Lecture On Water Treatment Plant: M/S Jindal Power Limited (4X250 MW) Opjstpp, Tamnar, Raigarh

LECTURE ON WATER TREATMENT
PLANT
M/s JINDAL POWER LIMITED (4X250 MW) OPJSTPP,

TAMNAR, RAIGARH
The Power behind water

WATER TREATMENT PLANT
Following topics are covered by Water Treatment Plant
 Pretreatment Plant (PT Plant)
 Demineralization Plant (DM Plant)
 Circulating Water Treatment (CW Treatment) & Side Stream

Filtration System
WATER TREATMENT Process
PROCESS DRIVING FORCE
Ion Exchange (IX) Chemical
Electrodialysis (ED) Electrical
Reverse Osmosis (RO) Pressure
Distillation (MSF) Thermal

PROCESS FEED TDS Product TDS

(PPM) max. (PPM)
IX 1500 <1
ED 3000 5-10% of feed TDS

RO 40000 1-5% of feed TDS
MSF 70000 5-10
ION EXCHANGE
The feed water to an Ion Exchange system must
meet the following specifications -
Suspended Solids Nil
Turbidity < 5 NTU
Heavy Metals < 0.05 PPM
Organic Matter Low
Fouling Index < 0.05
Oil Absent
Free Chlorine Nil
ION EXCHANGE
PROCESS FUNCTION
Softening Substitutes hardness with sodium
Dealkalization Removes hardness, Reduces alkalinity
Demineralization Reduce TDS

SOFTENING
Service stage is represented by the following reactions:
Ca(HCO3)2 (I) + 2 NaR (S) CaR2 (s) + 2 NaHCO3 (I)
MgCl2 (I) + 2 NaR (S) MgR2 (s) + 2 NaCl (I)
Hard Regenerated Exhausted Soft

Water Resin Resin Water
DEMINERALIZATION
There are two basic processes

• Two bed
• Mixed bed (MB)
But there are several extensions and combinations of these

basic processes which progressively improve the quality of
water and the efficiency of the processes.
DEMINERALIZATION
The reaction during service of the strong acid cation (SAC) exchanger are as
follows –
Ca(HCO3)2 (I) + 2HR (S) CaR2 (S) + 2 H2CO3 (I)

Temporary Regenerated Exhausted Carbonic
Hardness Resin Resin Acid
MgCl2 (I) + 2HR (S) MgR2 (S) + 2 HCl (I)

Permanent Regenerated Exhausted Free Mineral
Hardness Resin Resin Acid
Na2SO4 (I) + 2HR (S) 2NaR(S) + H2SO4 (I)

Sodium Regenerated Exhausted Free Mineral
Salt Resin Resin Acid
Carbonic acid is unstable and dissociates to carbon dioxide.

H2CO3(I) H2O(I) + CO2 (g)
ION-EXCHANGE PROCESS
Why Demineralization Required
• The impurities can seriously affect the

reliability and operating efficiency of a boiler.
Overheating caused by the buildup of scale or
deposits formed by these impurities can lead to
tube failures & thereby unscheduled down time
. Hardness ions, such as calcium and
magnesium, must be removed from the water
supply before it can be used as boiler feed
water. For high-pressure boiler feed water
systems, complete removal of all ions, including
carbon dioxide and silica, is required. Ion
exchange systems are used for efficient removal
of dissolved ions from water. The removal of
impurities is accomplished step by step in
demineralization system.
FILTERATION
• Before feeding the raw water into any exchanger bed it is
to be made sure that the water entering the exchanger
beds is free from any suspended particles/turbidity. This is
done in MGF (Multi-grade filter) . The MGF unit contains
different layers of sand and pebbles . The finest layer is on
the top of the bed and pebbles are at the bottom most part
of the bed. In normal course , the water enters from the
top of the bed and comes out of the bottom portion of the
bed . The outlet of the MGF will have a turbidity of 1 – 2
NTU .
• Backwash : When the differential pressure between inlet

and outlet of the bed increases to more than 0.6 kg/cm2 ,
the bed is to be given backwash.
Typical Diagram of MGF Unit
Cation Exchanger
• In Cation exchanger the Ca , Mg, K &

Na ions are exchanged with hydrogen
ion. Thus hardness is removed & the
outlet of cation water contains acids
like HCl, H2SO4 & H2CO3
CHEMICAL-STRUCTURE
Structure & Appearance-Cation Exchanger Resin
Difference in SAC & WAC Resin
Water
Inlet Dissolved
Gases
Water
Sprinkle
Fill Pack
Forced Air Blow
Dissolved Gases Free Water
DGWT
DEGASSIFICATION PROCESS
ROLE OF DEGASSER SYSTEM
DEMINERALIZATION
The reaction during service of the Strong Base Anion (SBA) exchanger are as
follows –
H2SO4 (I) + 2ROH(s) R2SO4 (s) + 2H2O(I)
HCl (I) + ROH (s) RCl (s) + H2O (I)
Free Mineral Regenerated Exhausted Demineralised
Acid Resin Resin Water
CO2 (I) + ROH (s) RHCO3(s)

Carbon Regenerated Exhausted
dioxide Resin Resin
SiO2 (I) + ROH (s) RHSiO3 (s)

Silica Regenerated Exhausted
Resin Resin
NaCl (I) + ROH(s) RCl(s) + NaOH

Cation Slip Regenerated Exhausted P -Alkalinity
Resin Resin
DEMINERALIZATION
The reaction during regeneration of Strong Acid Cation (SAC) exchanger are as
follows –
CaR2 (s) + 2HCl (I) 2HR (s) + CaCl2 (I)
MgR2 (s) + 2HCl (I) 2HR (s) + MgCl2 (I)
NaR (s) + HCl (I) HR (s) + NaCl (I)

Exhausted Hydrochloric Regenerated Waste
Resin Acid Resin Effluent
DEMINERALIZATION
The reaction during regeneration of Strong Base Anion (SBA) exchanger are as
follows –
R2SO4 (s) + 2NaOH (I) 2ROH (s) + Na2SO4(I)
RCl (s) + NaOH (I) ROH (s) + NaCl (I)
RHCO3 (s) + NaOH (I) ROH (s) + NaHCO3(I)
RHSiO3 (s) + NaOH (I) ROH (s) + NaHSiO3(I)
Exhausted Sodium Regenerated Waste

Resin hydroxide Resin Effluent
DEMINERALIZATION
Another Two bed demineralization process utilizes a Weak Base Anion (WBA)
exchanger after the Strong Acid Cation (SAC) exchanger when silica removal is
not required –
The reactions of the WBA resin during service are –
HCl (l) + R (s) R HCl (s)
H2SO4 (l) + R (s) R H2SO4 (s)

Free Mineral Regenerated Exhausted
Acid Resin Resin
RESIN TYPE-WBA-SBA
DEMINERALIZATION
The reactions of the WBA resin during regeneration are –
R HCl (s) + NaOH (l) R (s) + NaCl (l) + H2O (l)
R H2SO4 (s) + 2 NaOH (l) R (s) + Na2SO4 (l) + 2H2O (l)
Exhausted Sodium Regenerated Waste

Resin hydroxide Resin Effluent
COFLOW/COUNTERFLOW REGENERATION
 The direction of flow of the regenerant can be the same as that of the
service flow or opposite to it.
 When the regenerant flow is in the same direction as the service flow
the regeneration process is called cocurrent or coflow regeneration.
 When the regenerant flow is in the direction opposite to the service

flow, the regeneration process is called countercurrent or counterflow
regeneration.
REGENERATION PROCESS-SCHEMATIC
COFLOW REGENERATION
Coflow regeneration comprises the following basic steps –
 Backwash
 Regenrant injection
 Rinse
The rinse step may include a slow rinse followed by the final rinse.
COUNTERFLOW REGENERATION
 Counterfow regeneration provides superior quality of treated water as

compared to coflow regeneration.
 Consequently counterflow regeneration results in a lower consumption

of chemicals as compared to coflow regeneration.
 Counterflow regeneration needs some special requirements.

COUNTERFLOW REGENERATION
 Counterfow regeneration comprises the following basic steps –

• Regenerant Injection
• Regenerant Rinse
• Final Rinse
 Prior to regenerant injection a flushing of the spent acid collector is

done to facilitate smooth regeneration.
 Counterflow units are backwashed once in seven regenerations. After

the backwash the regeneration proceeds as above with twice the
quantity of regenerant (normally used) injected into the unit.
MIXED BED REGENERATION
 Mixed bed regeneration comprises the following basic steps -
• Backwash
• Regenerant Injection
• Regenerant Rinse
• Air Mix
• Final Rinse
 When the regenerants are injected and rinsed in sequence, the

regeneration is termed ‘Sequential’.
 When regenerants are injected and rinsed simultaneously, the

regeneration is termed ‘simultaneous’.
 The simultaneous regeneration results in a saving of time and waste

water besides valving.
MIXED BED
Water Conservation

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LECTURE ON WATER TREATMENT

M/s JINDAL POWER LIMITED (4X250 MW) OPJSTPP,

The Power behind water

Following topics are covered by Water Treatment Plant

 Pretreatment Plant (PT Plant)

 Demineralization Plant (DM Plant)

 Circulating Water Treatment (CW Treatment) & Side Stream

WATER TREATMENT Process

PROCESS DRIVING FORCE

Ion Exchange (IX) Chemical

Electrodialysis (ED) Electrical

Reverse Osmosis (RO) Pressure

Distillation (MSF) Thermal

PROCESS FEED TDS Product TDS

ED 3000 5-10% of feed TDS

Dealkalization Removes hardness, Reduces alkalinity

Demineralization Reduce TDS

Service stage is represented by the following reactions:

Ca(HCO3)2 (I) + 2 NaR (S) CaR2 (s) + 2 NaHCO3 (I)

MgCl2 (I) + 2 NaR (S) MgR2 (s) + 2 NaCl (I)

Hard Regenerated Exhausted Soft

There are two basic processes

But there are several extensions and combinations of these

Ca(HCO3)2 (I) + 2HR (S) CaR2 (S) + 2 H2CO3 (I)

MgCl2 (I) + 2HR (S) MgR2 (S) + 2 HCl (I)

Na2SO4 (I) + 2HR (S) 2NaR(S) + H2SO4 (I)

Carbonic acid is unstable and dissociates to carbon dioxide.

• The impurities can seriously affect the

• Backwash : When the differential pressure between inlet

• In Cation exchanger the Ca , Mg, K &

Forced Air Blow

Dissolved Gases Free Water

CO2 (I) + ROH (s) RHCO3(s)

SiO2 (I) + ROH (s) RHSiO3 (s)

NaCl (I) + ROH(s) RCl(s) + NaOH

CaR2 (s) + 2HCl (I) 2HR (s) + CaCl2 (I)

MgR2 (s) + 2HCl (I) 2HR (s) + MgCl2 (I)

NaR (s) + HCl (I) HR (s) + NaCl (I)

R2SO4 (s) + 2NaOH (I) 2ROH (s) + Na2SO4(I)

RCl (s) + NaOH (I) ROH (s) + NaCl (I)

RHCO3 (s) + NaOH (I) ROH (s) + NaHCO3(I)

RHSiO3 (s) + NaOH (I) ROH (s) + NaHSiO3(I)

Exhausted Sodium Regenerated Waste

The reactions of the WBA resin during service are –

HCl (l) + R (s) R HCl (s)

H2SO4 (l) + R (s) R H2SO4 (s)

The reactions of the WBA resin during regeneration are –

R HCl (s) + NaOH (l) R (s) + NaCl (l) + H2O (l)

R H2SO4 (s) + 2 NaOH (l) R (s) + Na2SO4 (l) + 2H2O (l)

Exhausted Sodium Regenerated Waste

 When the regenerant flow is in the direction opposite to the service

Coflow regeneration comprises the following basic steps –

 Counterfow regeneration provides superior quality of treated water as

 Consequently counterflow regeneration results in a lower consumption

 Counterflow regeneration needs some special requirements.

 Counterfow regeneration comprises the following basic steps –

 Prior to regenerant injection a flushing of the spent acid collector is

 Counterflow units are backwashed once in seven regenerations. After