang Layered Bed System (Water Treatment)
C

Ion Exchange Resin Demineralizer Operating Cost Wise Comparison (Co-current →Layered Bed)
■ Calculation of production capacity

Conventional Layered Bed

Type Unit Remarks
Cation resin Anion resin Cation resin Anion resin
TRILITE
TRILITE TRILITE TRILITE AW90LB
IER Grade Layered Bed
SCR-B SAR20 MC-08 TRILITE
KA18LB

Raw water ionic load (eq/m3) 1.35 1.24 1.35 1.24

Hourly production (m3/hr) 450 450 450 450

Raw water ionc load/ hr (eq/hr) 607.5 558 607.5 558

Effective quantity (ℓ) 12,500 15,000 12,500 16,780

Regeneration level (g/ℓ) 100.0 100.0 62.0 89.4
Operating capacity (meq/ℓ) 0.90 0.73 1.08 0.97

Safety factor & Loss rate (%) 1.05 1.10 1.05 1.10

Total operating capacity (eq) 10,714 9,955 12,857 14,788

Gross service quanity per cycle (m3/cycle) 7,937 8,028 9,524 11,926

Regeneration waste per cycle (m3/cycle) 63 75 63 84 5BV of resin

Net service quanity per cycle (m3/cycle) 7,874 7,953 9,461 11,842
Service hours per cycle (hr/cycle) 17.5 17.7 21.0 26.3 Select lower quanity
Actual production per cycle (m3/cycle) 7,874 7,953 9,461 11,842 between Cation & Anion

Annual cycle (a) (cycle/year) 391 336 1cycle = service time +

Annual production quanity(b) (m3/cycle) 3,076,672 3,175,807 regeneration time (4hrs)

■ Calculation of regenerant usage and netralization cost

Regenerant unit cost HCl \75/kg (35%)
NaOH \170/kg (25%)

Type Unit HCl NaOH HCl NaOH Remarks

Regenerant used per cycle (kg/cycle) 1,250.0 1,500.0 775.0 1,500.0 100% Regeneration
Regenerant cost per cycle (\/cycle) 267,857 1,020,000 166,071 1,020,000

Total cost per cycle (c) (\/cycle) 1,287,857 1,186,071

Acid excess (keq/cycle) 23.1 7.8 HCl MW 36.5

Alkali excess (keq/cycle) 29.9 26.2 NaOH MW 40.0

Regenerant used per cycle (kg/cycle) 709.7 1,913

Neutralizer cost per cycle(d) (\/cycle) 53,229 143,507

■ Calculation of IER cost

IER unit price Conventional Cation resin \1,900/ℓ Price of TRILITE SCR-B
Conventional Anion resin \4,500/ℓ Price of TRILITE SAR20
New Cation resin \2,200/ℓ Price of TRILITE MC-08
New Anion resin \6,500/ℓ Average price of TRILITE AW90LB, KA-18LB

Type Unit Cation resin Anion resin Cation resin Anion resin Remarks

Annual replacement rate (%/year) 5% 20% 5% 10%

Annual replacement quanity (ℓ/year) 625ℓ 3,000ℓ 625ℓ 1,687ℓ

Annual IER cost (e) (\/year) 14,687,500 12,282,000

■ Calculation of Wastewater treatment cost

Wastewater treatment unit cost \500/m3
Type Unit Conventional Layered bed Remarks

Wastewater per cycle (m3/cycle) 138 146

Treatment cost per cycle (\/cycle) 68,750 73,200

■ Calculation of annual operating cost and purewater production cost

Industrial water unit cost(g) \250/m3

Type Unit Conventional Layered bed Remarks

Annual operating cost (\/year) 1,404,695,278 1,304,339,655 Without UT cost, for same
Save on annual operating cost (\/year) 100,355,623 amount of production

Purewater production unit cost (\/m3) 457 424

The said production cost of pure water does not include energy and other UT costs, so the actual unit
price may increase. It is compared with existing facilities, on the same conditions of resin amount and
recycling; if the amount of resin is increased by utilizing the freeboard space above the existing resin
tower, capacity will increase more than twice, and the operational cost saving will also increase.
15 Samyang Layered Bed System (Water Treatment)
C

■ Case Study2(Water Block Count-current → Samyang Packed Bed System)

- Operating Cost Evaluation
This is a retrofit example of water block count-current system to Samyang Packed Bed
System.
Ⅰ) Feed water analysis
2+ -
Ca 0.46 meq/ℓ Cl 0.60 meq/ℓ
2+ 2-
Mg 0.30 meq/ℓ SO4 , etc 0.32 meq/ℓ
+ + -
Na ＋ K 0.59 meq/ℓ HCO3 0.43 meq/ℓ
Total Cations 1.35 meq/ℓ SiO2 0.12 meq/ℓ
※Total cations = TC Total Anions 1.47 meq/ℓ
Ⅱ) After Degasfier Anion
-
Cl 0.60 meq/ℓ ※FMA＝0.60＋0.32＝0.92meq/ℓ, Cl / FMA%=65.2%
2-
SO4 외 0.32 meq/ℓ ※Cl%＝0.60 / 1.24＝48.4%
-
HCO3 0.20 meq/ℓ ※Weak Acid＝TEA – FMA = 1.24–0.92 = 0.32
SiO2 0.12 meq/ℓ ※SiO2%＝0.12 / 1.24＝9.7%
TEA 1.24 meq/ℓ ※FMA / Weak Acids = 2.88
Ⅲ) Requirements
2B3T(2Bed 3Tower) system(Cation exchanger → degasifier → anion exchanger)
Flow Rate＝450 ㎥/hr, Running Time＝20hr
Operating Temperature＝15℃, Regeneration Temperature＝35℃
Required SiO2 Leakage＝150ppb as SiO2
Ⅳ) Cationic load(eq/cycle)＝TC×450 ㎥/hr×20hrs＝12,150eq/cycle
Anionic load(eq/cycle)＝TEA×450 ㎥/hr×20hrs＝11,160eq/cycle
Ⅴ) Cation exchange resin regeneration level ＝42.0g as 100% HCl/ℓ-R ,
Anion exchange resin regeneration level ＝50.0g as 100% NaOH/ℓ-R

Cation Anion
12,500ℓ SBA Type2
15,000ℓ
WBA
Cation 9,000ℓ
Retrofit 12,500ℓ
SBA
6,000ℓ

Per unit cost : 364 Won/Ton 353 Won/Ton

Annual save on Operating Cost : 34,804,007 WON/Year
In this case, total capacity can be increased more than twice by increasing
resin amount and modifying upper distributor, given the same area. Economic
increase in capacity can be derived for an existing facility.
16 Samyang Layered Bed System (Water Treatment)
C

Ion Exchange Resin Demineralizer Operating Cost Wise Comparison (Water block count-current →Layered Bed)
■ Calculation of production capacity

Conventional Layered Bed

Type Unit Remarks
Cation resin Anion resin Cation resin Anion resin
TRILITE
TRILITE TRILITE TRILITE AW90LB
IER Grade Layered Bed
SCR-B SAR20 MC-08 TRILITE
KA18LB

Raw water ionic load (eq/m3) 1.35 1.24 1.35 1.24

Hourly production (m3/hr) 450 450 450 450

Raw water ionc load/ hr (eq/hr) 607.5 558.0 607.5 558.0

Effective quantity (ℓ) 12,500 15,000 12,500 15,000

Regeneration level (g/ℓ) 42.0 50.0 42.0 50.0

Operating capacity (meq/ℓ) 1.08 0.86 1.08 0.97

Safety factor & Loss rate (%) 1.05 1.10 1.05 1.10
Total operating capacity (eq) 12,857 11,727 12,857 13,222

Gross service quanity per cycle (m3/cycle) 9,524 9,457 9,524 10,663
Regeneration waste per cycle (m3/cycle) 125 150 63 75 5BV of resin

Net service quanity per cycle (m3/cycle) 9,399 9,307 9,461 10,588
Service hours per cycle (hr/cycle) 20.9 20.7 21.0 23.5 Select lower quanity
Actual production per cycle (m3/cycle) 9,399 9,307 9,461 10,588 between Cation & Anion

Annual cycle (a) (cycle/year) 340 336 1cycle = service time +

Annual production quanity(b) (m3/cycle) 3,167,440 3,175,807 regeneration time (4hrs)

■ Calculation of regenerant usage and netralization cost

Regenerant unit cost HCl \75/kg (35%)
NaOH \170/kg (25%)
Type Unit HCl NaOH HCl NaOH Remarks

Regenerant used per cycle (kg/cycle) 525.0 750.0 525.0 750.0 100% Regeneration
Regenerant cost per cycle (\/cycle) 112,500 510,000 112,500 510,000

Total cost per cycle (c) (\/cycle) 622,500 622,500

Acid excess (keq/cycle) 1.1 1.0 HCl MW 36.5

Alkali excess (keq/cycle) 9.8 8.6 NaOH MW 40.0

Regenerant used per cycle (kg/cycle) 916.0 798

Neutralizer cost per cycle(d) (\/cycle) 68,702 89,812

■ Calculation of IER cost

IER unit price Conventional Cation resin \1,900/ℓ Price of TRILITE SCR-B
Conventional Anion resin \4,500/ℓ Price of TRILITE SAR20
New Cation resin \2,200/ℓ Price of TRILITE MC-08
New Anion resin \6,500/ℓ Average price of TRILITE AW90LB, KA-18LB

Type Unit Cation resin Anion resin Cation resin Anion resin Remarks

Annual replacement rate (%/year) 5% 20% 5% 10%

Annual replacement quanity (ℓ/year) 625ℓ 3,000ℓ 625ℓ 1,687ℓ

Annual IER cost (e) (\/year) 14,687,500 12,282,000

■ Calculation of Wastewater treatment cost

Wastewater treatment unit cost \500/m3
Type Unit Conventional Layered bed Remarks

Wastewater per cycle (m3/cycle) 275 138

Treatment cost per cycle (\/cycle) 137,500 68,750

■ Calculation of annual operating cost and purewater production cost

Industrial water unit cost(g) \250/m3

Type Unit Conventional Layered bed Remarks

Annual operating cost (\/year) 1,153,157,314 1,118,353,307 Without UT cost, for same
Save on annual operating cost (\/year) 34,804,007 amount of production

Purewater production unit cost (\/m3) 364 353

The said production cost of pure water does not include energy and other UT costs, so the actual unit
price may increase.
17 Samyang Layered Bed System (Water Treatment)
C

■ Case Study3(Samyang Packed Bed System Set-up 1)

- Operating Cost Evaluation
This is an example of operating cost evaluation for setting up a Samyang Packed Bed
System (Layered bed).
Ⅰ) Feed water analysis
2+ -
Ca 0.80 meq/ℓ Cl 1.00 meq/ℓ
2+ 2-
Mg 0.60 meq/ℓ SO4 , etc 1.00 meq/ℓ
+ + -
Na ＋ K 1.00 meq/ℓ HCO3 0.40 meq/ℓ
Total Cations 2.40 meq/ℓ SiO2 0.20 meq/ℓ
※Total cations = TC Total Anions 2.60 meq/ℓ
Ⅱ) After Degasfier Anion
-
Cl 1.00 meq/ℓ ※FMA＝1.00＋1.00＝2.00meq/ℓ, Cl / FMA%=50.0%
SO4 , etc
2-
1.00 meq/ℓ ※Cl%＝1.00 / 2.40＝41.7%
-
HCO3 0.20 meq/ℓ ※Weak Acid＝TEA – FMA = 2.40–2.00 = 0.40
SiO2 0.20 meq/ℓ ※SiO2%＝0.20 / 2.40＝8.3%
TEA 2.40 meq/ℓ ※FMA / Weak Acids = 5.00
Ⅲ) Requirements
2B3T(2Bed 3Tower) system(Cation exchanger → degasifier → anion exchanger)
Flow Rate＝300 ㎥/hr, Running Time＝20hr
Operating Temperature＝15℃, Regeneration Temperature＝35℃
Required SiO2 Leakage＝150ppb as SiO2
Ⅳ) Cationic load(eq/cycle)＝TC×300 ㎥/hr×20hrs＝14,400eq/cycle
Anionic load(eq/cycle)＝TEA×300 ㎥/hr×20hrs＝14,400eq/cycle
Ⅴ) Cation exchange resin regeneration level ＝50.0g as 100% HCl/ℓ-R ,
Anion exchange resin regeneration level ＝41.2g as 100% NaOH/ℓ-R

300Ton/hr WBA Actual treated volume : 6,600Ton/cycle

Cation 10,000ℓ
240 ㎲/㎝
13,700ℓ Treated water quality : 0.5∼0.7 ㎲/㎝
Silica 10ppm Silica leakage : 0.05∼0.08ppm
SBA
6,800ℓ

The unit cost for pure water production is 312 won/Ton, which is more
economical when packed bed system is newly installed than water block
counter-current system. The reduction of annual operating cost is expected to
be 9,454,161 won/year.
The case above does not include the reduced unit cost for construction; the
construction cost is low due to the reduction of actual vessel size and the
simple structure of resin tower.
18 Samyang Layered Bed System (Water Treatment)
C

Ion Exchange Resin Demineralizer Operating Cost Wise Comparison (Layered Bed Set-up1)
■ Calculation of production capacity

Conventional Layered Bed

Type Unit Remarks
Cation resin Anion resin Cation resin Anion resin
TRILITE
DIAION AW90LB
IER Grade DIAION SK1B TRILITE MC1 Layered Bed
SA20AP TRILITE
KA18LB

Raw water ionic load (eq/m3) 2.40 2.40 2.40 2.40

Hourly production (m3/hr) 300 300 300 300

Raw water ionc load/ hr (eq/hr) 720.0 720.0 720.0 720.0

Effective quantity (ℓ) 13,700 16,800 13,700 16,800

Regeneration level (g/ℓ) 50.0 41.2 50.0 41.2

Operating capacity (meq/ℓ) 1.05 82.00 1.11 95.00

Safety factor & Loss rate (%) 1.05 1.10 1.05 1.10

Total operating capacity (eq) 13,700 12,524 14,483 14,509

Gross service quanity per cycle (m3/cycle) 5,708 5,218 6,035 6,045

Regeneration waste per cycle (m3/cycle) 69 84 69 84 5BV of resin

Net service quanity per cycle (m3/cycle) 5,640 5,134 5,966 5,961

Service hours per cycle (hr/cycle) 18.8 17.1 19.9 19.9 Select lower quanity
Actual production per cycle (m3/cycle) 5,640 5,134 5,966 5,961 between Cation & Anion

Annual cycle (a) (cycle/year) 368 352 1cycle = service time +

Annual production quanity(b) (m3/cycle) 1,891,587 2,098,009 regeneration time (4hrs)

■ Calculation of regenerant usage and netralization cost

Regenerant unit cost HCl \72/kg (35%)
NaOH \155/kg (50%)
Type Unit HCl NaOH HCl NaOH Remarks

Regenerant used per cycle (kg/cycle) 685.0 692.2 685.0 692.2 100% Regeneration
Regenerant cost per cycle (\/cycle) 140,914 214,570 140,914 214,570

Total cost per cycle (c) (\/cycle) 355,484 355,484

Acid excess (keq/cycle) 4.6 3.7 HCl MW 36.5

Alkali excess (keq/cycle) 6.6 4.9 NaOH MW 40.0

Regenerant used per cycle (kg/cycle) 215.9 122

Neutralizer cost per cycle(d) (\/cycle) 15,544 8,796

■ Calculation of IER cost

IER unit price Conventional Cation resin \1,700/ℓ Price of TRILITE SK1B
Conventional Anion resin \4,500/ℓ Price of TRILITE SA20AP
New Cation resin \1,700/ℓ Price of TRILITE SK1B
New Anion resin \7,000/ℓ Average price of TRILITE AW90LB, KA-18LB
Type Unit Cation resin Anion resin Cation resin Anion resin Remarks

Annual replacement rate (%/year) 5% 20% 5% 10%

Annual replacement quanity (ℓ/year) 685ℓ 2550ℓ 685ℓ 1,680ℓ

Annual IER cost (e) (\/year) 12,504,500 12,924,500

■ Calculation of Wastewater treatment cost

Wastewater treatment unit cost \500/m3
Type Unit Conventional Layered bed Remarks

Wastewater per cycle (m3/cycle) 153 153

Treatment cost per cycle (\/cycle) 76,250 76,250

■ Calculation of annual operating cost and purewater production cost

Industrial water unit cost(g) \250/m3

Type Unit Conventional Layered bed Remarks

Annual operating cost (\/year) 664,378,671 654,924,510 Without UT cost, for same
Save on annual operating cost (\/year) 9,454,161 amount of production

Purewater production unit cost (\/m3) 351 312

The said production cost of pure water does not include energy and other UT costs, so the actual unit
price may increase. It is compared with existing facilities, on the same conditions of resin amount and
recycling; if the amount of resin is increased by utilizing the freeboard space above the existing resin
tower, capacity will increase more than twice, and the operational cost saving will also increase.
19 Samyang Layered Bed System (Water Treatment)
C

■ Case Study4(Samyang Packed Bed System Set-up 2) –Construction Cost

Evaluation
This is an example of operating cost evaluation for setting up a Samyang Packed Bed
System.
Ⅰ) Feed water analysis
2+ -
Ca 1.00 meq/ℓ Cl 1.00 meq/ℓ
2+ 2-
Mg 1.00 meq/ℓ SO4 , etc 1.00 meq/ℓ
+ + -
Na ＋ K 1.00 meq/ℓ HCO3 1.00 meq/ℓ
Total Cations 3.00 meq/ℓ SiO2 0.14 meq/ℓ
※Total cations = TC Total Anions 3.14 meq/ℓ
Ⅱ) After Degasfier Anion
-
Cl 1.00 meq/ℓ ※FMA＝1.00＋1.00＝2.00meq/ℓ, Cl / FMA%=50.0%
2-
SO4 , etc 1.00 meq/ℓ ※Cl%＝1.00 / 2.34＝42.7%
-
HCO3 0.20 meq/ℓ ※Weak Acid＝TEA – FMA = 2.34–2.00 = 0.34
SiO2 0.14 meq/ℓ ※SiO2%＝0.14 / 2.34＝6.0%
TEA 2.34 meq/ℓ ※FMA / Weak Acids = 5.88
Ⅲ) Requirements
2B3T(2Bed 3Tower) system(Cation exchanger → degasifier → anion exchanger)
Flow Rate＝200 ㎥/hr, Running Time＝22hr
Operating Temperature＝15℃, Regeneration Temperature＝35℃
Required SiO2 Leakage＝150ppb as SiO2
Ⅳ) Cationic load(eq/cycle)＝TC×200 ㎥/hr×22hrs＝13,200eq/cycle
Anionic load (eq/cycle)＝TEA×200 ㎥/hr×22hrs＝10,296eq/cycle
Ⅴ) Cation exchange resin regeneration level ＝50.0g as 100% HCl/ℓ-R ,
Anion exchange resin regeneration level ＝40.0g as 100% NaOH/ℓ-R

Degasifier

200Ton/hr Treated volume :

Cation Anion
300 ㎲/㎝ 14,500ℓ 14,800ℓ
4,400Ton/cycle
Silica 7ppm Treated water quality :
1.0 ㎲/㎝↓
Silica leakage : 0.1ppm↓
Ⅵ) Equipment and Volume of Fillings

Equipment Dimension Filling Material Volume Reference

Cation exchange
TRILITE MC-08 14,500ℓ
Cation exchanger 2,700 D x 2,875 H resin
TRILITE TR70 1,475ℓ Inert resin
Anion exchange
TRILITE MA-20 14,800ℓ
Anion exchanger 3,000 D x 2,900 H resin
TRILITE TR70 2,000ℓ Inert resin
20 Samyang Layered Bed System (Water Treatment)
C

Ⅶ) Construction Cost

Description Prices(￦)

1. Mechanical & Piping Part 350,000,000

Cation exchanger(SS41, Rubber lining)
Anion exchanger(SS41, Rubber lining)
Degasfier & tank(SS41, Rubber lining)
HCl measuring tank
NaOH measuring tank
Fan blower
Piping material & erection work
Engineering & drawing

2. Electric & Instrument Part 180,000,000

Instruments
Automatic valves
PLC panel
MMI system
Solenoid panel
Installing work
Engineering & drawing

3. Filling Media 100,000,000

TRILITE MC1
TRILITE MA2
TRILITE TR70

4. Overhead & Profit 50,000,000

Total amount 680,000,000

Note 1) Estimated amount may change if there is a sudden price fluctuation or exchange rate change.
Note 2) If there is a design change on your request, the amount of the quotation and the delivery date
may change.
Note 3) The above quotation is a reference value; actual estimation may vary depending on the
situation of the site.
All information contained in brochure is not absolute rather than relative one, created under the controlled environment
by Samyang Corporation. Therefore, Samyang Corporation has no legal responsibility with respect to any and all
information provided in brochure.
Samyang’s TRILITE Ion exchange resins are produced based on the ISO 9001, ISO 14001 certification.
Samyang Corporation, 31 Jong-ro 33-gil, Jongno-gu, Seoul, Korea Tel: (02)740-7732~7, Fax: (02)740-7140

http://samyangtrilite.com