Demineralization with UPCORE technology

EUROWATER has supplied a new water treatment plant to one of the largest miners and producers of zinc in the world. The electrolytic zinc production plant is located in the northern part of Germany. The new water treatment plant replaces an existing one and will supply 37 m³/h boiler feed water with a conductivity less than 2 µS/cm.

Before shipment the entire plant was assembled in the work-shop in Denmark.
Before shipment the entire plant was assembled in the work-shop in Denmark.
 

The water treatment plant

The water treatment plant consist of one raw water tank, two UPCORE units and two regeneration tanks and the entire plant will be controlled with a Siemens PLC. It will also reuse the customer`s raw water- and regeneration pumps. A very special feature of this plant is that the pipe system is constructed in IR-welded PP-H, where all welds are documented, both with a tag on the weldings and a welding report. Another special feature of this unit, is that the regeneration is done with sulphuric acid (H2SO4) and not hydrochloric acid (HCI) as normally used to regenerate demineralization units. The advantage of sulphuric acid is that it do not cause any problems with chlorids in the waste water. It does generate a lot of heat though, so a special flow transmitter and an ejector device in heat resistant PVDF are installed on the acid site of the unit.

A special flow transmitter and ejector device in heat resistant PVDF are installed on the acid site of the unit.
A special flow transmitter and ejector device in heat resistant PVDF are installed on the acid site of the unit.
 

Demineralization af water

The boiler feed water is demineralized according to the patented water treatment principle of UPCORE, combining all the known advantages of water demineralisation through ion exchange with the counter-flow principle. The term UPCORE is derived from the English UPflow COuntercurrent REgeneration system in which the flow direction of operation and regeneration is opposite. Thus, it is ensured that the water being demineralised constantly meets the ion exchangers (resin) that are better and better regenerated concurrently with the water passing through the ion exchange column. The principle ensures that the treated water leaves the best regenerated ion exchangers last.

Optimum utilisation of regenerant chemicals

Another advantage of the UPCORE principle are also to provide for more efficient use of the regenerant chemicals: hydrochloric acid and sodium hydroxide. The consumption of these chemicals is carefully balanced so that the need for neutralisation and rinse water is minimal, which benefits both the working environment and the surrounding environment.

Self-cleaning operating principle

However, the most groundbreaking feature of the operational mode is that the plant is self-cleaning, i.e. particulate impurities admitted via the water supply, broken ion exchangers (resin fines), etc. are rinsed out with every regeneration. This reduces the plant's pressure loss, thereby keeping the loss at a constantly low level. The self-cleaning effect makes it unnecessary to take out the ion exchangers from the water treatment plant itself to clean them. Furthermore, there is no need for water or air to keep the ion exchangers in position in connection with the plant regeneration.

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