Full Facility Water Management Presented by: Process and Water
What is Being Presented 1. Purified (RODI) Water System & Distribution Design 2. Rain/Gray & RO Reject Water System Design 3. Acid Waste pH Neutralization System Design
Incoming Water & Its Contaminants Suspended Solids – Rocks, Gravel, Sand, pH – High or Low Dissolved Ions – Salts Bacteria Pyrogens – Residue of Cells Organic Carbon
Pure Water Criteria 99% Of All High Purity Water Treatment Has Three Specific Objectives For End Purity: Ionic Purity – Measured By TDS, Resistivity Or Conductivity Viable Organism Purity – Measure By “Total Plate Count” Test Organic Purity – Measured By T.O.C. Testing
Pure Water What is Pure Water & How Do I Define Exactly What My Requirements Are??? Pure Water Is Defined Differently By Different Industries And Regulatory Agencies USP – Pharmaceutical Industry Purified Water Water For Injection ASTM Grades Of Water For Manufacturing, Power Utilities And Testing Labs Type I Type II Type III Type IV SEMI Grades Of Water For Electronics And Semiconductor Manufacturing ASTM Grades Of Water For Electronics And Semiconductor Manufacturing Type E-I Type E-II Type E-III Type E-IV
Component Selection • Facility water requirements dictate selection of equipment for: • Pretreatment • Primary Purification (i.e. RO) • Storage and Distribution and “Polishing”
Pure Water Treatment Operations PRE-TREATMENT: Multi-Media Filter – Removes Suspended Solids & Particulate Matter. Water Softener – Removes Hardness From Supply Using Ion Exchange. Carbon Filter (de-chlorination) – Removes Oxidizing & Organic Compounds. PRIMARY PURIFICATION: Reverse Osmosis – Removes 99% Of Ions, Organisms & Organic Compounds (MW Greater Than 150 – 200) POLISHING: MBDI/Electrodeionization (EDI) - Removes Ions Using Exchange Resin, or a Combination of Resin, Membranes and Electricity. UV Sterilization – Destroys Viable Organisms Using Ultraviolet Radiation.
Pretreatment Unit Typical Multimedia Filter, Water Softener, Carbon Filter
Adsorption Carbon Media Filtration • Binds Oxidizing Compounds (Chlorine) And Organic Molecules To The Surface Of The Media. • Prevents Oxidization Of The Membrane Surfaces & Resin Used In Downstream Processes. • Oxidation Quickly Reduces The Effectiveness Of Membranes In Removing Small MW Compounds. Oxidation “Eats Holes Into The Membrane Surfaces” • Maintenance of Carbon Media Extremely Important To Unit Performance And Membrane Life.
Traditional Pure Water Processing Equipment • Primary Purification Equipment • (Membrane & Ion Exchange Components) • Reverse Osmosis (RO) Units • Ultra-filtration (UF) Units • Nano-filtration (NF) Units • Electrodeionization (EDI) Units • Ion Exchange (IX) Units (Fixed & Service DI Units) • Gas Membrane Units • UV Sterilization
Reverse Osmosis Reveres Osmosis – Excludes Ions, Organisms And Organic Compounds Greater Than 200 MW. Significantly Concentrates Contaminants Commonly Found In Water By “Transporting” The Water Through the Membrane And Rinsing Away The Remaining Contaminates. Not 100% Efficient…typically 65% to 75% Efficient. Feed Water equipment must be sized accordingly.
How Ion Exchange Kinetics Works Cu ++ H + H + Cu ++ Zn ++ H + H + OH - -- SO 4 -- PO 4 Cu ++ H + H + H + H + -- OH - Zn ++ SO 4 OH - OH - -- PO 4 H + OH - SO 3 - H + H + Zn ++ Cu ++ OH - -- OH - -- SO 4 PO 4 H + Zn ++ H + H + - OH - -- OH - SO 3 PO 4 OH - OH - OH - OH - OH - H + H + H + H + (CH 3 ) 3 Ca ++ Ca ++ OH - Ca ++ H + OH - H + N (CH 3 ) 3 -- SO 4 SO 3 - Ca ++ H + H + N H + -- OH - -- PO 4 (CH 3 ) 3 H + SO 3 - OH - N CN - CN - CN - SO 4 CN - OH - CN - OH - Na + Na + H + H + Na + - OH - OH - H + SO 3 H + (CH 3 ) 3 N - SO 3 Na + (CH 3 ) 3 OH - Cl - Cl - N -- SO 4 (CH 3 ) 3 OH - N Cl - SO 3 - OH - Cl - Cl - OH - Cl - OH - (CH 3 ) 3 N
Mixed Bed Service De-ionization
Electrodeionization Electrodeionization – Effectively Removes Ions Using a Combination of Ion Exchange & Membrane Technologies. Mixed Bed Ion Exchange Resin Used to “Capture” Cations & Anions in Water Stream. Resins “Conduct” These Captured Ions to the Positive or Negative Terminals of a DC Field Through “Ion Selective” Membranes. Resins Act Like a “ Wire” in the Transport of Ions. Chambers Extremely Thin in Order to Maintain Current Flow. Requires Pretreated Water for Effective Operation. Electrical Current Continually “Regenerates” Ion Exchange Resins. Electrical Current Minimizes Biological Growth within the Dynamic Areas of the Cell. Minimal Maintenance Required.
EDI Technology
SDI vs. EDI Portable Mixed Bed Exchange Electro-Deionization Considerations • Portable Units available in Various • Requires single-pass RO water supply Sizes • Can be free standing or integrated • Size & quantity of Vessels depends into RO unit on flow rate • Sized to match RO permeate flow rate • Can achieve highest water quality • Can’t be installed in distribution loop • Doesn’t require RO for pure water • Minimal power consumption: production $0.06/1,000 gallons processed • No waste stream during operation • Minimal maintenance: 6 – month bolt • Can be installed Post RO and/or in torque Distribution Loop • Consistent quality: 12 – 15 Meg-ohm- • Water Quality declines over time cm • Handling considerations • Long life: 10+ yrs normal operation • Off-site quality control • Designs can be hot water sanitized
Traditional Pure Water Storage/Distribution Equipment • System Storage Tank • Distribution Pump(s) • UV Sterilization Units (Standard & “TOC Reducing”) • Final Filter Units • Distribution Loop Instrumentation
UV Sterilization Units • 254 nm Wavelength Unit for Bacteria Sterilization • 185 nm Wavelength Unit for Bacteria & TOC Reduction (less than 20 ppb) • Intensity Monitors Available in Analog & Digital Format
Final Filter Assembly • Select Filtration Level According to Water Quality Requirements • Typical USP Final Filter is 0.2-micron • Some ASTM Standards Require Tighter Levels of Filtration for TOC & Endotoxin Control
Distribution Loop Instrumentation • Loop Supply & Return Quality (Resistivity) • System Temperature • Flow Rate (can also be used to control Pump VFD’s) • TOC On-Line Monitors • Pressure (Indicators & Transmitters)
Generation Design Considerations • Determine “Daily” Water Consumption • What is a “Day”? • Average Water Usage Over Day Period • Maximum Water Draw (Volume & Frequency) • Space Available for Storage • “Ideal” Design: Storage = Daily Usage • “Not Ideal” – RO Generation Relative to Maximum Draw & Tank Size
1. Generation Sizing Examples Ideal: 1500 gallons/12 hour day usage…12 hour “off - time” 1500 gallon storage tank RO Generation = 1500/720 = ~ 2 GPM “Not ideal”: 2000 gallons/12-hr day usage, 750 gallon storage tank 600 gallons max draw in 1 hour (once/day 1 st hour) ~ 130 gallons/hour average usage Is 2 GPM OK?
2. Generation Sizing Examples • Is 2 GPM OK….YES 2 GPM x 60 = 120 gallons generated in first hour; 600-120 = 480 gallons used from storage tank 750-480 = 270 gallons left in storage tank after 1 st hour Hours 2-12: 120 – 130 = 10 gal/hr net loss, 160 gals. stored after hour 12 More difficult situation: 2,000 gallons/12-hr day, max draw 2x/day 600 gallon draw 2x/day (4 hours apart) ~ 80 gallons per hour average usage Is 2 GPM still OK?
3. Generation Sizing Examples • Is 2 GPM still OK….NO After hour one, 270 gallons remain, as in previous example After hours 2 through 4, 120 gallons added to storage (3 hours x 40 gallons per hour net gain) Start of hour 5…390 gallons in storage As before, the net loss of 600 draw is 480 390 gallons - 480 gallons results in a 90 gallon deficit
4. Generation Sizing Example • There are two ways to modify the system to meet the water demand. • The first and least expensive option is to increase the size of the storage tank by at least 100 gallons. • Many projects do not have additional space to allow for a larger tank. • In that case, increasing the RO System to a 3 gpm or next larger system will meet the water demand.
Distribution Sizing Considerations • Distribution Loop Design • Individual Floors (Riser and Return) • Serpentine (continuous) • Overall Pressure Loss • Location of Distribution Equipment • Determine desired minimum velocity at maximum use • Max draw determines Non-use Flow rate
Distribution Sizing Example • 600 gallon maximum draw in hour = 10 GPM • Also consider maximum “instantaneous” draw • Pump Skid increments 10, 20, 30, 40 GPM etc.. Polypropylene Pipe 40 mm (1- 1/4”) Desired velocity in System during max draw: ~ 2-3 ft./sec 20 GPM, 40 mm pipe: 4.9 ft./sec 12 GPM remains at ~ 3 ft./sec • Must Consider: Pressure Drop per 100 ft. of pipe May need to increase pipe size due to loop length (Example, 40 mm Pressure loss is 3.23 PSIG per 100 ft.)
Design Review • Determine Proper Equipment from User Requirements • Obtain Daily Water Usage Information • Determine Storage Size Available • Size RO per Storage and Maximum Draw • Determine Loop Design, Pressure and Flow Rate • Select Distribution Skid for Acceptable Velocities at Minimum and Maximum Water Draw Rates
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