Dow

Liquid Separations

DOWEX
Ion Exchange Resin

Guide to Condensate Polishing

May 2003
Table of Contents
An Introduction to Condensate Polishing
Condensate Polishing–A Preventative Approach 3
The Role of Ion Exchange in Condensate Polishing 3
The Purpose of This Guide 4
The Type of Condensate Polishing Operation Depends on the Operating Parameters
Boiler Pressure 4
Condensate Polishing Systems Currently Used or Proposed for Operation
Cation Exchange–“Condensate Scavenging” 5
Cation/Anion Mixed Bed 5
Lead Cation Resin Followed by Mixed Bed of Strong Cation/Strong Anion Resins 7
Cation-Anion Stacked Bed (Tripol System) 7
Operating Cycle Options
DOWEX* Resin Selections for Condensate Polishing 8
Hydrogen Cycle Operation 9
BWR Primary Cycle–Neutral pH Condensate 9
Hydrogen Cycle with All Volatile Treatment (AVT) 10
The Ammonia Cycle with All Volatile Treatment (AVT) 10
Morpholine, Ethanolamine and Other Alternative Amines 11
Use of Bori
Boricc Acid
Acid in PWR Second
Secondary
ary Cycles
Cycles for Interg
Intergran
ranula
ularr Atta
Attack
ck and Stress
Stress Corros
Corrosion
ion Crack
Cracking
ing Contro
Controll 13
Factors Affecting Resin Performance
Resin Characteristics (Cation and Anion) 13
Particle Size Uniformity 13
Particle Size Uniformity and Separability for Regeneration 15
Filtration 15
Capacity 15
Selectivity 15
Bead Integrity 16
Kinetics 16
Oxidative Stability 17
Rinse and Regeneration Efficiency 17
Color 17
Resins Specifications Can Help You Select the Right Resin 17
System Operating Considerations
Temperature 18
Organics 18
Regeneration 18
Separation 18
Regenerants 20
Remixing Resin 20
System Operation 20
Dow Technical Backup
References
Figures
Figure 1. Typical Steam Turbine Loop 3
Figure 2. Particulate Filtration in a Typical Cation/Anion Mixed Bed 5
Figure 3. Battery of Condensate Polishers 6
Figure 4. Typical External Regeneration System 6
Figure 5. Lead Cation Resin with Mixed Bed Condensate Polisher 7
Figure 6. Cation-Anion-Cation Stacked Bed 7
Figure 7. Effluent Iron from New Resin Beds vs. Control Resin Bed–Nine Mile Station Unit 2 9
Figure 8. Cation Resin Selectivity vs. Cross-Linkage 10
Figure 9. Resin Beads with Gaussian and Narrow Size Distributions 13
Figure 10. Condensate Polisher Performance–DOWEX MONOSPHERE* MONOSPHERE* Resin–
Simulated Condenser Seawater Leak Studies 14
Figure 11. Condensate Polisher Performance–DOWEX
Performance–DOWEX MONOSPHERE Resin–
During Actual Condenser Leak 14
Figure 12. Sodium Ion Leakage Based on Equilibria with Hydrogen Ion 16
Figure 13. Chloride Ion Leakage Based on Equilibria with Hydroxide Ion 16
Figure 14. AnAnion Rinse Down Cu Curves–DOWEX MONOSPHERE Resins vs. Gaussian Gel Resins 17
Figure 15. Terminal Settling Velocity Distributions and After-Backwash Column Profiles
for Gaussian and Narrow Size Distribution Resins in Mixed Beds 19
Tables
Table 1. EPRI
EPRI Guidelines
Guidelines to Maximum
Maximum Impurity
Impurity Levels in PWR Steam
Steam Generator and BWR Reactor Water
Water Systems 5
Table 2. Typical Bulk Properties (H + Form) for DOWEX Cation Exchange Resins 8
Table 3. Typical Bulk Properties (OH - Fo Form) for DOWEX Anion Exchange Resins 8
Table 4. Typical Ratios of Cation to Anion Resin Used in Mixed Bed Condensate Polishing 8
Table 5. Results Summary for the Controlled Aging Studies (150 F/65 C) for Several Prototypes of the
˚ ˚

DOWEX MONOSPHERE 575C versus the DOWEX MONOSPHERE 650C Cation Resins 12

Page 2 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
An Introduction to Condensate Polishing
Condensate Polishing – A Preventative Approach
Condensate polishing is an important part of water treatment for any utility or industrial power generating system. This
includes power generating facilities using once-through steam generators (OTSG), critical and supercritical steam
generators, nuclear-fueled boiling water reactors (BWR) and pressurized water reactors (PWR).
Figure 1 is a block diagram of a typical steam-condensate loop. As shown in this diagram, steam from the boiler passes
through a series of turbines and expends most of its’ energy. The low-pressure steam is then condensed in a heat
exchanger system where it is recovered in hotwells and routed to storage tanks. This condensed water or “condensate” is
then recycled to the boiler and converted back into steam. The continuous cycling or re-circulation of the steam and
condensate is commonly referred to as the steam-condensate loop or steam-condensate cycle. Recovering and recycling
the return condensate stream is an obvious way to significantly reduce the cost of operation.
Within this cycle, some water is lost due to leaks and boiler blowdown, so a continuous make-up water source is required to
maintain the total energy within the cycle. A local river, lake or well is used as the source for make-up water. In order to
maintain a feedwater stream with a low level of dissolved solids the raw water is demineralized using ion exchange (IX)
resins, reverse osmosis (RO) membranes or a combination thereof. In some cases, demineralization of the make-up water 
is accomplished via evaporation. Regardless of the technology, the operation is commonly referred to as the “make-up water 
demineralizer” system. In most cases, the make-up water is injected into the condenser hotwells or storage tanks.
The boiler make-up water is only one determinant of feedwater purity, the other being the condensate return stream. In fact,
condensate purity is of greatest concern in high-pressure utility units, where condensate represents the bulk of boiler 
feedwater, making it the major potential source of contaminant introduction. To this end, purification or “polishing” of the
return condensate is an essential ingredient to guarantee a high quality feedwater stream to the downstream boiler.

The Role of Ion Exchange in Condensate Polishing

The role of ion exchange technology is fundamental to condensate polishing. And condensate polishing is a unique
application for ion exchange resins. Unlike treatment of make-up water, the condensate polishing system must deal
principally with impurities that arise inside the steam system itself, rather than those that figure in the raw water analysis.
These include a return condensate stream with a limitless inventory of impurities – solid, gel-like, and dissolved. These
impurities originate from a host of sources, such as vacuum-induced leaks, corrosion of metal surfaces and careless repair 
work. Under normal conditions the raw condensate is considered high quality with respect to dissolved contaminants,
however, corrosion products are picked up as the steam and condensed water pass through piping, heat exchangers and
other associated equipment in the steam-condensate loop. A far more serious threat is the inleakage of dissolved
contaminants that occurs when cooling water in the condenser system leaks into the condensate stream. For these reasons,
condensate polishing is an operation that cannot be taken casually or ignored.

Figure 1. Typical Steam Turbine Loop

Saturated
Steam
       ▼

▼ ▼
▼ ▼
HP IP LP
Turbine Turbine Turbine
     ▲
Blowdown ▲
▼

Economizer ▼
Condenser Cooling Water
Reheat Steam ▲ ▲

Boiler Hotwell
▲ Make-Up
▲ Demineralization
Water System
       ▼
Deaerator ▼
L-P Heaters Condensate
▲ Storage Raw Water
     ▲ ▼
     ▲      ▲

H-P Heaters Condensate

▼ ▼
▼ Polishers
     ▲      ▲      ▲
▼

▼ ▼

Page 3 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
 Another aspect of condensate polishing is high flow rate design, because full-flow polishing of the large flows of condensate
may be necessary. In addition, water temperatures are often high and in some systems can approach the temperature limits
of the resins.
The original designs for condensate polisher systems incorporated two approaches: 1) the use of deep beds of bead type ion
exchange resins, and 2) the use of powdered ion exchange resin presented as a precoat on a filter element. A more recent
development is the combination of a non-precoat filter system followed by a deep-bed ion exchange resin system. In all
designs the purpose of the condensate polisher is twofold: removal of suspended solids by filtration and removal of dissolved
solids by ion exchange.
For deep-bed systems the removal of suspended corrosion products occurs by in-depth filtration. This means the
suspended particulates penetrate deep into the bed of the ion exchange beads instead of their accumulation on the top
surface of the bed. The filtration capacity of a deep bed is increased via this mechanism. High flow rates and proper bead
size are critical to obtain in-depth filtration. Part of the requirement of “condensate grade” resins include a specification on
bead size distribution to balance the pressure drop and filtration characteristics with those of the surface area available for 
mass transfer and ion exchange kinetics.
Even under high flow rate conditions the dissolved ionic contaminants should be easily removed by deep-beds of ion
exchange resins. Normally the mixed bed consists of cation resin initially in the hydrogen form and anion resin in the
hydroxide form. In some cases, the cation resin is used in an amine form after an initial period in the hydrogen form. This
provides a means of extending the service cycle run length and reducing the costs associated with regeneration. More
discussion on this topic is provided in the section on “Operating Cycle Options”.
Powdered resin precoat systems offer good filtration but are limited in their demineralization capacity since the resins volume
are restricted by the available precoat depth on the septum filter. No additional information is presented in this publication for 
powdered resin systems.

The Purpose of This Guide

The primary emphasis in this publication is on the application of ion exchange resins to d eep bed condensate polishing
operations. Included are operating cycle options and a section on the factors that affect resin performance. Also presented
are the various condensate polishing systems in use or under development and the types of steam generator systems most
likely to use them.

The Type of Condensate Polishing Operation Depends on the Operating Parameters

Boiler Pressure
Low Pressure.  At steam pressures below 600 psig (41 bar), condensate polishing is normally not required. In these low
pressure systems, boiler feedwater is treated to prevent hard scale formation and corrosion in the boiler. Some type of 
chemical addition, such as phosphate addition, is used. Boiler water salts are kept from the steam cycle by control of the
entrainment carryover and by boiler blowdown. Gross particulate filtration and decarbonation are also employed.
Medium Pressure.  For boiler pressures of 600 to 2,400 psig (41 to 165 bar), control of silica, control of corrosion, and
removal of particulate matter are required. Control of silica is necessary to prevent silica from volatilizing with the steam and
depositing on the turbine blades. Makeup feedwater demineralization with an anion bed can control silica levels in the water 
if it cannot be controlled economically with boiler blowdown.
Depending on the feedwater composition and concentration, chemicals may be added to the boiler water to control
corrosion. Phosphates are typically used, but all volatile treatment (AVT) may also be used. AVT uses ammonia or other 
volatile amines to adjust water pH and control corrosion. Condensate “scavenging” is often used to remove corrosion
products from condensate returning from the turbine. Condensate scavenging uses a cation resin deep bed operated in the
sodium or amine form to filter the particulate matter. This method also removes hardness ions.
While many systems in the 600 to 2,400 psig (41 to 165 bar) pressure range do not require condensate polishing, there are
exceptions. For example, nuclear-fueled boiling water reactors (BWR) have historically been “zero solids” systems, even
though the boilers used are typically in the range of 1,250 psi (86 bar). They have stringent feedwater quality requirements
and full-time condensate polishing requirements. Neither AVT nor phosphate chemistry is practical in BWR primary systems
since condensate circulating through the nuclear r eactor has the potential for induced radioactivity.

Page 4 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
High Pressure. As pressure increases beyond 2,450 psi (169 bar), water chemistry becomes “zero solids chemistry”.
Demineralization of make-up water becomes mandatory to satisfy the water quality requirements of the major contaminant ions,
such as sodium and silica. Chemical treatment of the boiler or steam generator system shifts from phosphate to AVT using
ammonia or amines such as morpholine or monoethanolamine to elevate pH and control corrosion in the high temperature and
wet-steam areas of the steam-condensate loop. The optimum pH range depends on the materials of construction; at least 9.3
for all-ferrous systems and 8.8-9.2 for systems containing copper. Full-flow condensate polishing is a critical operation for the
removal of soluble and insoluble corrosion products, and for the removal of contaminant ions as a result of condenser inleakage.
In North America, pressurized water reactor (PWR) plants using recirculating-type steam generators (RSG’s) have focused
their secondary cycle water chemistry program on the minimization of insoluble corrosion product transport and sodium-to-
chloride molar ratio control in the tubesheet crevice areas of the steam generator. A shift to the use of organic amines
(monoethanolamine in most cases) for pH control and procedural changes in the resin regeneration process have been
instrumental in achieving the desired improvements in secondary cycle water chemistry. In addition to AVT chemistry,
hydrazine is added to scavenge trace amounts of dissolved oxygen and maintain reducing conditions.
The Electric Power Research Institute (EPRI) continues to work closely with the utility industry to help define the water 
quality requirements for PWR secondary cycles and BWR primary cycles. Table 1 provides a summary of the year 2000
revision by EPRI for the recommended guidelines of the major contaminant ions in PWR steam generator and BWR reactor 
water systems. Recognize that the values shown in Table 1 represent the maximum allowable levels to satisfy Action Level
1 status. In actual practice, plant chemists are striving for less than 1 ppb concentration levels for all contaminant ions listed
in Table 1. An understanding of the design and operational limitations of the deep-bed condensate polishing system
becomes the most critical aspect of that effort.

Condensate Polishing Systems Currently Used or Proposed for Operation

Ion exchange resins can be used in a number of ways to treat condensate. Several of the most widely used approaches will
be presented in some detail and the main features and limitations of each will be described.

Cation Exchange — “Condensate Scavenging”

Used mainly with industrial low- and medium-pressure boilers, a deep bed of a strong acid cation exchange resin operated in
the sodium or amine form can act as a “condensate scavenger.” This type unit is primarily for the removal of corrosion
products from the condensate. Insoluble particulate corrosion products are filtered in-depth on the resin bed and some
hardness ions are interchanged with the cation on the resin. The choice of cation resin ionic form depends on the chemistry
of the circulating water system.

Cation/Anion Mixed Bed

The most common ion exchange system used in condensate polishing is a mixed bed of strong acid cation exchange resin
and strong base anion exchange resin. Mixed beds produce very high quality demineralized water, because ion leakage
from either cation or anion resin is quickly removed from the water by the other resin. Deep-bed, in-depth filtration (see
Figure 2) is accomplished by maintaining the flow rate high enough to keep surface filter cakes from forming. Typically, the
flow velocity is about 50 gpm/ft 2 (120 meters/hr.). Using a bed depth of approximately 3 feet (1 meter) allows pressure drop
across the bed to be maintained at economically acceptable levels. In most cases, a mixed bed condensate polishing system
consists of several vessels operating in parallel (see Figure 3). Used resins are transferred to a separate system for cleanup
and regeneration. In some cases, systems employ disposable mixed bed resins.

Table 1. EPRI Guidelines for Maximum Impurity Levels in Figure 2. Particulate Filtration in a Typical
PWR Steam Generator and BWR Reactor Water Systems Cation/Anion Mixed Bed
Raw Condensate In
       ▲
Inlet
Action Level 1 Action Level 1 Distributor

Parameter PWR Steam Generator BWR Reactor Water  

     ▲
Sodium 5 ppb – Resin
Return

Chloride 10 ppb 5 ppb

Sulfate 10 ppb 5 ppb
Underdrain
Distributor
       ▲
       ▲
Resin
Polished Removal
Condensate Out

(Particulate shown in gray.)

Page 5 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
Hydrogen Cycle with All Volatile Treatment (AVT)
With AVT in the steam-condensate cycle, the load on the cation exchange resin is near a 1 ppm concentration level which under 
normal conditions is many orders of magnitude greater than the steady-state amount of contaminant ions, such as sodium, in
the condensate return stream. The amine used in AVT exchanges onto the functional site of the cation exchange resin. When
the service cycle run time is terminated at or before the onset of amine breakthrough, the operation of the condensate polisher is
referred to as the “hydrogen cycle”. Hydrogen cycle operation is necessary to prevent the occurrence of the sodium “spike”.
This spike occurs because residual sodium left on the cation resin after regeneration will be displaced from the resin by the
amine. The concentration of sodium in the spike is a function of the amine type and its’ concentration in the condensate, the
amount of sodium on the cation resin, and the selectivity of the cation resin for the amine relative to the sodium.
In order to extend the service run time of the condensate polishers in hydrogen cycle operation, a resin volume ratio of 2:1
cation to anion resin has been employed. Extending the run time reduces the frequency of regeneration thereby reducing the
costs associated with regeneration chemicals, manpower and waste disposal. If the TDS of the cooling water is high, as with
seawater, an increase in the percentage of anion resin in the mixed bed may be necessary to provide more protection from
influent anions (see Table 4).
With hydrogen cycle operation the utilization of the cation resin is limited. A 1996 survey4 of PWR stations in North America
indicated that only 45-65% of the cation resin converts to the amine form prior to the onset of amine breakthrough. A cation resin
with higher capacity and smaller diameter is now available commercially as DOWEX MONOSPHERE 575C (see Table 2). The
combination of greater surface area and density of exchange sites enables greater utilization of the fixed volume of cation resin.

The Ammonia Cycle with All Volatile Treatment (AVT)

Operating the polishers past the ammonia break is one way to reduce the operating costs in a system with AVT chemistry.
When operating in the ammonia cycle, ion exchange shifts from H+/OH- chemistry to NH4+/OH- chemistry. The cation resin,
now in the ammonium form, exchanges ammonium ions for contaminating ions, such as sodium. Because this on-line
ammoniation competes with the selectivity for sodium, it is essential to minimize the sodium residual on the cation resin
during the regeneration cycle. This can be achieved with the proper choice of resin products and regeneration procedures.
More discussion on this topic is provided in the section on “Factors Affecting Resin Performance.” Some operations start
with pre-ammoniated resins to eliminate step-change increases in sodium leakage. The drawback of this method is loss of 
hydrogen capacity as part of the total run length.
While increased run length and reduced regeneration costs are very attractive, there is a risk. Namely, the driving force for 
the uptake of contaminant ions is significantly reduced by virtue of hundredfold increases in the competing ion
concentrations. For instance, in the ammonia cycle, the competing ion, NH4+, is at a solution concentration near 10-5
equivalents per liter. In contrast, the competing ion, H+, in the hydrogen cycle is at a solution concentration of only 10-7
equivalents per liter. Consequently, sodium leakages will be much greater (as much as 100x) with ammonia cycle operation.
Many stations that choose to operate in the ammonia cycle use a 20% cross-linked macroporous cation resin due to a belief 
that this resin offers a higher selectivity coefficient for sodium relative to ammonia. The literature5 contains data that states
the resin’s preference for one cation over another is a function of the degree of cross-linkage within the resin matrix. Figure
8 shows this data as the relationship between the cross-linkage and ion selectivity. However, as shown in this figure, the
selectivity for sodium relative to ammonia is about 0.71 to 0.72 for both the 20% macroporous and the 10% gel cation resins.
Suffice to say, a lot more work is still required to truly understand the selectivity properties in multi-component systems.

Figure 8. Cation Resin Selectively vs. Cross-Linkage

24

22
DOWEX MSC-1
20 20
   B
   V
   D
 , 18
   t
  n
  e
  c
  r 16
  e
   P
  s
  a 14 H+ Na+ NH4+
  e
  g
  a DOWEX HGR-W2
   k 12
  n
   i DOWEX
   l
  - MONOSPHERE 650C
  s
  s 10 10
  o
  r
   C DOWEX HCR-W2
8 8

4
0.8 1.0 1.2 1.4 1.6 1 .8 2.0 2.2 2.4 2.6 2.8 3.0
Selectivity

Page 10 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
Operating in the ammonia cycle also affects the operation of the anion exchange resin. In the presence of the ammonium
ion, dissolved carbon dioxide ionizes to form the carbonate ion. Carbonate is a divalent ion, and consequently it is much
more selectively held by the anion resin in dilute solutions of monovalent ions (i.e., service cycle where the OH - ion is at a
solution concentration near 10-5 equivalents per liter). As a result, the carbonate ion will selectively displace chloride and
sulfate ions from the strong base functional sites of the anion resin.
The anion resin in a condensate polisher also serves to protect against silica contamination sourced from condenser 
inleakage and/or make-up water. But with operation in the ammonia cycle, the concentration of hydroxide ions is roughly
100 times greater than that in the hydrogen cycle. So the already low silica selectivity of the anion resin is further 
compounded by the high pH conditions. Consequently, silica leakages may be much greater with ammonia cycle operation.
The anion resin’s selectivity for silica is also affected by temperature. At temperatures in excess of 120 F (49 C), silica
˚ ˚

leakage may increase due to lower selectivity. At temperatures above 140 F (60 C), silica can hydrolyze from the resin,
˚ ˚

leaving little, if any, effective capacity for silica. Any of these conditions may dictate a condensate polisher design with a
higher percentage of anion resin.
 Aging is another consideration of anion exchange resin, particularly with respect to surface kinetics, and therefore, leakage
of sulfate ions. The deterioration of strong base anion exchange resin usually results in the formation of some weak base
functionality. Weak base sites are kinetically slower than strong base sites. If sulfuric acid comes in contact with the anion
resin due to cross-contamination during the regeneration, then the anion resin is converted to the bisulfate form. In the
subsequent rinse steps, sulfuric acid can be hydrolyzed from either two adjacent bisulfate ions or from the weak base sites of 
the resin, resulting in increased sulfate leakage. In addition, the accumulation of any of the variety of aromatic-based organic
species on the anion resin surfaces can eventually impact the resins’ surface kinetic properties. This phenomenon, too, will
cause impaired performance of the anion resin during rinse-down operations, not to mention the ability to manage condenser 
inleakage situations.

Morpholine, Ethanolamine and Other Alternative Amines

The preferred amine for pH control, formerly ammonia, depends on the system – component materials, use of condensate
polisher, etc – as well as steam-turbine design features. The amines protect the metal surfaces by disassociation to form
OH- ions, which then neutralize feed water acids. For a wider pH control over all parts of the cycle, many PWR stations have
switched to using organic amines, such as morpholine or monoethanolamine. With lower volatility compared to ammonia,
organic amines have a greater preference for water than for steam in a two-phase fluid. Consequently, organic amines yield
higher pH and provide greater protection for extraction lines, heater shells and other wet-steam regions where flow-
accelerated corrosion (FAC) is likely to occur.
Morpholine has been used with very good success in nuclear plants and in some industrial boiler applications without
condensate polishing. Improvement in corrosion protection throughout the steam-condensate circuit has been demonstrated
in PWR stations in France and the United States by raising the pH by one unit. Data is available on the use of morpholine in
systems using condensate polishers.6 Morpholine is exchanged onto a cation exchange resin in much the same manner, as
is ammonia. The selectivity, which the cation resin exhibits for morpholine, in reference to the sodium ion, is still a subject of 
much debate. In work reported by Sadler, a 10% cross-linked cation gel resin had approximately equal selectivity for 
morpholine and sodium.7 In other EPRI workshops for condensate polishing it has been reported that cation resins with a
20% cross-linked macroporous structure have a much greater selectivity for sodium relative to morpholine compared to gel
resins. However, other studies have provided data to indicate the sodium selectivity of a cation resin in a morpholine
environment depends on many factors including the quantity of sodium on the cation resin and the presence of other cationic
species, such as ammonia. One study8 in particular used pilot-size column experiments and a 10:1 equivalent ratio of 
morpholine to ammonia as the influent stream. Interestingly, the 10% gel cation resin performed equal to the 20%
macroporous cation resin with respect to sodium breakthrough.
Despite this demonstrated superiority of morpholine over ammonia, even broader protection was deemed necessary. This
situation was especially true of plants using deep-bed polishers, because of morpholine adsorption and exchange onto the
cation resin. Today, the most popular amine selection for PWR stations in North America is monoethanolamine (ETA),
adopted by some two dozen plants.

Page 11 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
While ETA has provided enormous benefits in reducing the transport of corrosion products to steam generating and
downstream components, some stations continue to experience difficulty in maintaining the desired secondary cycle
chemistry under full-flow condensate polishing conditions. Although different stations appear to have different problems, a
few common pitfalls exist. Following a chemical regeneration of the cation and anion resins, steam generator sulfate
excursions and long, sluggish rinses of the anion resin have become more commonplace. The severity of these steam
generator sulfate disturbances vary depending on the length of the pre-service rinse, the rate of flow velocity change when
switching to the full-flow service condition, and other system related factors. Resin sampling and analysis from polisher 
systems at many PWR stations clearly show that long rinse time is symptomatic of anion resin with impaired surface kinetic
properties. As a result, many PWR stations have moved to operating without the deep-bed polishers (100% by-pass),
operating with a long, extended pre-service rinse, or have begun intentionally skipping the regeneration of their anion resin.
Even still, not all stations fell victim to resin performance difficulties following their switch to ethanolamine chemistry. In fact,
a 1996 survey9 of all U.S. PWR stations indicated that the stations processing higher temperature condensate (>130 F, ˚

54°C) were the ones that reported more of the resin performance problems. This finding prompted a research effort in
accordance with EPRI to study the properties of DOWEX MONOSPHERE 650C resins under controlled laboratory
conditions in separate environments of deionized water, ammonia and ethanolamine.10 Each resin system was sampled at
regular intervals over a period of 12 weeks. TOC leachables from the cation resin and surface kinetic properties of the anion
resin were the key parameters of interest. All experiments were controlled at 150 F (66°C) and kept under deoxygenated
˚

conditions. Several samples of the DOWEX MONOSPHERE 575C cation exchange resin were included in this study to
measure the impact, if any, of a resin with higher cross-linkage. As shown in Table 5, the ethanolamine environment is
clearly the most unfavorable resulting in the greatest impairment of anion surface kinetics and all the cation resins showing
the highest degree of TOC leachable release. In comparing the two cation resin types, all prototype samples of the DOWEX
MONOSPHERE 575C resin showed improved compatibility in both the ammonia and ethanolamine environments. Work is
still in progress, however, to identify the root cause of premature impairment of anion resin kinetics for systems with
ethanolamine chemistry and elevated condensate temperature.

Table 5. Results Summary for the Controlled Aging Studies (150 F/65 C) for Several Prototypes of the DOWEX
˚ ˚

MONOSPHERE 575C versus the DOWEX MONOSPHERE 650C Cation Resins

Net Anion Net Anion Net Anion

Cation cation kinetic Cation cation kinetic Cation cation kinetic
Aging time resin ionic TOC MTC resin ionic TOC MTC resin ionic TOC MTC
Resin designation (weeks) form (ppb) (10 m/s) form (ppb) (10 m/s) form (ppb) (10 m/s)
0 Hydrogen 0 2.14  Ammonium 0 2.14 Ethanolamine 0 2.14
DOWEX 6 “ 834 2.02 “ 1,068 2.07 “ 3,343 1.82
MONOSPHERE 650C 9 “ 1,236 2.03 “ 1,494 2.02 “ 7,309 1.58
12 “ 2,041 1.88 “ 2,405 1.84 “ 18,054 1.43
0 Hydrogen 0 2.14  Ammonium 0 2.14 Ethanolamine 0 2.14
DOWEX 6 “ 785 2.09 “ 925 2.09 “ 2,386 1.95
MONOSPHERE 575C 9 “ 1,192 2.06 “ 1,319 2.06 “ 5,410 1.79
12 “ 1,905 2.01 “ 2,118 1.92 “ 13,191 1.64
0 Hydrogen 0 2.14  Ammonium 0 2.14 Ethanolamine 0 2.14
DOWEX 6 “ 797 2.09 “ 913 2.11 “ 2,505 1.90
MONOSPHERE 575C 9 “ 1,206 2.06 “ 1,310 1.99 “ 5,423 1.71
12 “ 2,110 2.02 “ 2,092 1.89 “ 13,330 1.59
0 Hydrogen 0 2.14  Ammonium 0 2.14 Ethanolamine 0 2.14
DOWEX 6 “ 745 2.03 “ 972 2.00 “ 2,795 1.92
MONOSPHERE 575C 9 “ 1,155 1.94 “ 1,386 1.93 “ 6,214 1.82
12 “ 1,892 1.92 “ 2,190 1.85 “ 15,160 1.63

Page 12 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
References
1. Smith, J.H., et.al., 3 rd EPRI Condensate Polishing Workshop, Miami 1981.

2.  Asay, R., et.al., “Advanced Resin Cleaning System at Grand Gulf Nuclear Station: Performance Update and Plant
Impact on Water Chemistry”, EPRI Condensate Polishing Workshop, September 1997.

3. Becker, M.W., “Requalification of Low-Crosslinked Resin for Iron Control”, EPRI Condensate Polishing Workshop, June
26-28, 2000.

4. Najmy, S.W., “Ion Exchanger Run Length Evaluation at Northeast Utilities Millstone Nuclear Power Station”, EPRI
Condensate Polishing Workshop, June 1996.

5. McCoy, M.J., “Resin Regeneration Essentials”, 27 th Liberty Bell Corrosion Course, Philadelphia, 1989.

6. Kristensen, J., “The Use of Morpholine at Indian Point 3 Nuclear Power Plant”, Ultrapure Water , February 1993.

7. Darvill, et.al., EPRI Condensate Polishing Workshop, 1987.

8. Libutti, B.L., et.al., “Powdered Ion Exchange Resin Performance in Morpholine Treated Condensate”, International
Water Conference, 1991.

9. Gaudreau, T., “EPRI Survey on Resin Performance with Alternate Amines”, EPRI Condensate Polishing Workshop,
June 1996.

10. McCoy, M.J., “Cation Resin Degradation in Certain Amine Forms”, EPRI Condensate Polishing Workshop, September 
1997.

11. Scheerer, C., CIPSCO, 5 th EPRI Condensate Polishing Workshop, October 29-31, 1985.

12. Harries, R.R., “Anion Exchange Kinetics in Condensate Purification Mixed Beds – Assessment and Performance
Prediction”, 5th EPRI Condensate Polishing Workshop, October 29-31, 1 985.

13. Cutler, F.M., “Testing and Evaluation of Condensate Polisher Resin”, Proceedings: Condensate Polishing and Water 
Purification in the Steam Cycle, June 1996, San Antonio, TX.

14. Stahlbush, J., et.al., “Prediction and Identification of Leachables from Cation Exchange Resins”, International Water 
Conference, November 1987.

15. Cutler, F.M., “Measurement of Cation Resin Extractables”, Ultrapure Water , Vol. 5, No. 6, 1988, pp. 40-48.

16. Najmy, S.W., “Case History for CP Optimization in a PWR Secondary Cycle with Ethanolamine”, EPRI Condensate
Polishing Workshop, February 2002.

17. Strauss, S., Power Magazine, May 1988.

Page 22 of 23 * Trademark of The Dow Chemical Company Form No. 177-01331-503

DOWEX Ion Exchange Resins
Dow Liquid Separations Offices.
For more information call Dow Liquid Separations:

Dow Europe Dow Pacific Dow North America

Dow Customer Information Group Dow Chemical Australia Ltd. The Dow Chemical Company
Liquid Separations Liquid Separations Liquid Separations
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Notice: Oxidizing agents such as nitric acid attack organic ion exchange resins under certain conditions. This could lead to anything from slight resin degradation to a violent
exothermic reaction (explosion). Before using strong oxidizing agents, consult sources knowledgeable in handling such materials.

Notice: No freedom from any patent owned by Seller or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and
may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer’s use and for ensuring
that Customer’s workplace and disposal practices are in compliance with applicable laws and other governmental enactments. Seller assumes no obligation or liability for the
information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY EXCLUDED.

Page 23 of 23 *Trademark of The Dow Chemical Company Form No. 177-01331-503