BHARAT ALUMINIUM COMPANY LTD

CAPTIVE POWER PLANT-540MW

QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 1 of 8

COUNTER FLOW REGENERATION:-

Conventionally the regenerant flow follows the same route through the resin bed as the
service water. Counter flow regeneration reverses this pattern. It has long been suspected
that considerable savings in regenerants could be achieved by this method, but it was not
until the late “fifties” that an acceptable technique was established to hold the resin bed
packed during regeneration. The technique involved the placing of a rubber bag above or
within the resin bed. During regeneration the bag was inflated to take up the free board in
the column. This pressed-bed system has now been superseded and the techniques in
current use will be discussed in the following sections. By counter flow regeneration the
lower resin layers are most highly regenerated and act as a polishing layer on the end-
product as it leaves the plant. Leakage is low even at normal regeneration levels and the
chemical efficiency of the resin is also increased significantly by counter flow
regeneration . Counter flow regenerated plants are used in industry and power stations
where high – purity water is required at the lowest possible cost and in large volumes.

SODIUM LEAKAGE

Influent water, % Alkalinity % Regeneration level g/l Leakage ppm

sodium sodium

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date
 BHARAT ALUMINIUM COMPANY LTD
CAPTIVE POWER PLANT-540MW
QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 2 of 8

30 36 48(H2SO4) <0.01
21 47 60(HCL) <0.20
21 47 45(HCL) <0.01
44 30 48(H2SO4) <0.15
46 15 56(H2SO4) 0.04

COFLOW AND COUNTERFLOW CAPACITIES FOR AMBERLITE RESINS:-

---------------------------------------------------------------------------------------------------------
Capacity of strongly acidic cation resin
Feed analysis mg/l as CaCo3, Na 10, Mg 20, Ca 70, HCO3 60

-------------------------------------------------------
Coflow Counterflow
-------------------------------------------------------
Book capacity, g CaCO3/l 22.5 24.5
Actual capacity, g CaCO3/l 20.3 24.5
Regeneration ration at 48 g H2SO4/l 2.41 2.00
------------------------------------------------------
Feed analysis , mg/l as CaCO3, Na 50, Mg 30,Ca 20,HCO3 60
----------------------------------------------------
Coflow Counterflow

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date
 BHARAT ALUMINIUM COMPANY LTD
CAPTIVE POWER PLANT-540MW
QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 3 of 8

---------------------------------------------------
Book capacity, g CaCO3/l 27.3 30
Actual capacity, g CaCO3/l 24.5 30
Regeneration ratio at 48 g H2SO4/l 2.00 1.63
Capacity of strongly basic anion resins
----------------------------------------------------
Coflow Counterflow
---------------------------------------------------
Regeneration level, g NaOH/l 64 48
IRA 910 capacity , g CaCO3/l 34.0 34.5
IRA 458 capacity, g CaCO3/l 35.0 35.0
------------------------------------------------------------------------------------------------------------

COUNTERFLOW REGENERATED PLANT:-

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date
 BHARAT ALUMINIUM COMPANY LTD
CAPTIVE POWER PLANT-540MW
QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 4 of 8

The main differences between coflow and counterflow regenerated units are flow
patterns, valves and distribution systems used to control them. The most important
engineering function which a counterflow regeneration system must perform is to prevent
the resin from mixing during or after regeneration. It is essential therefore to maintain the
resin bed in a packed condition during regeneration, and a number of different methods
for achieving this are available:

a) Packed bed
b) Air hold down
c) Water hold down
d) Fluidized bed

a) Packed bed:- In the simplest packed bed system the resin column a nozzle plate at the
top and another at the bottom. The space between the two nozzle plates is filled
completely with resin. Service flow may be upwards or downwards with regenerant flow
in the reverse direction. The system has one major drawback: there is no space to allow
for the expansion which takes place when the resin changes its form from “exhaustion” to
fully regenerated. Although this swelling may be no more than about 7 % of the
exhausted resin volume it may be sufficient to impose large mechanical stresses. For this

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date
 BHARAT ALUMINIUM COMPANY LTD
CAPTIVE POWER PLANT-540MW
QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 5 of 8

reason packed-bed systems are limited to small plants where the total swelling effect is
not great.

In larger units retention of the resins is achieved by a compression bed of polyethylene

beads which is located on top of the resin bed. The compression bed is inert in respect of
the exchange reactions and capable of absorbing the changes in resin size between
regeneration and exhaustion. Disturbances of the resin bed is thus eliminated no matter
how large the diameter of the exchange unit. As a result , the initiation of regeneration is
simple and straight forward as in the coflow method. Furthermore, the compression bed
has a supplementary mechanical filtering action and also assists the uniform flow
distribution during exhaustion and regeneration cycles. After 40 to 50 operating cycles, it
is advisable to back wash the resin bed. For this operation the compression bed is r
removed from the unit and stored temporarily in a transfer tank. Since the specific
gravity of the compression bed is less than unity, it is buoyant and can be washed out of
the top of the unit by columns. After backwashing has been completed, the compression
bed is put back by hydraulic flow and firmly compacted on the resin.

b) Air hold down:-

In this design the resin bed is held in compaction by a cushion of air. The ion exchange
column is of conventional design. At the surface of the active(or working) resin bed a

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date
 BHARAT ALUMINIUM COMPANY LTD
CAPTIVE POWER PLANT-540MW
QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 6 of 8

series of collector pipes are positioned. These consist of perforated, lateral tubes wrapped
with mesh and connected to a header pipe. Perforations are provided in both the top and
bottom of the tubes, the top being for air collection and the bottom for water collection.
The material used is stainless steel.

A layer of ion exchange resin is provided above the stainless steel collector to assist in
bed retention. This additional resin plays no part in plant ion exchange capacity. There is
a free board between the top of the resin bed and backwash water outlet.

Each regeneration is preceded by a surface flush of the top layers of resin. The flow
enters via the buried header and lateral and leaves via the backwash outlet. The working
resin is undisturbed during this operation which removes any suspended matter filtered
out by the resin and, of course, resin fines. Water inflow is then stopped and air is
introduced at the top of the vessel, displacing all the water above the buried collector.
Regenerant enters the unit under the bottom nozzle plate and passes upflow through the
resin and out of the buried collector. After injection the regenerant is displaced from the
active resin by a slow in upflow. The air flow is maintained through the resin above the
collector during injection and displacement. The unit is then refilled with water via the
buried collector and is then given a final rinse downwards.

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date
 BHARAT ALUMINIUM COMPANY LTD
CAPTIVE POWER PLANT-540MW
QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 7 of 8

After some 50 operating cycles a full-bed backwash is recommended. This is followed

by a double regeneration to ensure that the bottom layers of the bed are highly
regenerated. If the plant is not correctly operated it is possible to produce a condition in
which the ion exchange resin bed lifts as a plug, exerting a piston action on the buried
distributor and sometimes resulting in damage. Some manufacturers use a technique
which obviates this possibility. The distributor in this case comprises a header and lateral
arrangement positioned above the top of the resin bed from which stalks(vertical pipes) ,
fitted with strainer-type nozzles, protrude into the resin bed. This system achieves its air
buffer by extraction rather than by applying compressed air.

c) Water hold down:-

This design is essentially similar to that used for air hold-down systems but instead of air
it is the feed water which performs the hold-down action. Two variants of the system
have been used , the first reusing spent regenerant as the hold-down medium, the other
using fresh regenerant. This latter system is known as “split –flow” or counterflow
regeneration. Here the buried collector is located near the bottom of the bed and the
regenerant flows from the top and bottom collectors simultaneously . Since the resin
above the collector is regenerated (in the coflow direction) there is no wasted resin , in
contrast to the other designs.

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date
 BHARAT ALUMINIUM COMPANY LTD
CAPTIVE POWER PLANT-540MW
QESH MANAGEMENT SYSTEM

WORK INSTRUCTION : QESH/CPP2/DMP/CNR-01 COUNTER FLOW REGENERATION

ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NAME : Monitoring and Measurement of Process
ISO : 9001 ISO :14001/OHSAS :18001
ELEMENT NUMBER : 8.2.3, 4.4.6
REV.NO.00 VERSION NO.00 W.I. NO : QESH/CPP2/DMP/CNR-01 Page 8 of 8

PREPARED BY: APPROVED BY:

PANKAJ NIGAM R.K.DHANCHOLIA

Asst Manage (QA) AGM (O), CPP 540 MW
Sign & Date Sign & Date