Optimized Regeneration Control (ORC)
ORC metering and DI water valves pictured above
INTRODUCTION TO ORC
Optimized Regeneration Control (ORC) is the latest technological advancement is optional on all Water Innovations Regenerable Ion Exchange (WI-RIX) which fully automates the media renewal process that utilizes Georg Fischer EA25 metering valves and Signet conductivity (uS) sensors. When sophisticated components are paired with intelligent controls logic, ORC technology maximizes the lifespan of ion exchange media, decreases chemical consumption, ensures consistent water quality, and maximizes resource recovery.
All ion exchange media will eventually reach exhaustion and must be regenerated. The process of regeneration is crucial to an ion exchange system’s operational efficiency and performance. Common practice in the industry is to use system outlet flow and/or outlet conductivity data as the key metric(s) to either determine or react to when regeneration should occur. However, this approach can result in over-running the media, contamination of DI water, or a loss in DI water production. Instead, Water Innovation’s employs a proactive approach to triggering regeneration using the Feed Forward method.
A Calculated Approach: Feed Forward
WI systems rely on sophisticated, real-time measurements to determine exactly when regeneration is needed. The Programmable Automation Controller (PAC) continuously monitors the loading on the media by calculating "grains" of contamination every second using the Inlet Conductivity and Outlet Flow sensor. When the accumulated grain total exceeds the designated capacity for either the cation or anion media, the system immediately initiates an automated Feed Forward regeneration cycle, eliminating risk of water quality dips due to exhausted resin. When the Feed Forward process fails to accurately track the loading of the resin, typically due to an inadequate regeneration of the media, conversely a Feed Back condition is triggered.
ORC Benefit #1: Intelligent Regeneration
Unlike many traditional regeneration methods, on a WI system, chemical is drawn through an Ethernet/IP controlled GF EA25 Metering Valve via an inline eductor tee with DI water to create an acidic or alkaline regenerant. The chemical is then thoroughly blended by an inline static mixer to homogenize the regenerant solution. The process is monitored with unprecedented accuracy using a GF 20.0 cell Conductivity Sensor. This sensor directly correlates with the specific gravity measurement of the regenerant solution and is used to continuously adjust the metering valve’s position, allowing for an increase or decrease of chemical as required. See below Piping & Instrumentation Diagram from a WI-RIX-25-WR-ORC system that highlights the components utilized in this process.
Precision Metering Valves: Chemical dosing is controlled by specialized components: ORC Acid Metering Valve and ORC Caustic Metering Valve. These are high-performance +GF+ EA25 Electric Actuated Valved are equipped with Ethernet/IP Positioners for superior control and communication within the equipment network.
Optimal Mixing: The chemical solutions are homogenized using dedicated ORC static mixers before contacting the resin beds.
Real-time Quality Control: +GF+ SIGNET conductivity sensors: ORC Cation Regen mS and ORC Anion Regen mS are utilized to monitor the quality of the regeneration DI water as the process occurs. These sensors typically measure up to 400 millisiemens (mS).
Chemical Management: The system handles the necessary regeneration chemicals: Hydrochloric Acid (HCl) or Sulfuric Acid (H2SO4) is used for cation media regeneration, while Sodium Hydroxide (NaOH) is used for anion media regeneration. The PAC monitors the chemical inventory, including low alarm levels for HCl/H2SO4 and NaOH.
ORC Benefit #2: Minimized Waste & Maximized Recovery
Optimized Regeneration Control not only produces the perfect regenerant, but it also ensures valuable resources are conserved throughout the process. This includes monitoring the regenerant waste and diverting any recyclable water from the regeneration process back to the system’s feed tank for re-use. See below Piping & Instrumentation Diagram from a WI-RIX-25-WR-ORC system that highlights the components utilized in this recovery process.
Automated Waste Diversion: Spent regeneration solutions are accurately segregated using dedicated valves: cation waste diversion valve and the anion waste diversion valve. Cation waste is sent to the on-site (typically metal bearing) acidic wastewater holding tank and anion waste is sent to the on-site (also typically metal bearing) alkaline waste holding tank. Near the end of the regeneration rinse, wastewater uS is monitored and diverted back to the system feed tank when appropriate.
Recovery is Key: +GF+ SIGNET conductivity sensors: cation waste uS and anion waste uS are utilized to monitor the quality of the wastewater as the process occurs. These sensors measure up to 10,000 microsiemens (uS).
The Bottom Line: A Recipe for Success
✅ Eliminates variability in chemical consumption and regeneration quality.
✅ Automatically adjusts for fluctuations in chemical viscosity due to changes in ambient temperature.
✅ Automatically adjusts for changes in total dynamic head in the chemical bulk tank or drum.
✅ Automatically compensates for changes in backpressure on the chemical eductor due to excessive fouling of the resin. An increase in backpressure will reduce, or in severe cases, can completely stop the chemical draw process.
✅ Provide additional insight and feedback to the operator of the entire regeneration process. For example, if chemistry is not delivered to the equipment due to a mechanical or electrical failure, the system shuts down and the operator is notified.
✅ By optimizing every step of the regeneration process, a Water Innovations Regenerable Ion Exchange system achieves exceptional resource conservation. The WI-RIX-25-WR model, for example, is estimated to achieve a remarkable total water recovery rate of 96.3%.