GRADUATE TRAINEE PROGRAM CONFIDENTIAL

Weekly Trainee Report

Trainee Name : Rifky Hidayat Pakpahan

Mentor Name : Teguh Budi Utomo
Depart/ Area : Energy / Liquor Site
Date : July 4th, 2016

I. Background

Boiler feed water must not consist of solubel minerals and gas. To disappear or decrease
minerals and gas doing by advance process use active carbon filter, anion and cation exchanger
degasifier and mixbed echnger.

II. Process

Boiler feed water use to make steam supply from demineralization water plan that free
from minerals and gases. Minerals and gases must be eliminatid for preventive scale and corotion
in boiler. The outlet of water treatment plant still consisted small solid, minerals and gas. And the
demineralization process steep consist of :

1. Activated Carbon Filter

Activated Carbon Filter is vertical tank with active carbon inside. active carbon bed use to
filter solid and chlorine residual that still suspence in WTP outlet water, increase water
purify and decrease water smells.
Cara kerja alat :
WTP product enter in active carbon filter on top of tank. Water will direct contact with
carbon and the carbon bed will filter the solid and absorb colours and smells of water. In
the time, carbon filter will be saturate condition cause by continually use and needs to
backwash for optimal filter result. Backwash do when pressure drop between upper and
botton bed reach certain value. Backwash doing by use counter current flow inlet, thats
flow air first to make distance between carbon and then flow water from the bottom tank.
The solid that settle in bed will be out on top tank together with backwash water.
Conditioning did before the carbon filter in service with flow water and let water out for a
few minutes (wash off). Carbon filter will ready to use after wash off finished.

2. Cation Exchanger
Outlet of carbon filter will continue process use cation exchanger to reduce positif
ion minerals such as Ca+, Mg2+, Fe2+, SiO2. if it doesn’t eliminate will make scale and
corotion in equipment.

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The cation exchanger use cation exchnger resin ( acid resin ) type Amberlite IR 120 inside.
Cara kerja alat :
Inlet water will enter from top of the exchanger tank and make contact with resin.
Minerals ion will reactions with resin and produce acid substance.

Ca(HCO3)2 + 2RZH → Ca(RZ)2 + 2H2CO3

Mg CL2 + 2RZH → Mg(Cl)2 + 2HCl
NaSO4 + 2RHZ → 2Na(RZ) + NaCl

Acid from reaction will decrease cation exchanger outlet water pH.
Continually use will make resin saturated and needs to regeneration to back resin
performance. Regeration did use HCl as regerant. Before resin regeneration did, resin must
be backwashed to remove traped solid and air bubble inside. After back wash, HCl will
enter the from bottom exchanger and contact with resin for regeration. Regeneration
process will return resin formula and produce salt that will flow with outlet flow in the
middle tank. And the regeneration reaction is:

Ca(RZ)2 + HCl → 2RHZ + CaCl

Mg(Cl)2 + HCl → 2RHZ + MgCl2
2Na(RZ) + HCl → 2RHZ + NaCl

Regeration finished if the conductifity back to normal, and cation exhcanger ready to use.

3. Degasifier
Cation exchanger outlet water contain of CO2 and H2CO3 product of exchanger
reaction. H2CO3 must be reduce first because acid condition will decrease anion exchanger
ability. For efesien work, H2CO3 mus be compsed to CO2 use O2 from air and then make
it easier to separate from water using blowing air.
2H2CO3 + O2 → CO2 + 2H2O
Cara kerja alat :
Cation exchanger outlet spreyed to intermediet tank from top to make grain water
increase contact surface. Air blowed from middle of tank use blower. Contact between
water and air did by counter current flow, so CO2 transfer can more effective.

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4. Anion Exchanger
Anion exchanger have same function with cation excanger, the diffrent is to
eliminate / decrease minerals with negatif ion like CO32-, Cl-, SO4-2 in water. Anion
exchanger use Amberlite IRA-485 type resin as OH exchange.
Cara kerja alat :
Degasifeier outlet water pump to top exchanger tank and then contact with resin bed. The
minerals ion will reaction with exchanger resin as bellow:
H2CO3 + 2RZOH → CO3(RZ)2 + 2H2O
2 HCl + 2RZOH → Cl2(RZ)2 + 2H2O
H2SO4 + 2RZOH → SO4 (RZ)2 + 2H2O
H2SiO2 + 2RZOH → CO3(RZ)2 + 2H2O
The reaction produce alkali and make pH water increase when out the exchanger tank.
Continually use will make resin saturated and needs to regeneration use NaOH.
Before regeneration start, first back wash must did to eliminate solid and gas bubble. Back
wash doing by spray air and then inject water from buttom tank, conter current flow with
process. After back wash finish, NaOH injected to exchanger tank from tank bottom and
out from outlet nozzle in middle tank body. And regeneration reaction process follow
reaction as below:

CO3(RZ)2 + NaOH → Na2CO3 + RZOH

Cl2(RZ)2 + NaOH → NaCl+ RZOH
SO4 (RZ)2 + NaOH → Na2SO4 + RZOH
CO3(RZ)2 + NaOH → Na2SiO3 + RZOH

The product water of cation exchanger will saved in Demin tank.

5. Mix bed Poilisher

Mix bed poslisher is ion exchanger that use two type resin, cation resin and anion
resin. Demin water will pumped to mix bed polisher to eliminate positif and negatif ion
that still left in water. Regeneration of saturated resin doing use HCl and NaOH at once,
HCl come from buttom and NaOH on top inlet. And regeneration outlet in the middle of
tank.
Product of mixbed pilisher will pump to mixing demin tank and then will mixing
with steam condensat.

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6. Condensat Filter.
Saturated steam that condesated in process send back demineralization plant to
condensat tank for conductifity monitoring. Return condensat consist of suspend solid
and oil that needs to wliminate use condesat filter. Condensat filter that use is anthracine.
Filter cleared use backwash method.
Product of ceondensat filter will mixed with demineralize water in mixing tank and ready
to use for boiler feed water.

For keep the water quality, process must complicated standart parameters as below:

Carbon Filter
Deskripsi unit min max
Resudial Cl2 ppm 0,1

Cation exchanger outlet

Deskripsi unit min max
pH 3,2 3,7
Conductivity μs/cm 80
FMA ppm 7
CO2 ppm

Intermediet Tank
Deskripsi unit min max
pH 3,2 3,7
Conductivity μs/cm 80
FMA ppm 7
CO2 ppm 2

Anion Exchanger outlet

Deskripsi unit min max
pH 6,5 9,5
Conductivity μs/cm 10
SiO2 ppm 1

Mix bed outlet

Deskripsi unit min max
pH 6,5 8
Conductivity μs/cm 1
SiO2 ppm 0,02

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7. Demineralization Water Flow Diagram

Blower
Fresh Air

Saturated Steam
From Process

Intermediet
Tank
Condensast Tank

From Filtered
Reservoar

Condensat Filter
Carbon Filter Cation Exchanger Over Flow Anion Exchanger Mix Bed Exchanger
Outlet P-21

Condensat
Polisher
Demin Tank
Mixing Tank
Dearator

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III. Understanding new think

 Water demineralization have diffrent way when the water source is diffrent. The minerals
in water influent the process.
 Blowing air in degasifier for decompose H2CO3 menjadi CO2 use oxigen from blow air.
 Regeration in mixbed polisher can doing at once
 Acid and alkali characteristic of exchanger oulet is influence by reaction between resin and
mineral ion when exchanging process run.

IV. Literate Description

Manual book Multi Fuel Boiler, Water treatment plan dan Boiler feed water.
Powell, S.T., Water Conditioning for industry.

V. Conclusion

 The minerals in water determine demineralization process.

 Backwash and regeneration in filter bed and resin needed to stabilized and keep the
performance

Signed

Rifky Hidayat Pakpahan Teguh Budi Utomo

Graduate Trainee Mentor

Center of Excellence 2016