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Full Facility Water Management

Presented by: Process and Water

1. Purified (RODI) Water System & Distribution Design

2. Rain/Gray & RO Reject Water System Design

3. Acid Waste pH Neutralization System Design

What is Being Presented

Incoming Water & Its Contaminants

Suspended Solids – Rocks, Gravel, Sand,

pH – High or Low

Dissolved Ions – Salts

Bacteria

Pyrogens – Residue of Cells

Organic Carbon

Pure Water Criteria

99% Of All High Purity Water Treatment Has Three Specific Objectives For End Purity:

Ionic Purity – Measured By TDS, Resistivity Or Conductivity

Viable Organism Purity – Measure By “Total Plate Count” Test

Organic Purity – Measured By T.O.C. Testing

Pure Water

Pure Water Is Defined Differently By Different Industries And Regulatory Agencies

USP – Pharmaceutical Industry

Purified Water

Water For Injection

ASTM Grades Of Water For Manufacturing, Power Utilities And Testing Labs

Type I

Type II

Type III

Type IV

SEMI Grades Of Water For Electronics And Semiconductor Manufacturing

ASTM Grades Of Water For Electronics And Semiconductor Manufacturing

Type E-I

Type E-II

Type E-III

Type E-IV

What is Pure Water & How Do I Define Exactly What My Requirements Are???

• Facility water requirements dictate selection of equipment for:

• Pretreatment

• Primary Purification (i.e. RO)

• Storage and Distribution and “Polishing”

Component Selection

Pure Water Treatment Operations

PRE-TREATMENT:

Multi-Media Filter – Removes Suspended Solids & Particulate Matter.

Water Softener– Removes Hardness From Supply Using Ion Exchange.

Carbon Filter (de-chlorination) – Removes Oxidizing & Organic Compounds.

PRIMARY PURIFICATION:

Reverse Osmosis – Removes 99% Of Ions, Organisms & Organic Compounds (MW Greater Than 150 – 200)

POLISHING:

MBDI/Electrodeionization (EDI) - Removes Ions Using Exchange Resin, or a Combination of Resin, Membranes and Electricity.

UV Sterilization – Destroys Viable Organisms Using Ultraviolet Radiation.

Pretreatment UnitTypical Multimedia Filter, Water Softener, Carbon Filter

AdsorptionCarbon Media Filtration

• Binds Oxidizing Compounds (Chlorine) And Organic Molecules To The Surface Of The Media.

• Prevents Oxidization Of The Membrane Surfaces & Resin Used In Downstream Processes.

• Oxidation Quickly Reduces The Effectiveness Of Membranes In Removing Small MW Compounds. Oxidation “Eats Holes Into The Membrane Surfaces”

• Maintenance of Carbon Media Extremely Important To Unit Performance And Membrane Life.

• Primary Purification Equipment

• (Membrane & Ion Exchange Components)

• Reverse Osmosis (RO) Units

• Ultra-filtration (UF) Units

• Nano-filtration (NF) Units

• Electrodeionization (EDI) Units

• Ion Exchange (IX) Units (Fixed & Service DI Units)

• Gas Membrane Units

• UV Sterilization

Traditional Pure Water Processing Equipment

Reverse Osmosis

Reveres Osmosis – Excludes Ions, Organisms And Organic Compounds Greater Than 200 MW.

Significantly Concentrates Contaminants Commonly Found In Water By “Transporting” The Water Through the Membrane And Rinsing Away The Remaining Contaminates.

Not 100% Efficient…typically 65% to 75% Efficient. Feed Water equipment must be sized accordingly.

How Ion Exchange Kinetics Works

SO3-

SO3-

SO3-

SO3-

SO3-

SO3-

SO3- (CH3)3N

(CH3)3

N (CH3)3

N(CH3)3

N

(CH3)3

N(CH3)3

N

(CH3)3

N

Zn ++

H + H+H+

H+

H+

H+

H+

Cu ++

Ca++

Na +

Zn ++H + H+

H+

H+H+

H+

H+

Cu ++

Ca++

Na +

Zn ++

H + H+

H+

H+

H+

H+

H+

Cu ++

Ca++

Na +

Zn ++

H + H+

H+

H+

H+

H+

H+

Cu ++

Ca++

Na +

PO 4--

OH-OH-

SO4--

OH-

OH-

Cl- OH-

CN-

OH-

SO4--

OH-OH-

PO 4--

OH-OH-

CN-

OH-

Cl- OH-Cl-OH-

CN-

OH-

PO 4--

OH-

OH-

SO 4--

OH-

OH-

PO 4-- OH-

OH-

SO4--

OH-

OH-

CN-

OH-

Cl-OH-

Cl-

SO4--

PO 4--

CN-

SO4--Cl-

OH-OH-

OH-

Mixed Bed Service De-ionization

Electrodeionization

Electrodeionization – Effectively Removes Ions Using a Combination of Ion Exchange & Membrane Technologies.

Mixed Bed Ion Exchange Resin Used to “Capture” Cations & Anions in Water Stream. Resins “Conduct” These Captured Ions to the Positive or Negative Terminals of a DC Field Through “Ion Selective” Membranes.

Resins Act Like a “ Wire” in the Transport of Ions.

Chambers Extremely Thin in Order to Maintain Current Flow. Requires Pretreated Water for Effective Operation.

Electrical Current Continually “Regenerates” Ion Exchange Resins.

Electrical Current Minimizes Biological Growth within the Dynamic Areas of the Cell.

Minimal Maintenance Required.

EDI Technology

SDI vs. EDI

Portable Mixed Bed Exchange

• Portable Units available in Various Sizes

• Size & quantity of Vessels depends on flow rate

• Can achieve highest water quality• Doesn’t require RO for pure water

production• No waste stream during operation• Can be installed Post RO and/or in

Distribution Loop• Water Quality declines over time• Handling considerations• Off-site quality control

Electro-Deionization Considerations

• Requires single-pass RO water supply• Can be free standing or integrated

into RO unit• Sized to match RO permeate flow rate• Can’t be installed in distribution loop• Minimal power consumption:

$0.06/1,000 gallons processed• Minimal maintenance: 6–month bolt

torque• Consistent quality: 12 – 15 Meg-ohm-

cm• Long life: 10+ yrs normal operation• Designs can be hot water sanitized

• System Storage Tank

• Distribution Pump(s)

• UV Sterilization Units (Standard & “TOC Reducing”)

• Final Filter Units

• Distribution Loop Instrumentation

Traditional Pure Water Storage/Distribution Equipment

• 254 nm Wavelength Unit for Bacteria Sterilization

• 185 nm Wavelength Unit for Bacteria & TOC Reduction (less than 20 ppb)

• Intensity Monitors Available in Analog & Digital Format

UV Sterilization Units

• Select Filtration Level According to Water Quality Requirements

• Typical USP Final Filter is 0.2-micron

• Some ASTM Standards Require Tighter Levels of Filtration for TOC & Endotoxin Control

Final Filter Assembly

• Loop Supply & Return Quality (Resistivity)

• System Temperature

• Flow Rate (can also be used to control Pump VFD’s)

• TOC On-Line Monitors

• Pressure (Indicators & Transmitters)

Distribution Loop Instrumentation

• Determine “Daily” Water Consumption

• What is a “Day”?

• Average Water Usage Over Day Period

• Maximum Water Draw (Volume & Frequency)

• Space Available for Storage

• “Ideal” Design: Storage = Daily Usage

• “Not Ideal” – RO Generation Relative to Maximum Draw & Tank Size

Generation Design Considerations

Ideal:

1500 gallons/12 hour day usage…12 hour “off-time”

1500 gallon storage tank

RO Generation = 1500/720 = ~ 2 GPM

“Not ideal”:

2000 gallons/12-hr day usage, 750 gallon storage tank

600 gallons max draw in 1 hour (once/day 1st hour)

~ 130 gallons/hour average usage

Is 2 GPM OK?

1. Generation Sizing Examples

• Is 2 GPM OK….YES

2 GPM x 60 = 120 gallons generated in first hour; 600-120 = 480 gallons used from storage tank

750-480 = 270 gallons left in storage tank after 1st hour

Hours 2-12: 120 – 130 = 10 gal/hr net loss, 160 gals. stored after hour 12

More difficult situation:

2,000 gallons/12-hr day, max draw 2x/day

600 gallon draw 2x/day (4 hours apart)

~ 80 gallons per hour average usage

Is 2 GPM still OK?


• Is 2 GPM still OK….NO

After hour one, 270 gallons remain, as in previous example

After hours 2 through 4, 120 gallons added to storage

(3 hours x 40 gallons per hour net gain)

Start of hour 5…390 gallons in storage

As before, the net loss of 600 draw is 480

390 gallons - 480 gallons results in a 90 gallon deficit


• There are two ways to modify the system to meet the water demand.

• The first and least expensive option is to increase the size of the storage tank by at least 100 gallons.

• Many projects do not have additional space to allow for a larger tank.

• In that case, increasing the RO System to a 3 gpm or next larger system will meet the water demand.

4. Generation Sizing Example

• Distribution Loop Design • Individual Floors (Riser and Return)• Serpentine (continuous)• Overall Pressure Loss• Location of Distribution Equipment• Determine desired minimum velocity at maximum

use• Max draw determines Non-use Flow rate

Distribution Sizing Considerations

• 600 gallon maximum draw in hour = 10 GPM

• Also consider maximum “instantaneous” draw

• Pump Skid increments 10, 20, 30, 40 GPM etc..

Polypropylene Pipe 40 mm (1-1/4”)

Desired velocity in System during max draw: ~ 2-3 ft./sec

20 GPM, 40 mm pipe: 4.9 ft./sec

12 GPM remains at ~ 3 ft./sec

• Must Consider:

Pressure Drop per 100 ft. of pipe

May need to increase pipe size due to loop length

(Example, 40 mm Pressure loss is 3.23 PSIG per 100 ft.)

Distribution Sizing Example

• Determine Proper Equipment from User Requirements

• Obtain Daily Water Usage Information

• Determine Storage Size Available

• Size RO per Storage and Maximum Draw

• Determine Loop Design, Pressure and Flow Rate

• Select Distribution Skid for Acceptable Velocities at Minimum and Maximum Water Draw Rates

Design Review

Purified Water System Video Review

∗YouTube link for video: (Will be embedded in presentation) https://youtu.be/qlsJcDw557Q

https://youtu.be/qlsJcDw557Q

• Conservation…Save Nature’s “Most Precious” Resource

• LEED Points, Some Projects Demand LEED/Green Design

• Construction Advantages

• Cost Effective (in certain areas)

• Certain Cities or Areas Require Water Reuse or Limit the Type or Amount of Water Sent to Drain.

Why Reclaim Water

• Equipment Reject (ex: Reverse Osmosis, Backwash)

• RO Reject Water is typically clean treated water that is just higher in salt concentration.

• Rain Water from Roof Tops (Clean/Smooth)

• Max collection area for a building is determined by available roof area

• 1” of Rain = .62 gallon per ft2 (1,000 ft2 = 620 gallons)

• Avoid Storm Water Run-off Areas (ex: parking lots)

Water Reuse Collection Areas

• Toilet/Urinal Flush

• Vivarium Applications

• Cooling Tower Water Blend

• Boiler Feed Water Blend

• Irrigation

• Non-Potable Wash Areas

Recycled Water Uses

• Each person requires ~ 5 gallons per day for toilet & urinal flushing

• Turf irrigation- typical football or soccer field located within ¼-mile track (~ 2.35 acres) could require 95,000 gallons of water per month

• Cooling tower/Boiler Feed etc… as applicable

How Much Water?

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Boston 3.36 3.25 4.32 3.74 3.49 3.68 3.43 3.35 3.44 3.94 3.99 3.78

Hartford 3.15 2.65 3.57 3.88 3.89 3.99 4.00 3.66 3.48 4.14 3.84 3.35

Philly 3.03 2.65 3.79 3.56 3.77 3.43 4.35 3.50 3.78 3.18 2.99 3.56

NYC 3.3 3.3 3.8 4.1 4.3 3.6 4.3 4.0 4.0 3.1 4.0 3.6

Average Rainfall in Some Northeast Cities

New York City: $7,000.00

Chicago: $3,700.00

Houston: $7,600.00

Jacksonville: $6,800.00

Atlanta: $16,200.00

San Francisco: $12,500.00

Boston: $13,000.00

(Charges per 1,000,000 GPY facility consumption)

Institutional Rates may be half the Commercial rates

Commercial Water/Wastewater ChargesVarious US Cities (Approximate)

• Usually, a Large Cistern collects rainwater after primary filtration (vortex/downspout filter)

• Pumped to building system for “day” storage, secondary treatment/filtration and distribution

• Stored water receives some form of dis-infection (UV, chlorine injection)

• For toilets/urinals, water may also receive dye injection

• Boiler & Cooling tower feed is not dye injected

Rain Water Basic System Construction

• Initial Debri Separator

• Cistern

• Cistern transfer “sump” pump(s)

• Internal “Day” Storage Tank

• Repressurization pump(s)

• Filtration: Screen, Cyclone, Cartridge

• Dis-infection: UV, Chlorine Injection

• Bladder Pressure Tank or VFD controlled pumps

• Dye Injection

• Potable Water Valve make up

• Recycle valve/timer System

Typical System Components

• Example: 1000 person School (Student/Faculty/Staff)

• 5000 gallons per Day required

• Cistern Size relative to Roof and Rainfall

• Indoor “Day Tank” Sizing…max available volume/size

• Recirculate most of daily use

• Pressure Bladder Tank…maximize “Draw-down” (Ex.: 119G – 35)

• “Dead-head” plumbing System

• Recommend VFD’s for Pump(s)

• Do fixtures have minimum Pressure and Filtration Requirements?

• Design for Minimum “contact” maintenance

• Simplest design to meet regulations…limit instruments

• Suggest potable water supply directly into plumbing line

Rain Water System Sizing

Typical Rainwater Treatment and Pump System

• What is pH Neutralization

The chemical treatment of acid (low pH) and Alkali (high pH) levels in special waste piping streams.

pH is measured on a 0-14 scale

pH Neutralization Systems

• Assumptions:

Lab sink usage = 1.0 GPM

Cup Sink usage = 0.5 GPM

Note: Actual continuous usage is 20% to 30%

• Sample Calculation:

50 Lab sinks x 1.0 GPM = 50 GPM

25 Cup sinks x 0.5 GPM = 12.50 GPM

⁼ 62.50 GPM x 25% (actual usage) = 15.6 GPM (round up 20%) = 20 GPM

• Neutralization Tank Sizing:

20 GPM x 20 minute retention time = 400 gallon reaction tanks

Note: A typical design would include rounding neutralization tank volume to 500 gallons for a single stage design or 300 gallons for a two (duplex) stage tank design.

Flow Through pH Neutralization System Sizing

Influent pH Design Considerations

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Influent pH dictates the number of stages for flow through systems

Reagent

Grade

Waste.

Reagent

Grade

Waste

StandardAcidic

Waste Streams

Standard Basic

Waste Streams

Reagent Grade Waste

• Waste Stream 1%+ acid/caustic

• Generally two stage pH neutralization system with residence

time and number of stages based on flow rate and pH.

• Requires in process temperature monitoring or control.

Standard Grade Waste

• Waste Stream 2-6 or 8-12 pH range

• Flow through and batch systems applicable

• Residence time and number of stages based on flow rate

and pH.

pH Adjustment System Treatment Tanks/Agitation Sizing

•Residence time

•Rate of mixing

•Material Compatibility

Influent

Flow

The treatment tanks in a pH adjustment system are designed as continuously

stirred-tank reactors (CSTR). They are sized and agitated to create ideal

mixing so the pH in the tank is equivalent to the pH leaving the tank.

Important Considerations:Rate of Mixing:1.5 x tank

volume

pumping rate

required for well

mixed solution

Due to the

ideal model of

the CSTR,

multiple stages

are more

efficient then

one large

stage

Effluent

Flow

1. We discussed Purified (RODI) Water Systems & Distribution Design including Equipment Selection & Sizing.

2. We learned about Different Styles of Rain/Gray & RO Reject Water Systems and Components

3. The Design & Sizing of a Continuously Flowing Acid Waste pH Neutralization System.

In Conclusion

Process and Water Presentation

Full Facility Water Management

ASPE CEU Questions

1. High purity water is free from:

1. Minerals

2. Bacteria

3. Pyrogens

4. All the above

2. Granular activated carbon:

1. Removes chlorine in tap water

2. Removes dissolved solids in tap water

3. Reduces TOC (total organic carbon) in tap water

4. 1 and 3

3. One of the disadvantages in using Portable Mixed bed Exchange is:

1. No waste stream off the beds during operations

2. Water quality does decline over time

3. Cannot be installed in distribution loop

4. Require RO water quality feed

4. A Pure Water Generation Consideration is:

1. How much salt to put in the water softener brine tank

2. Determine daily water consumption

3. Space allotted for storage

4. 2 and 3

5. A purified water system requires in order to reduce TOC (total organic carbon) to less than

20 PPB results.

1. Acid injection

2. 185 nm (nanometer) ultraviolet system

3. None of the above

4. Pressure transmitter on the final DI water loop

6. A Distribution Sizing consideration is:

1. Location of equipment

2. How big the water softener is

3. Overall pressure loss of distribution loop

4. 1 and 3

7. Wastewater with a pH of 1.0 would be considered:

1. Alkaline

2. Neutral

3. Acidic


8. Which of the following is typically part of a continuously flowing pH neutralization system:

1. pH meter and probe

2. Mixing tank

3. Chemical injection pump

4. All the above

9. A good rule of thumb on retention time for a flow through pH neutralization system is:

1. 1-minute

2. 20 minutes


4. All the above

10. Most pH neutralization system require final monitoring of

1. Final pH

2. Final free chlorine

3. Final Flow

4. 1 and 3

11. Which of the following treatment options reduces bacteria growth in rain water?

1. Particulate filtration

2. Ultraviolet light

3. Chlorine injection

4. 2 and 3

12. Captured rain and RO reject water can be used for:

1. Cooling tower make up

2. Irrigation.

3. Flushing toilets.

4. All the above.

Answer Key:

1. 4

2. 4

3. 2

4. 4

5. 2

6. 4

7. 3

8. 4

9. 2

10. 4

11. 4

12. 4

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