Water Innovations, Inc. specializes in Best-in-Class ion exchange water recycling systems for deionized water & highly-automated wastewater treatment equipment

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Newly Installed HFX75D ion exchange water recycling and integrated wastewater treatment system at Bristol Industries

By Water Innovations Admin

Water Innovations’ VP of Sales Steven Ward with from right-to-left Greg Sutcliffe, GF’s Senior Automation Manager; Richard French of Bristol Industries; Rick Hines, GF’s Director of Automation; and Yves Serra, GF’s President & CEO

 
Steven Ward was honored to have the opportunity to show off Water Innovations’ (WI) newly-installed HFX75d ion exchange water recycling and integrated wastewater treatment system at Bristol Industries, an aerospace fastener manufacturer in Brea, CA to representatives of Georg Fischer (GF) which has been a key supplier to WI for 15 years for actuation & instrumentation and is the world-leader in such products.

Click on GF’s video of WI’s system at Bristol and a discussion with Steve and GF about WI’s utilization of GF’s products.

 
At Water Innovations, Inc. we engineer solutions for wastewater treatment, closed loop water recycling and purification.  We utilize ion exchange to produce the highest quality water with the lowest waste volume. Our Best-In-Class ion exchange systems utilize Smart Regeneration Control (SRC) delivering precise regeneration chemistry feeds, controlled regeneration rinse volume and grain set-point automatic adjustment. Click on the video to learn more…

Designed to meet your challenge

Smart Regeneration Control (SRC), Programmable logic control (PLC) & touchscreen human machine interface (HMI). Variable components sizes to meet a wide range of requirements. Best-in-class system components and state-of-the-art designs & engineering. Engineered to treat a wide range of industrial applications. Related products: HFX, CIX, WDI, SIX, Cyanide Oxidation, Chrome Reduction, Batch Treatment & Final Neutralization

Water Innovations can be reached at sales@waterinnovations.net  or by telephone at 760.466.7583

Filed Under: Water Systems Tagged With: Automated Waste Treatment, Batch Treatment Systems, BTS, BTS Batch Treatment, chemical precipitation, chemical treatment, final neutralization, Georg Fischer, GF, Industrial waste water, Industrial waste water treatment, Rinse Water Treatment, Steven Ward, Waste Water Treatment, Wastewater treatment

Ion Exchange Systems – Industrial Water Recycling

By Water Innovations Admin


At Water Innovations, Inc. we engineer solutions for wastewater treatment, closed loop water recycling and purification.  We utilize ion exchange to produce the highest quality water with the lowest waste volume. Our Best-In-Class ion exchange systems utilize Smart Regeneration Control (SRC) delivering precise regeneration chemistry feeds, controlled regeneration rinse volume and grain set-point automatic adjustment. Click on the video to learn more…

Water Innovations can be reached at sales@waterinnovations.net  or by telephone at 760.466.7583

Filed Under: Water Systems Tagged With: Basic Principles of Ion Exchange, deionized water, Industrial Water Recycling, Ion Exchange, Ion Exchange Process, ion exchange rinse water recycling, Ion Exchange Systems, Ion exchange Water Recycling, Ion exchange Water Recycling Treatment, Rinse water recycling, Rinsewater Recycling, Wastewater treatment, Water Deionizer

Wastewater Batch Treatment Systems

By Water Innovations Admin

Industrial Wastewater Treatment

In a batch treatment system, a volume of wastewater is gathered, treated by chemical / physical / biological means, and discharged. Storage Tanks accumulate waste often segregated as acid, alkaline, cyanide and hexavalent chrome-bearing which is transferred to a single cone-bottom Treatment Tank that’s from less than 1,000 up to 10,000-gallons depending upon the volume of waste per day and the number of daily treatments wanted.  System components include at a minimum a mixer for vigorous solution agitation; level & pH/ORP sensors to monitor the process; electric metering or air diaphragm pumps (depending upon the required volume) to add treatment chemicals; and flow control valves for influent, effluent, and sludge.

Highly – automated Batch Treatment and Continuous chemical treatment systems for metals precipitation, cyanide oxidation, chrome reduction, and suspended solids removal.

Water Innovations specializes in ion exchange (IX) systems for rinse recycling & deionized (DI) water. Our batch wastewater treatment systems complement our IX systems to treat regeneration waste and also process waste baths.  Designed for heavy-metals, O&G, BOD, and a wide variety of other wastewaters from many industrial metal finishing applications.  Our expert understanding of waste treatment chemicals ensures a well-designed and operating system.

For more information on Industrial Batch Treatment Systems call 760-466-7583 or email us at sales@waterinnovations.net 

Filed Under: Water Systems Tagged With: Acid waste tank, Alkaline water tank, Batch Treatment, BTS Batch Treatment, Filter Press, Industrial waste water treatment, Industrial wastewater, PCB Waste water Treatment, Recycle water treatnment, Rinse Water Treatment, Sludge Tank, waste water batch treatment, Wastewater treatment, Water Innovations

Waste Water Batch Treatment System

By Water Innovations Admin

Industrial Wastewater Treatment

Batch Treatment Systems (BTS) are intended for lower daily volumes of wastewater typically less than 10,000 gallons per day and designed to “batch” treat wastewater from start to finish at one time.

In a batch treatment system, a volume of wastewater is gathered, treated by chemical / physical / biological means, and discharged. Storage Tanks accumulate waste often segregated as acid, alkaline, cyanide and hexavalent chrome-bearing which is transferred to a single cone-bottom Treatment Tank that’s from less than 1,000 up to 10,000-gallons depending upon the volume of waste per day and the number of daily treatments wanted.  System components include at a minimum a mixer for vigorous solution agitation; level & pH/ORP sensors to monitor the process; electric metering or air diaphragm pumps (depending upon the required volume) to add treatment chemicals; and flow control valves for influent, effluent, and sludge.

 The treatment process and system components can be manually controlled by an operator for each process step, or highly-automated by the programmable automation controller executing operator-adjustable treatment set-points through a touch screen also providing electronic data-logging and archiving for regulatory compliance.

INDUSTRY APPLICATIONS

  • Metal Finishing & Plating
  • Electroplating
  • Printed Circuit Board
  • Paint & Finishing
  • Aerospace & Defense
  • Automotive & Transportation
  • Electronics
  • Semiconductor

FEATURES & BENEFITS

  • Standardized and pre-engineered
  • Modular and ready to install & use
  • Best-in-Class high quality components
  • Intuitive yet powerful operating control
  • Scalable based on pumps and tank sizes
  • 304-SS polyurethane-coated frames
  • Non-metallic tanks & bases for long-life
  • Schedule 80-PVC and true union valves

Batch Waste Treatment

Industrial Waste Treatment System

Batch Waste Treatment
Industrial Waste Treatment System Side View

Automation

  • Rockwell Automation software
  • Allen-Bradley Compactlogix PAC
  • Allen-Bradley Panelview Plus HMI
  • Allen-Bradley Components
  • Integrated HMI data-logging
  • Internet-based remote access

Standard Components

  • Separate acid & alkaline waste holding tanks
  • Cone-bottom reaction tank & gear-drive mixer
  • pH, ORP, & level process-control sensors
  • AOD or electronic chemical feed pumps
  • Supernate discharge ports & transfer pump
  • Sludge feed tank with auto pump control
  • Programmable Logic Control (PLC) automation
  • Touch Screen human-machine interface (HMI)

 Scalability

  • Holding Tank
  • Pump Skid
  • Controls
  • Chemical Feeds
  • Mechanical Mixers
Batch Waste Treatment
Industrial Batch Treatment Systems Top

Water Innovations specializes in ion exchange (IX) systems for rinse recycling & deionized (DI) water. Our batch wastewater treatment systems complement our IX systems to treat regeneration waste and also process waste baths.  Designed for heavy-metals, O&G, BOD, and a wide variety of other wastewaters from many industrial metal finishing applications.  Our expert understanding of waste treatment chemicals ensures a well-designed and operating system.

For more information on Industrial Batch Treatment Systems call 760-466-7583 or email us at sales@waterinnovations.net 

Filed Under: Water Systems Tagged With: Acid waste tank, Alkaline water tank, Batch Treatment, BTS Batch Treatment, Filter Press, Industrial waste water treatment, Industrial wastewater, PCB Waste water Treatment, Recycle water treatnment, Rinse Water Treatment, Sludge Tank, waste water batch treatment, Wastewater treatment, Water Innovations

Ion Exchange Systems – Theory of Technology

By Water Innovations Admin

Theory of Technology

Basic Principles of Ion Exchange

Ion exchange refers to a process where different ions in solution are exchanged, or replaced, by other ions.  An ion exchange media, or resin, is used to accomplish this.

Ion exchange resin is an insoluble, porous, polymer bead.  The beads have a very high molecular weight and carry a functional group with either positive (+) or negative (-) charge, known as exchange sites.  Negatively charged resin is called cation resin and attracts positive ions, or cations.  Positively charged resin is called anion resin and attracts negative ions, or anions.  They can be further classified as weak and strong acid cation resins and weak and strong base anion resins.  The porosity of the bead allows water to flow through the bead, increasing the amount of contact with the exchange sites.

Complete Ion Exchange System_Left Side_CIX1000S
Complete Ion Exchange System_Left Side_CIX10S

The strength and characteristics of the exchange sites, along with the characteristics of the ions, determine a resin’s affinity for certain ions.  For example, ions with multiple charges, (e.g. Ca++) have a stronger attraction to the resin than ions with single charges.  Ions of equal charge are selected by the resin based on molecular weight.  Heavier ions are selected first.  A resin’s selectivity is also based on an equilibrium principle.  Basic water softening theory originated from this principle.  In general, calcium has a +2 charge, while sodium has a +1 charge.  A cation exchange resin has a higher affinity for calcium over sodium in a weak solution, such as tap water.  However, in a concentrated sodium chloride brine solution, the selectivity reverses.  Thus, cation exchange resin in a water softener is rinsed with a brine solution to remove the calcium from the resin bed.  This is known as regeneration.

The ion exchange process is used to soften water, deionize water, scavenge metals, and recycle waste water (another form of deionization).  All of these processes are accomplished utilizing the above methods.

When designing an ion exchange system, the characteristics of the influent stream need to be examined.  Based on this data, a determination is made as to the most beneficial type of ion exchange treatment.  The following explains these parameters.

The total dissolved solids (TDS) of the inlet water provides the total quantity of contaminants in the water and is reported as parts per million (ppm) or mg/l.  The higher level of TDS, the more often the system will regenerate.  Levels above 750 mg/l TDS should not be treated with ion exchange.  Often times the TDS of the water is equated with the conductivity.  Due to different conductive characteristics of different ions, that is not always accurate.  For example, a stream with no contaminants other than silica will be very low in conductivity, yet may have very high TDS.  While there are charts and equations that correlate TDS with conductance, it is best to initially analyze specifically for TDS and individual ions.

The total suspended solids (TSS) is the quantity of solids in the water that can be removed by filtration.  These solids are not dissolved in the water and will not be removed by ion exchange resin.  High concentrations of TSS require additional filtration.  Levels should not be above 5 mg/l entering the ion exchanger, or the chance for suspended solids fouling greatly increases.

The level of suspended oils and greases coming into an ion exchange bed should not be above 0.1 mg/l.  Higher levels will cause a fouling of the ion exchange resin, which would prevent it from operating properly. The inlet temperature of the water should not exceed 100oF.  If the temperature does exceed this level, special design considerations are required.  A temperature of 140oF can be deionized with special resins; however, expected resin life at this temperature is not more than two years. The level of organics can greatly affect the structure and ability of ion exchange resins.  This is also true for free chlorine.  When levels of chlorine or organics exceed 1 mg/l, additional treatment through carbon or other absorbent material is recommended.  Both the maximum and average values for each of these parameters should be taken into account.  While the maximum averages may be well within specifications, peak levels may drastically affect the deionization process.

Prefiltration of the water is almost always a must.  Solids, which are in the water, if not removed, will plug any ion exchange column.  This is especially true in the packed-bed designs of high purity systems.  Adequate filtration for deionization applications is less than 5 micron filtration, usually through replaceable bags or cartridges.  Particles smaller than this size are usually passed through the resin bed, causing it no harm.

This first step of the actual deionization process uses cation resins to remove positively charged ions from the water.  Using the “opposites attract” rule, the negatively charged cation resin binds and removes positively charged molecules from the water.  These constituents include sodium, calcium, magnesium, iron, and other metals.  As these positively charged molecules are removed, hydrogen ions are released from the resin.  This is the element which is exchanged off the cation resin in the deionization process.

Following the cation exchange process, the negatively charged molecules in the water are removed by the anion exchange process.  Typical anion molecules present in water include chlorides, sulfates, nitrates, carbon dioxide, and silica.  As the resin removes these molecules, an hydroxide ion (OH) is released.  It is important that the cation exchanger be functioning properly and located before the anion.  Should multivalent cations come into contact with the anion resin, they will usually precipitate within the resin bed and foul it.  This is the most common type of fouling which can occur, and especially common with calcium.  The H+ ions from the cation exchanger and the OH– ions from the anion exchanger immediately recombine to form water.

Complete Ion Exchange System_right Side_CIX1000S_3DA polishing unit, either a cation or a mixed bed (a combination of both cation and anion resin) can be used following the cation/anion process.  Without any polishing, the minimum quality of water that can be produced is between 50,000 ohm/cm (50 K) and 1,000,000 ohm/cm (1 meg).  With the polishing unit, the quality can be raised all the way to 18,300,000 ohm/cm.  This quality is achieved by the use of a mixed bed polisher.  A cation polisher will raise the quality to above 5,000,000 ohm/cm (5 meg).  When any of the resins used in the deionization process become exhausted, or have exchanged off all of their respective ions, the resins must be regenerated.

Cation resins use acids to regenerate (25-50% strength).  Hydrochloric is the preferred and easiest acid to use.  While other acids may be used, special regeneration techniques are required. Anion resins use sodium hydroxide (caustic) for their regeneration.  The regeneration process can either be co-current flow or countercurrent.  This means in the same direction as the process flow, or in the opposite direction.  A countercurrent system will maximize the chemical’s ability to regenerate the resin and minimize the volume of waste.

The solution produced from this regeneration sequence will contain the same constituents as the incoming water, however, they will be concentrated and in a strong acid or caustic background. By combining the regeneration from the cations and anions, a partial neutralization can be made.  However, the pH range can vary greatly in this type of mixture.  It is usually necessary to send this solution to a neutralization system prior to its being discharged.

Water Innovations can be reached at sales@waterinnovations.net  or by telephone at 760.466.7583

Filed Under: Basic of Tagged With: Basic Principles of Ion Exchange, deionized water, Ion Exchange, Ion Exchange Process, ion exchange recycling, ion exchange rinse water recycling, Ion Exchange Systems, Rinse water recycling, Wastewater treatment

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