EDI TRAINING Matarvatensektionen utbildningsdag 5 oktober 2016

Transcription

1 EDI TRAINING Matarvatensektionen utbildningsdag 5 oktober 2016

2 Welcome to EDI training

3 Who am I? Born 1966 in Copenhagen Education in Export sales and Electronic and Mechanical engineering Started in EUROWATER in 1989 Work fields: technical advisor, site supervisor, product manager, product development Export Manager since 2006

4 Established in Employees EUR 50 Million turnover

5 Pre-engineered design Refined through experience Design > Build > Learn Build > Build > Build >

6 International network 23 sales and service offices in 14 countries Independent distributors in 18 countries

7 Experience Since 1936 EUROWATER has worked exclusively with professional water treatment. In 2011 all employees were gathered in Denmark to celebrate the 75 year anniversary.

8 Who are you?

9 Agenda - Introduction to EDI (History, evolution, market situation) - Process principle - Equipment design, features and function - Control logic - Feed water and plant design - Installations and start-up - Operation and optimization - Cleaning and maintenance - Troubleshooting, repair and replacement - Shut down and storage

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11 Original training material

12 What is EDI? Electrodeionization (EDI) A process that removes ionizable species from liquids using an electrical potential to influence ion transport The most general term for electrochemical deionization processes Can be a batch or a continuous process

13 EDI Development History - first described in a publication by scientists at Argonne Labs in January 1955 (Walters, et. al.) - earliest known patents describing a EDI device and process was awarded in 1957 (Kollsman) - first pilot device incorporating mixed resins was developed by Permutit Company (UK) in the late 1950's - first detailed theoretical discussions of EDI was written in December 1959 (Glueckauf) - first fully commercialized in early 1987 by a division of Millipore - now several thousand EDI systems in commercial operation for the production of high purity water Main technology providers are: - GE, E-Cell - EVOQUA, Ionpure - SNOWPURE, Electropure - DOW, Omexell - MEGA - QUA Water Technologies 1987 Millipore, first commerciel EDI 1988 Electropure, thin cell 1994 Ionics, thin cell 1996 Christ, Septron, sprial wound 1997 E-Cell, MK series, thick cell 2001 Ionpure, LX series, thick cell 2003 IE-Cell, MK3 series, thick cell

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19 How does EDI work?

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22 Ion Movement in an EDI or CEDI Module

23 Ion Removal in a Ionpure CEDI Module

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36 What is hard to understand? What is worth to understand?

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38 Main components in an EDI-unit EDI module DC power supply Control system Measuring equipment (indicators, sensors, transmitters) Pipe system Skid, Frame, Rack

39 Field Experience Electropure XL SG water Ionpure MX, LXM (Z&X) and LXM-HS E-Cell, MK2, MK2ph, MK3 and 3X First system sold in 2001 More than 260 systems sold More than 1200 EDI modules supplied

40 EW EDI Evolution First units in 2001 Electopure XL E-Cell MK2 E-Cell MK2ph

41 EW EDI Evolution First units in 2001 E-Cell MK2 EDI plant with large control cabinets Ionpure LX30X

42 Rigas Siltums, Riga, Latvia District heating Steam turbine for electricity production Flow 2 x 5 m³/h Conductivity <0,2 S/cm Activated carbon ACH x RO x EDI i

43 Symrise, Germany Chemical industry Makeupwater for steam boiler Flow 4 m³/h Conductivity <0,2 S/cm Silica <20 ppb Softening unit SMH 602 RO units 2 x EUROTEC EDI i Online measurement equipment for hardness and silica Bagfilter EF2 as resin trap PLC control Siemens DDC

44 FERTIN PHARMA, Vejle, Denmark Pharmaceuticals (chewing gum) Purifyed water Flow 500 l/h Conductivity <0,2 S/cm RO 01-2 EDI 1-440i PPn

45 WTP-F with Ionpure LX Fisia Flow rate: 2 x 3,0 m³/h

46 Standard based IONPURE MX and LX

47 EDI customer information - Ionpure EDI i

48 WTP-F Pharma with Ionpure LX Hasco Flow rate: 1 x 2,0 m³/h

49 Projects with E-Cell MK3

50 WTP-F with E-Cell MK3 Kalmar Flow rate: 2 x 3,5 m³/h

51 EDI new standard units in 2007 Development of new standard EDI based on GE E-Cell MK3 IONPURE LXM30Z GE E-Cell MK3 Lower operating voltage (max 300VDC) Lower power consumption Less resistance increase over time No torque tightening of stack bolts Guaranteed leak free SiO2 guarantee based on E-Calc Less susceptible to thermal damage

52 Standard EDI units based on E-Cell MK3 and 3X EDI e

53 WTP-F with E-Cell MK3 Kevo Flow rate: 2 x 4 m³/h

54 WTP-F with Ionpure LX BWSC Flow rate: 1 x 8,0 m³/h 1 x 1,4 m³/h

55 Engineered solutions for Heat and Power applications with E-Cell MK3 and 3X

56 PI-diagram of MK3 in co-current configuration

57 EDI units with E-Cell MK3

58 PLC log with trend curves and electronic log book

59 Operation logic Continuous operation Start-Stop operation Water hammer Over pressure Temperature measuring Individual DCPS Individual Current measuring all streams recycle or optimum: Stand-by regeneration longer runs logic, soft starting pumps, slow moving valves etc safety valve to control cold water makeup when circulating, shut down or alarm to allow equal (sufficient) current distribution to guide individual flow regulation of each stack

60 Don't neglect the pre-treatment Most problems reported on EDI is actually problems in the pre-treatment

61 Pre-treatment Chemical treatment (coagulation, flocculation, oxidation, disinfection etc.) Filtration UF Scavenger Activated carbon to be considered if feed TOC is >1ppm ix softening anti-scaling only together with DPRO. Resin type. Permeate softening Temperature control possible range 5-40 C, preferred C, optimum: 15 C Brake tank open vented tank for recycle of EDI concentrate and electrolyte NaOH dosing ph >8,3 (in reality up till 9,0) RO elements use HR elements or optimum: DPRO Membrane degassing CO2 must be <10ppm, optimum: <5ppm, operation mode CAVP or SASB Permeate storage tank air vent filter with CO2 trap, 1um filter on outlet

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63 3 x 25m3/h DPRO-PLUS and EDI

64 3 x 25m3/h DPRO-PLUS and EDI

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77 EDI - FAQ What is the lifetime of an EDI-module? Can the resin in EDI module be exchanged? What is the lifetime of an EDI DC Power Supply What is the cleaning interval on an EDI? Does working with high current means higher wear? Is the CO2 content important? What is the optimum water temperature for EDI? What is the concentrate flow on an EDI? Do you recommend to install a ix MB after EDI? Is circulation of product water a good idea? How to operate a duplex EDI? 3 5 years. However very strongly depending on pre-treatment and feed water quality. If pre-treatment includes double pass RO (or ix scavenger, ix softener, gac, RO) then rather 5-7 years may be expected No. The only field maintenance possible is changing the fittings. >10 years (Temperature!) 3 24 months. The cleaning chemicals are pure NaCl, HCl and NaOH. The standard cleaning program is made on site with a CIP unit similar to that of an RO. No. Only higher OPEX. Yes. CO2 is a load on the EDI that takes out capacity equivalent to 2,7uS/cm per ppm. Recommended is <5pppm and maximum is 10ppm 15 degrees C. Outside the range 10-25C SiO2 retention is reduced. Warmer water means higher risk of bio-fouling. 5-10% of feed. The recovery is determined mainly from the feed water hardness. A minimum flow is required for cooling. As the full concentrate and electrolyte flow is normally reused the recovery of an EDI is less critical. Yes. As the service life is very long typically 1-2 years the cost for the safety provided by the MB is relatively low. The MB will allow maintenance on 1 line systems. Note that replacement must be initiated by volume and not on E.C. measurement. Only if two MB columns in serial are used the E.C. can be used to determine the resin exchange. Yes. Using stand-by periods for circulation and thus regenerating the working zone of the EDI dilute chamber has proved to be very efficient in prolonger cleaning intervals and stack life in general. Highly recommended! max 24h stand-by. Stand-by should be maximum 24 hours (depending on ambient temperature). A short 10minutes replacement rinse every 24hours can be used for periods up till three weeks. Longer lay-up should be made be regeneration (CIP if needed), drain down and sealing.

78 Maintenance Look for the problem before it occurs Keep settings Act in time Log Book Keep daily record of all operation data Process the data in a normalisation calculator E-Calc Know your base line expected values Water Analysis Monitor important values. TOC, TEA, SiO 2, CO 2

79 Maintenance Service Report

80 Maintenance Measuring Points

81 Maintenance Check List

82 Maintenance Log Book

83 Maintenance Log Book

84 Mass Balance Calculation

85 Cleaning interval

86 Shutdown standby / lay up Risk Biofouling 0-3 days No action needed If ambient temperature is >25 C a daily replacement rinse is recommended 4-14 days Preferably - run the EDI (with power) daily for minimum 30 minutes Alternatively - apply a daily replacement rinse Longer periods Drain off all water from the EDI stacks and seal all connections (thereby keeping the resin moist and preventing dirt from entering) Preferably regenerate the stacks fully before lay up If the log shows an upcoming need for cleaning this is best done before lay up

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93 93 10 October 2016 Reported Problems (Symptoms) High product conductivity High electrical resistance High power consumption High pressure loss Failure of the DC Power Supply

94 Information The operation data journal The PI-diagram The feed water analysis

95 95 10 October 2016 Typical causes CO2 > 10ppm Water temperature < 10 C TOC > 0,5ppm Blocking of fan air filter

96 The mass balance calculation

97 97 10 October 2016 Case story EDI i + and cables swapped between control box and EDI modules! not checked in production! not checked during start-up! not checked during initial trouble shooting! Symptoms: 1 A = 0,1 us/cm 12 A = 6,8 us/cm

98 Case story EDI i + and cables swapped between control box and EDI modules! Electrode broken after 1-2 days of operation Happened on 2 LX24 modules

99 Case story EDI i By-pass valve on Membrane degasser open! 1 EDI module resin exhausted and electrical resistance increased 2 DCPS hit maximum 600V / 6A 3 Conductivity increased 4 DCPS burned off! (4KW continuously operation) After opening the MD by-pass valve the system recovered!

100 Case stories TOC

101 Case stories TOC EDI 1 x LX30 unit at "Kara Roskilde" Q product = 2,0 m3/h Q concentrate = 0,2 m3/h CD product = 0,06 us/cm CD feed = 3,5 us/cm CO2 feed = 0 ppm (ph before RO = 9,3) T feed = 11,5 C U = 600 V I = 1,4 A R total = 429 ohm P total = 0,84 KW P relative = 0,42 KW per m3/h

102 Case stories TOC EDI 2 x LX30 unit at "IBV Vielsalm" Q product = 4,5 m3/h Q concentrate = 0,24 m3/h CD product = 0,07 us/cm CD feed = 4,0 us/cm CO2 feed = 5 ppm (membrane degassing in combo mode) T feed = 12 C U = 615 V I = 6,5 A R total = 94,6 ohm P total = 5,35 KW P relative = 1,34 KW per m3/h

103 Case stories TOC EDI 2 x LX30 unit at "AF Aarhus" (Partial circulation) Q product = 4,0 m3/h Q concentrate = 0,4 m3/h CD product = 0,06 us/cm CD feed = 3,80 us/cm CO2 feed = 5 ppm (membrane degassing in combo mode) T feed = 11,6 C U = 535 V I = 10,0 A R total = 53,5 ohm (average per module = 107 ohm) P total = 5,35 KW P relative = 1,34 KW per m3/h

104 Case stories TOC EDI 3 x LX30 unit at "MV3 Moscow" Q product = 5,0 m3/h Q concentrate = 0,6 m3/h CD product = 0,07 us/cm CD feed = 10,3 us/cm CO2 feed = 5 ppm (membrane degassing in combo mode) T feed = 24 C U = 613 V I = 8,4 A R total = 73 ohm (average per module = 219 ohm) P total = 5,15 KW P relative = 1,03 KW per m3/h

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107 Why should you work with optimization of your EDI system? - to get better water quality (Lower conductivity, Na, SiO2) - to increase stability (Fewer interruptions due to errors, malfunctions, brake downs, cleanings) - to reduce running cost: - to get longer stack life - to have longer time between cleanings - to reduce power consumption - to reduce waster water

108 Elements to optimize Plant Design Commissioning Operation Maintenance & CIP Repair & CIP

109 Mass Balance Calculation (Stoichiometric)

110 Water splitting and regeneration

111 EDI is always out of balance Load (flow, ions, CO 2, organics) Capacity (Current, temperature, condition/age)

112 E-Cell MK3 process principles

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114 Plant design Pre-treatment Chemical treatment (coagulation, flocculation, oxidation, disinfection etc.) Filtration UF Scavenger Activated carbon to be considered if feed TOC is >1ppm ix softening anti-scaling only together with DPRO. Resin type. Permeate softening Temperature control possible range 5-40 C, preferred C, optimum: 15 C Brake tank open vented tank for recycle of EDI concentrate and electrolyte NaOH dosing ph >8,3 (in reality up till 9,0) RO elements use HR elements or optimum: DPRO Membrane degassing CO2 must be <10ppm, optimum: <5ppm, operation mode CAVP or SASB Permeate storage tank air vent filter with CO2 trap, 1um filter on outlet Flow direction Co-current when low counter pressure is possible Counter current for high hardness tolerance (1,0ppm CaCO3 / 0,4ppm Ca / 0,06GH ) Operation logic Continuous operation all streams recycle or optimum: Stand-by regeneration Start-Stop operation longer runs Water hammer logic, soft starting pumps, slow moving valves etc Over pressure safety valve Temperature measuring to control cold water makeup when circulating, shut down or alarm Individual DCPS to allow equal (sufficient) current distribution Individual Current measuring to guide individual flow regulation of each stack

115 Operation parameters Softener RO MD EDI Regeneration level Recovery Quality rinse limit and time Interval rinse Air flow Vacuum level Pre- and Post run time Electrical current (amperage) Product flow (norm +/-50% ) Electrolyte flow Concentrate flow (recovery) Specific pressure Relative pressure Interval rinse Tank level for start-stop Minimum operation cycle time

116 EDI upsets are most often a consequence of challenging feed water and insufficient pre-treatment. Thus optimizing operation also involves improvements of the pre-treatment.

117 Questions

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