METHOD FOR REDUCING DILUTION EFFECTS IN FLUID TREATMENT VESSELS

Abstract

A fluid treatment apparatus comprising a tank containing a bed of at least one fluid treatment medium, a distributor plate separating the bed from an end portion of the tank, and an inert medium comprising amorphous particles having a harmonic mean diameter from 2.5 to 250 mm and a density from 0.57 to 0.998 cm3/g. The volume of the end portion containing inert medium is from 25 to 95% of the total volume of the end portion.

Description

BACKGROUND

This invention relates generally to a method for reducing dilution effects in fluid treatment vessels.

Ion Exchange Resins are regenerated with a chemical solution once they are exhausted. The volume of regeneration liquid depends in part on the concentration of the liquid. Free water present in a vessel will negatively influence the effectiveness of the regeneration, leading to lower operating capacity, increased chemical consumption and more waste. For example, US2014/0263069 discloses the use of filler material in the end portions of the vessel, i.e., those portions not containing a fluid treatment medium. However, this reference does not disclose an efficient method.

STATEMENT OF INVENTION

The present invention is directed to a fluid treatment apparatus comprising:

• • (a) a tank comprising a bed of at least one fluid treatment medium,
  • (b) a distributor plate separating the bed from an end portion of the tank, and
  • (c) at least one inert medium comprising amorphous particles having a harmonic mean diameter from 2.5 to 250 mm and a density from 0.57 to 0.998 cm³/g;
  • wherein volume of the end portion containing inert medium is from 25 to 95% of total volume of the end portion.

DETAILED DESCRIPTION

All percentages are weight percentages (wt %), and all temperatures are in ° C., unless otherwise indicated. Averages are arithmetic averages unless indicated otherwise. All operations are performed at room temperature (18 and 25° C.) unless specified otherwise. Weight average molecular weights, M_w, are measured by gel permeation chromatography (GPC) using polyacrylic acid standards, as is known in the art. The techniques of GPC are discussed in detail in Modern Size Exclusion Chromatography, W. W. Yau, J. J. Kirkland, D. D. Bly; Wiley-Interscience, 1979, and in A Guide to Materials Characterization and Chemical Analysis, J. P. Sibilia; VCH, 1988, p. 81-84. The molecular weights reported herein are in units of daltons. Percentages of monomer units in a polymer are based on total polymer weight (dry weight). The “harmonic mean diameter” (HMD) is defined by the following equation:

$\mathrm{HMD}=\frac{N}{{\sum }_{i=1}^N\left(\frac{1}{d_i}\right)}$

where i is an index over the individual beads; d_i is the diameter of each individual particle; and N is the total number of beads. A particle that is not spherical is considered to have a diameter equal to the diameter of a sphere having the same volume as the particle. “Sphericity” (Ψ) is the degree to which a particle is spherical and is characterized by using two of the three principal orthogonal axes of the object, a (longest), b (intermediate), and c (shortest), as follows: Ψ=c/ a. “Roundness” (R) is defined as the ratio of the average radius of curvature of the corners and edges of an object's silhouette to the radius of the largest circle which can be inscribed within the silhouette. Sphericity and roundness are described in more detail in H. Waddell, The Journal of Geology, vol. 41, pp. 310-331 (1933).

The volume of the end portion containing inert medium is defined by the upper boundary of the inert medium when at rest. For example, if one defines a plane touching all of the uppermost particles of inert medium, i.e., a plane defining an upper surface of the inert medium, then the volume of the end portion below this plane is the volume of the end portion containing inert medium. For clarity, this is not the total volume of the particles themselves. Preferably, the volume of the lower end portion containing inert medium is at least 30% of the volume of the lower end portion, preferably at least 35%, preferably at least 40%, preferably at least 45%, preferably at least 50%; preferably no more than 90%, preferably no more than 85%.

Preferably, the amorphous particles have an average sphericity from 0.7 to 1.0 and an average roundness from 0.4 to 1.0. Preferably, average sphericity is at least 0.75, preferably at least 0.80; preferably no more than 0.95, preferably no more than 0.92, preferably no more than 0.90. Preferably, average roundness is at least 0.45, preferably at least 0.50, preferably at least 0.55; preferably no more than 0.95, preferably no more than 0.90, preferably no more than 0.85, preferably no more than 0.80, preferably no more than 0.75, preferably no more than 0.70. Preferably, the average sphericity and the average roundness are not both greater than 0.95, preferably 0.90.

Preferably, the amorphous particles have a harmonic mean diameter no greater than 150 mm, preferably no greater than 100 mm, preferably no greater than 50 mm, preferably no greater than 25 mm, preferably no greater than 10 mm, preferably no greater than 6 mm.

Preferably, the amorphous particles have a density of at least 0.60 cm³/g, preferably at least 0.65 cm³/g, preferably at least 0.70 cm³/g, preferably at least 0.75 cm³/g, preferably at least 0.80 cm³/g, preferably at least 0.85 cm³/g. Preferably, the amorphous particles have a density no greater than 0.997 cm³/g, preferably no greater than 0.996 cm³/g.

Typical end portions (also known as dish heads) of tanks used for fluid treatment include, e.g., Klopper heads, elliptical heads and spheroid heads. Typically, dish head water volume is 15-35% of the installed resin volume in the main portion of the tank and dish head water volume is 40-100% of the resin void water in the main compartment. Preferably, the main portion of the tank is cylindrical.

Reduction of void water due to the presence of inert material in the end portions is calculated as follows for a spheroid end portion.

• V_s=spheroid compartment volume
• V_sx′=the spheroid remaining free water after (partial) filling of X ml IF62 (ml)
• S_x=the solid fill of the spheroid volume due to the X ml filling with IF62 (ml)
• X=inert filling (ml)
• F_w=free water (%)

V _sx ′=V _s−(X*F_w)

S _x =V _s −V _sx′

Preferably, the fluid treatment medium in the main (center) compartment of the tank is an ion exchange resin, activated carbon, an adsorbent, a non functionalized co polymer or a zeolite. Preferably, the fluid treatment medium is an ion exchange resin, preferably in the form of spherical beads. Preferably, the beads are crosslinked polymer beads.

• Depending in the technology applied:
• Co-flow systems have 10-60% filling
• Countercurrent systems:
  • Packed beds: 85%-97,5% filling
  • Blocked beds 25-60% filling
  • Mixed beds 25-60% filling

Inert filling in the main compartment (cylinder) depends on the system technology and is either a fixed value ranging from 10-12 cm in an Amberpack/Schwebebett or a range of heights depending on the vessel diameter. Typically <1000 mm:150 mm; <2500:200 mm and all other over 2500:300 mm

Or 15-25 cm as block layer in a blocked bed system with air hold down.

EXAMPLES

The equipment used in the present examples was as follows:

• • 2 PVC columns in parallel for the comparison; Outer diameter 6 cm and column height 1000 mm
  • Top and bottom compartments 160 mm wall height equipped with nozzle plates. The compartment represent the vessel spheroid dish head net volume V_s=350 ml; the compartment is physically separated from the resin column by a nozzle plates to retain the filling.
  • Instrumentation: 8 rotameters,
  • 2 manometers
  • Other equipment: 2 water tanks (1 m³),
  • 2 chemical tanks (NaOH 30% HCl 37%),
  • 4 pumps (2 feed, 2 dosing)
  • 2 conductivity meters

[We should describe how the PE particles are made, since this is not a commercial product]

IWAKI Electromagnetic Metering
pumps	Model	EWN-B16VCER
Capacity	65 mL/min · 3.9	Power	100-240	VAC
	L/h · 0.09-0.18	supply
	mL/stroke
Disch. Press.	7	bar	Frequency	50/60	Hz
Pressure	8	bar	Current	0.8	A
Max.			(Input)
Stroke	50-100%	(0.5-1.0 mm)	Power	20	W
Length			(Input)
Stroke Rate	0.1-100	(1-360 spm)	Materials	PVC (head)
				PTFE + EPDM
				(diaphragm)

Example 1: Tests with Upper and/or Lower Compartments Filled

Operating Conditions for the Tests

Configuration                  1 column
Regen. technology              UPCORE ™
Resins                         DOWEX ™ MARATHON ™ 1200H
                               New commercial name Amberlite
                               HPR1200 H
                               DOWEX ™ UPCORE ™ IF-62
                               New commercial name Amberlite 62i
Setups                         None compartment filled
                               Bottom compartment filled
                               Bottom + Top compartment filled
Feed water                     Raw water after sand filter
                               treatment
Regenerant                     HCl 4.5%
Cycles monitoring              Conductivity measurement
DOWEX MARATHON ™ 1200 - UPCORE ™
Floating inert                 DOWEX ™ UPCORE ™ IF-62
Floating inert height(1) (mm)  85
Freeboard (mm)                 50
Filling inert                  DOWEX ™ UPCORE ™ IF-62
Volume of filling inert(2) (L) 0.350
Volume of resin in             1.89
swollen form (L)
Resin height (mm)              865
COMPACTION
Direction                      UPFLOW
Influent                       Demineralized water
Flow rate (L/h)                60
Linear velocity (m/h)          30.6
REGENERANT INJECTION
Direction                      UPFLOW
Regenerant                     HCl 35% w/w %
Quantity (g/LR)                120
Regenerant solution            4.5
concentration (w/w %)
Flow rate (L/h)                15.0
Specific flow rate (BV/h)      8.6
Duration (min)                 18
Linear velocity (m/h)          7.6
Volume (L)                     4.5

Regenerant Displacement (Slow Rinse)

Direction                 UPFLOW
Effluent                  Demineralized water
Flow rate (L/h)           15.0
same as during regenerant injection
Specific flow rate (BV/h) 8.6
End point                 Conductivity < 1000 μS/cm
SETTLING
Duration (min)            10
FAST RINSE (RINSE TO QUALITY)
Direction                 DOWNFLOW
Influent                  Demineralized water
Flow rate (L/h)           55.0
same as loading cycle
Specific flow rate (BV/h) 29.1
same as loading cycle
End point                 Conductivity after SBA < 10 μS/cm
LOADING CYCLE
Direction                 DOWNFLOW
Influent                  Water after sand filters
Flow rate (L/h)           55.0
Specific flow rate (BV/h) 29.1
Linear velocity (m/h)     28
End point                 Conductivity after SBA > 2 μS/cm

Results

	Regeneration cycles
			AVG BV for fast
	Loading cycles	BV for	rinse to reach
	Op. Cap. (eq/LR)	displacement	10 μS/cm
No compartment	1.34 ± 0.01	5.9 ± 0.2	2.06	Fr = 0%
filled
Bottom	1.47 ± 0.07	6.2 ± 0.3	1.58	Fr = 66.5%
compartment
filled
Bottom and Top	1.58 ± 0.03	6.2 ± 0.6	1.41	Fr = 66.5%
compartment
filled
[Cations] (eq/liter) = Total cation concentration obtained from the feed water analysis.
VT = Throughput (liter): Total amount of water treated at the resin breakthrough point.
VR = The volume of resin loaded (liter)

$\mathrm{Op}.\mathrm{Capacity}=\frac{\mathrm{VT}\times \left[\mathrm{Cations}\right]}{\mathrm{VR}}\left(\mathrm{Eq}\text{/}{1}_{\mathrm{resin}}\right)$

Compared to F_wr=0% (no filling), the resin operating capacity improves at 100% filling of V_s at F_wr=66.5%

F_wr=free water reduction in compartment

V_s=spheroid compartment volume

The fast rinse volume to reach 10 μS/cm is improved from 2.06 to 1.41 bed volumes.

Example 2: Tests with Gradual Filling of Lower Compartment

The operating conditions and fill in the main compartment were the same as in Example 1.

Results

Operating Capacity

	% of Compartment		Standard
Cycles	Containing Filling	Op. Cap. (eq/LR)	deviation
inert filling 0 ml	0	1.31	0.06
inert filling 100 ml	28.6	1.44	0.06
Inert filling 200 ml	57.1	1.48	0.02
Inert filling 300 ml	85.7	1.48	0.01
Inert filling 350 ml	100	1.47	0.07

Displacement (BV)

	% of Compartment
Cycles	Containing Filling	Displacement (BV)	St. Dev.
Regen_0	0	5.8	0.3
Regen_100	28.6	6.2	0.4
Regen_200	57.1	6.9	0.3
Regen_300	85.7	6.3	0.2
Regen_350	100	6.2	0.3

Displacement performance is substantially independent of the percent of the compartment which contains fill.

Claims

1. A fluid treatment apparatus comprising: (a) a tank comprising a bed of at least one fluid treatment medium,(b) a distributor plate separating the bed from an end portion of the tank, and(c) at least one inert medium comprising amorphous particles having a harmonic mean diameter from 2.5 to 250 mm and a density from 0.57 to 0.998 cm3/g;wherein volume of the end portion containing inert medium is from 25 to 95% of total volume of the end portion.

2. The method of claim 1 in which the amorphous particles have an average sphericity from 0.7 to 1 and an average roundness from 0.4 to 1.

3. The method of claim 2 in which volume of the end portion containing inert medium is from 30 to 90% of volume of the end portion.

4. The method of claim 3 in which the harmonic mean diameter is from 2.5 to 100 mm.

5. The method of claim 4 in which the amorphous particles have an average sphericity from 0.7 to 0.95 and an average roundness from 0.45 to 0.95.

6. The method of claim 5 in which the fluid treatment medium is an ion exchange resin.

7. The method of claim 6 in which volume of a lower end portion containing inert medium is from 40 to 90% of volume of the lower end portion