Optimized Regeneration Control (ORC)
GF EA25 actuated Type 523 proportional valves
INTRODUCTION
An optional system upgrade that automates regeneration chemical feed and optimizes rinsewater recovery, ORC adjusts HCl & NaOH feed by actuated valves controlled by uS sensors and recovers rinse water by monitoring uS to divert it to the feed tank instead of waste treatment.
Combining automation & innovation, ORC decreases chemical usage by 10% and waste by 20%, providing consistent product water quality by replacing manual with automated operations.
This is on top of our best-in-class “feed-forward” activation that triggers cation & anion regenerations independently prior to resin exhaustion by measuring feedwater TDS & totalized volume, and counter-current regeneration of packed resin beds that consumes 50-60% less chemicals and produces 60% less waste than non-packed bed co-current regenerating ion exchange systems.
Automatic Regeneration Adjustment
Whereas our standard regeneration requires periodic manual checking of regenerant specific gravity by the operator, knowing regeneration of cation resin requires 4% HCl and anion resin 6% NaOH. ORC controls chemical feed through a GF EA25 actuated Type 523 metering valve that precisely blends it with DI water to create the required regenerant concentrations measured by a Signet uS sensor inputting to a Signet 9950 that continuously adjusts the valve position, increasing or decreasing its throughput.
See below P&ID illustrating the components enabling this precise & automatic regeneration chemical feed control.
Minimized Waste & Maximized water Recovery
First added to one of our systems in 2016, requested by a customer for a new HFX who manually recovered regeneration rinsewater based on uS with his old system, and named the “AJ-Valve” in his honor. Recognizing a good idea when we saw one, we initially offered it as a stand-alone option. But seeing the cost savings of its reduction in wastewater, we incorporated it as the 2nd feature of our ORC.
Knowing the final approximately 20% of regeneration rinsewater will have conductivity in the range of typical feedwater, we employ a Signet conductivity sensor controlling a GF PPA actuated 3-way valve to divert to the feed tank what would otherwise be waste once it drops below 1,200 uS. See below P&ID that illustrates its components.
Combined Benefits
1. Automates regeneration, the most important factor in system operation, eliminating need for operator involvement.
2. Dramatically improves deionized product water quality by ensuring consistently effective resin regeneration
3. Adjusts for fluctuations in chemical supply from changes in viscosity or problems with its delivery
4. Adjusts for changes in system performance due to increased back-pressure and diminished capacity as resin ages
5. Reduces frequency of regeneration, chemical consumption, and wastewater volume by approximately 10%
6. Reduces volume of wastewater requiring chemical treatment and discharge to sewer by approximately 20%
ORC optimizes Water Innovations’ regenerable ion exchange systems to achieve total water recovery of >96%.