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Contents
11.1 Fundamentals ......................................................................................................... 2 11.2 Process and Operation Overview ....................................................................... 3 11.2.1 Wastewater Collection ................................................................................ 3 11.2.2 Wastewater Mixing ...................................................................................... 3 11.2.3 pH Measurement ......................................................................................... 5 11.2.4 Wastewater pH Adjustment ....................................................................... 6 11.3 Equipment Design and Options ......................................................................... 7 11.3.1 Batch Tank ..................................................................................................... 7 11.3.2 Tank Mixing Eductor ................................................................................... 7 11.3.3 Centrifugal Pumps ...................................................................................... 8 11.3.4 pH Sensor ...................................................................................................... 9 11.3.5 Valves and Piping ........................................................................................ 9 11.4 Application and Design ..................................................................................... 10 11.4.1 Application.................................................................................................. 10 11.4.2 Design Calculations .................................................................................. 10 11.4.3 Expected Results ......................................................................................... 13
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Waste Neutralization
Neutralization
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Waste Neutralization
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Waste Neutralization
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Waste Neutralization
11.2
Process and Operation Overview The process of neutralization involves the following: Collection of wastewater resulting from the regeneration of various ion exchange systems Combining and mixing wastewater streams Measuring the pH of the combined wastewater streams Adjusting the pH of the wastewater so it is within acceptable limits for discharge to drain
11.2.1 Wastewater Collection The wastewater remaining at the conclusion of an ion exchange resin regeneration cycle generally has an extreme pH and cannot simply be sent to drain. Instead the wastewater is directed to a batch neutralization tank. Figure 11.2-1 on the opposite page shows a typical batch neutralization tank. The purpose of the tank is to hold the wastewater streams in one location. Once collected, the goal is to use the wide variations in pH of the streams and cause them to neutralize each other.
11.2.2 Wastewater Mixing For complete neutralization to occur in a reasonable amount of time, the acidic and alkaline waste volumes in the batch tank must be thoroughly mixed. There are several mixing approaches that can be considered. A motor-driven mixer on a shaft can be used to mix the contents of the tank. The tall tanks often used in this application necessitate the use of long shafts that require careful balancing with submerged bearings to keep the shafts in place. Mounting the mixer assembly on the side of the tank removes these requirements but adds an underwater seal. The maintenance for either of these approaches can be difficult. Mixing can also be achieved by blowing air into the bottom of the neutralization tank. This method avoids the use of moving parts and the associated maintenance concerns, but requires a suitable supply of air. This procedure usually requires a large set of blowers to produce the volume and pressure of air required to mix a full tank of water.
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Waste Neutralization
Another mixing method lets centrifugal pumps recycle the wastewater in the tank. This approach provides a fast and efficient mix with a relatively low-maintenance piece of equipment. Only one pump operates, and any additional pumps are for redundancy. Figure 11.2-2 below shows a pair of recycle pumps.
Recycle/Discharge Pumps
Figure 11.2-2: Recycle / Discharge Pumps In a recycle mixing design, water flows from the bottom of the neutralization tank and proceeds to the suction of the operating recycle pump. After being discharged from the pump, the water is directed back into the batch tank. The time required to pump the entire contents of the tank one time is the turnover rate. This can be measured in turns per hour, with one turn being equal to the volume of the batch tank flowing through the pump one time.
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Waste Neutralization
Suction
Parallel Section
Suction
Nozzle
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Waste Neutralization
As it enters the tank, the water passes through an eductor that mixes water from the pump (the motive fluid) and water from another part of the tank (the entrained fluid). The batch tank contains a series of eductors, equally spaced on laterals, to thoroughly mix the tanks contents. Figure 11.2-3 below shows the arrangement of eductors inside the batch tank.
11.2.3 pH Measurement While the wastewater is being recycled, an inline sensor continuously monitors its pH. As the wastewater in the tank is being mixed, the pH is checked to verify that it is within acceptable limits for discharge. If the pH of the batch is acceptable, the water is sent to drain. If the pH of the batch is outside the acceptable range, additional chemicals are added to bring the pH to a desirable level before it is discharged.
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Waste Neutralization
11.2.4 Wastewater pH Adjustment If the batch of mixed wastewater from a cation resin regeneration and an anion resin regeneration does not yield an acceptable pH for discharge, then the batch must be adjusted. Based on the pH measurement, an algorithm in the control system determines the amount of acid or caustic that must be added to the batch tank. Figure 11.2-5 below shows where the chemicals are added. If the pH of the batch is too high, acid is added. If the pH of the batch is too low, caustic is added. The amount added should be sufficient to bring the pH of the batch tank contents into the acceptable range. The chemicals used are commonly the same chemicals used for cation or anion resin regeneration.
Acid
Caustic
After the adjustment chemical is added and the contents of the tank are thoroughly mixed, the pH of the wastewater batch is measured again to confirm that it is within the acceptable range. If the pH is acceptable, the contents of the batch neutralization tank are sent to drain. If the pH is not acceptable, another adjustment cycle is executed until the pH of the batch is acceptable.
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Waste Neutralization
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Waste Neutralization
11.3
Equipment Design and Options The equipment for a waste neutralization system is relatively straightforward. Due to the extreme pH of the wastewater and the adjustment chemicals, the choice of construction materials is critical.
11.3.1 Batch Tank The batch tank is an atmospheric tank designed to withstand the extreme pH of the cation and anion resin wastewater. Figure 11.3-1 on the opposite page shows the batch tank. The tank itself is made of either fiberglass (FRP) or carbon steel. Due to the extreme pH of the wastewater streams, a carbon steel tank is lined with an epoxy polyamide sprayed lining or natural rubber sheet lining. For more information on atmospheric tanks, see Section 9.1.
11.3.2 Tank Mixing Eductor A series of eductors are used to mix the contents of the batch tank in a shorter amount of time than required by a traditional agitator. By using the flow of water through the eductors to create suction, water is drawn into the eductor from other parts of the tank and combined with the water from the recycle pump. Typically, for every gallon of water pumped into an individual eductor, four additional gallons are drawn in to be mixed. This creates a circulation ratio of 5:1; five gallons leave the eductor for every one that is pumped in. Figure 11.3-2 below shows a single tank mixing eductor. For good mixing, the discharge plume of the eductor should cover most of the height of the tank. An eductor typically provides a discharge plume (in feet) of about half the driving pressure (in psi). Since tanks are usually taller than they are wide, and eductors are mounted at an angle, a 60 psig driving pressure is typically used.
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Waste Neutralization
11.3.3 Centrifugal Pumps The centrifugal pumps supply the mixing energy for the system. They can also be used to send the neutralized tank contents to drain. Figure 11.3-3 below shows a typical centrifugal pump arrangement.
Motor
Pump
The pump materials of construction must be able to withstand the pH extremes of the wastewater and the chemicals present. For more information on centrifugal pumps, see Section 9.2.
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11.3.4 pH Sensor The inline pH sensor monitors the pH of the wastewater. The sensor measures the electrical potential between a reference material and the wastewater flowing past an inline probe. The signal is converted to electrical current and transmitted to the control system. The results are used to determine whether the Reference wastewater batch is Display Material within an acceptable range for discharge. It also monitors the batch as it is being discharged. If the pH is not acceptable, the control system determines what type of adjustment chemical should be added to bring the batch into the In-line acceptable range. Figure 11.3-4 shows pH Probes probes and associated electronics. Figure 11.3-4: Inline pH Monitor
11.3.5 Valves and Piping Like other components of the waste neutralization system, the valves and piping must be able to withstand the extremes in pH of the incoming wastewater streams. Stainless steel is a typical choice as the material of construction due to its corrosion resistance. However, if hydrochloric acid (HCl) is used as an adjustment chemical, components that come in contact with the concentrated acid must be protected (due to the corrosive effects of high chloride levels). If carbon steel is used, it must be lined with polypropylene (PPL) or a Teflon-type material (TFE). PVC pipe is often a good choice in sizes smaller than 8 inches. Larger size PVC fittings tend to be fragile. Similarly, piping just downstream of a sulfuric acid injection point must be protected from the heat generated by the dilution reaction. Plastic pipe is not a wise choice in this application.
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Pump Size
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11.4
11.4.1 Application A waste neutralization system is generally used when wastewaters with extreme pH values are generated by the regeneration of resins in ion exchange systems. If the facility or municipal waste treatment systems cannot handle the wide variations in pH along with the peak flows, a neutralization system is required.
11.4.2 Design Calculations Figure 11.4-1 on the opposite page shows the components of a waste neutralization system for which key attributes must be calculated. The following input data are assumed: The amount of wastewater (in resin volumes) generated by each resin regeneration step: ANION Backwash Pre-Heat Caustic Displace Rinse Total volumes Volumes 2 1 2 1 10 16 CATION Backwash Acid Displace Rinse Total volumes Volumes 2 2 1 6 11
Volumes could be lower depending on the ion exchange vessel and whether rinse water is recycled. Actual volumes of waste produced are normally calculated with detailed ion exchange process calculations. The desired turnover rate. (Assume 4 turnovers to thoroughly mix the batch and 10 minutes per turnover to quickly process the batch.)
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Batch Tank Volume To use the wastewater from an anion resin regeneration to neutralize the wastewater from a cation resin regeneration, the batch tank must be able to hold all of the wastewater from the regeneration of both systems. A safety factor of 50% is added to this total to account for conditions (for example, regeneration cycle alarms) that might increase the amount of wastewater generated. The batch tank must also include extra volume for the low level cut-off alarm (5% of total), high level alarm (5% of total) and overflow alarm (5% of total). The total volume of the batch tank is calculated as follows: VTotal = (Vcation waste + Vanion waste ) x 1.5 [safety factors] x 1.15 [total alarm factors} Where: Vcation waste = cation resin volume x waste volume generated per cation resin volume Vanion waste = anion resin volume x waste volume generated per anion resin volume The calculations must be done in consistent units, usually cubic feet (as resin volumes are mostly expressed in cubic feet) then converted to U.S. gallons using the conversion factor 7.5 U.S. gallons/cubic foot. For a system with 170 cubic feet of cation resin and 226 cubic feet of anion resin per vessel: Vcation waste = 170 ft3 x 11 ft3 waste per ft3 resin = 1,870 ft3 waste Vanion waste = 226 ft3 x 16 ft3 waste per ft3 resin = 3,616 ft3 waste VTotal= (1,870 ft3 + 3,616 ft3) x 1.5 x 1.15 = 9,463.35 ft3 Converting to US gallons: VTotal= 9,463.35 ft3 x 7.5 USgal/ft3= 70,975 US gallons (or 71,000 gallons) The height and diameter of the tank can be adjusted to accommodate this volume and the location of the waste neutralization system.
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Eductor Quantity and Size Eductors are available in a range of sizes, however, larger sizes tend to be machined and thus quite expensive. If small units are selected, the installation cost tends to be high because of the large quantity required. Currently, a 1 unit appears to be the largest standard size available at a cost-effective price. Table 11.4-1 below provides the operating characteristics of this unit as a function of operating pressure. Note that, at all pressures, the circulation ratio is very close to 5 gpm of circulation per gpm of motive flow.
Eductor Model ME4OP (1.5 inch) Pump Pressure (psi) Motive Flow (gpm) Circulating Flow (gpm) 10 33 165 15 40 202 20 47 233 25 52 261 30 57 286 35 62 309 40 66 330 50 74 369 60 81 404
The mixing flow, or total eductor capacity, is calculated by dividing the tank volume by the desired turnover time: Mixing flow (gpm) = VTotal (gal) / turnover time (minutes) The mixing flow is divided by the eductor circulation ratio to determine the actual flow to the eductors, called the motive flow: Motive flow (gpm) = mixing flow (gpm) / circulation ratio The circulation ratio depends on the eductor selected but usually varies only slightly across a specific eductor product line. The minimum number of eductors required is calculated by dividing the total motive flow by the motive flow per eductor at the operating pressure selected, and rounding up to the next integer. Mechanical layout considerations may increase this number slightly but do not need to be considered during process calculations with standard eductors.
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Continuing with the sample system and using the 10-minute turnover time initially selected, the values for mixing flow and motive flow can be calculated as follows: Mixing flow = 71,000 gallons / 10 minutes = 7,100 gpm Motive flow = 7,100 gpm / 5 = 1,420 gpm At 60 psi driving pressure, each 1 eductor uses 81 gpm of water, yielding a total eductor count of 18: Eductor count = 1,420 / 81 = 17.53, or 18 Pump Size The pump size is fixed by the number of eductors selected (above). The pump flow equals the number of eductors times the motive flow per eductor. The pump pressure is the operating pressure (normally 60 psig) selected to get a reasonable plume height. For the example above: Pump flow = 18 eductors x 81 gpm per eductor = 1,458 gpm Pump head = 60 psig x 2.3 ft TDH per psig = 138 ft TDH. 11.4.3 Expected Results After mixing and potential adjustments, the contents of the batch neutralization tank will have a pH within local acceptable limits for discharge to the wastewaters final destination (stream, well, or sewer leading to a municipal waste treatment plant).
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