The Problems

The need to reduce the hardness of water is the most

common form of water treatment. Hard water is
created when naturally soft rain water percolates
through subterranean rock strata and dissolves many
solids including, in particular, Calcium and Mangnesium.
There are many areas therefore where the supply water
contains a significant level of these salts. It is called hard
water because of the hard deposits created when this
type of water is used in many applications.

The deposits are often called scale. However it is

actually more like concrete, forming a thick coating on
heat exchange elements and the insides of boilers,
tanks and pipes. In addition, the hard minerals left in
solution significantly detract from the performance of
soaps and detergents which then have to be used in
greater quantities to achieve the necessary cleaning
performance. This not only adds to the level of deposits
occurring inside systems and equipment, it also adds
significantly to the chemical waste discharged into our
sewer systems.
Duplex softeners can be specified with a number of
The other main problem created by scale build up is the different valve options depending on size and
reduction in efficiency of all heat exchange systems due manufacturer preference. The one above is a Fleck
to the insulating effect of the deposit. This will increase 9000 SE digital valve in a “slave / master”
the energy costs and, in addition, can create configuration. On larger systems there may be two
overheating on the surfaces of the heat source, thereby complete valves with a seperate control box.
causing premature failure.

The Solutions Duplex Softeners

A cost effective way to solve these problems is to Duplex softeners function similar to simplex units,
remove the dissolved hard mineral salts from the water except that they consist of two resin columns where
and exchanging them with “soft salts” which are more one is in service and the second is in standby. The
soluble and therefore do not form hard scale. This is flow of water to service is metered and when the
achieved by using one of our wide range of fully first column reaches exhaustion the control valve
automatic water softeners. automatically switches the service flow to the
second column and then regenerates the first
They work by a process know as ion exchange. The hard column. It is then put on standby until required
water passes through a high quality exchange resin again for service.
column inside a pressure vessel. The resin removes the
Calcium and Magnesium ions from solution and In this way a duplex softener is capable of giving a
exchanges them for Sodium ions . When the resin is continuous 24 hour supply of softened water.
about to become exhausted the softener commences Duplex softeners are therefore ideal for sites with
the regeneration phase which is initiated by timer or large variations in water demand and for
volume control. The actual regeneration is achieved applications where a continuous and uninterrupted
when the softener draws a solution of common salt suppy of soft water is essential.
water (brine) through the column of resin which
displaces the captured Calcium and Magnesium ions Duplexes are usually sized so that each vessel
and replaces them with the Sodium ions in the brine. regenerates once per day but more frequent
Throughout the regeneration period, the unwanted ions regens are possible as long as there is enough time
and the subsequent rinse water is flushed to drain and in between for the salt to saturate the water (The
does not enter the service line. The regeneration period minimum period is 4 hours). Paralell run systems are
takes between 60 and 120 minutes depending upon the also available on larger systems where both vessels
size of the softener and can be repeated as necessary can be online at the same time with a staggered
over many years without significant loss of performance. regen.
 Specifying & Sizing Valve Specification
Fundamentally, the size of a water softener is governed Softener control valves are sized and specified
by the amount of exchange capacity that is required according to the flow rate of the application. The inlet
by the application. The capacity of ion exchange resin and outlet connection ports generally range between
is a function of the volume of the water that passes 3/4” and 3” for standard control valves with flow rates
through it, the hardness of the incoming water, and the up to 50m3 per hour.
regeneration brine setting. On the chart below we
show the capacity of each size of softener assuming Steady demand applications are suitable for either
the feed water has a hardness of 300mg/litre (21 timer control or volume control via in-built metering.
degrees Clarke) and a brining rate of 140g NaCl per
litre of resin. The volume can be adjusted for different
levels of hardness. Another important criteria to Consumables & Maintainence
consider is the continuous flow rate required. This
affects the size of valve that can be used and Automatic water softeners need a supply of
sometimes the size of the resin column, since the water appropriate salt to make the required brine for
needs to have a minimum contact time with the resin regeneration purposes. Salt is most commonly supplied
to achieve full softening. Short time higher peak flows in 25kg bags of either granular or pellet type. This type
can be tolerated, but this sometimes results in a low of salt is manufactured specifically for water softening
level of hardness passing through into service and can purposes and has a very high purity level. Other types
increase the pressure drop across the softener. At of salt should not be used due to the levels of impurity
design flow rates you can expect a pressure drop of or additives. The only attention required from the user
between 3/4—1 bar. The minimum pressure required is is to check on a regular basis that the level of salt in
2 bar and the maximum is 8 bar. the brine tank is kept topped up to ensure a saturated
brine solution is available for regeneration. Although
All softeners require an electrical supply of 240v. softeners are very reliable, as with any other piece of
Transformers are supplied (12V for Clack and 24V for essential plant, routine servicing is strongly
Fleck). recommended. This will ensure many years of reliable
service from the plant.

Softener Sizing Table

Resin Volume (Litres) 25 50 75 100 150 250 350 500 750 1000 1250 1500 2000
(multi (multi
valve) valve)

Service Flow m3/hr 1” 1.0 2.0 3.0 4.0 6.0

1.5” 10 11.6
2” 14.0 20 24
3” 40 50 60 80

Vessel Type 935 1054 1354 1465 1665 2162 2472 3072 3672 4272 4872 6367 6386

Brine Tank Volume (Litres) 120 160 300 300 500 750 1000 1000 1000 1500 1750 1000 1500
(measuring (measuring
tank) tank)

Salt Used Per Regen (Kg) 3.5 7.0 10.50 14.0 21.0 35.0 49.0 70.0 105 140 175 210 280

Capacity Table
Resin Volume (Litres) 25 50 75 100 150 250 350 500 750 1000 1250 1500 2000

Capacity at 100ppm (m3) 12.5 25.0 37.50 50.00 75.00 125.00 175.00 250.00 375.00 500.00 625.00 750.00 1000.00

Capacity at 150ppm (m3) 8.37 16.75 25.125 33.50 50.25 83.75 117.25 167.50 251.25 335.00 418.75 502.50 670.00

Capacity at 200ppm (m3) 6.25 12.50 18.750 25.00 37.50 62.50 87.50 125.00 187.50 250.00 312.50 375.00 500.00

Capacity at 250ppm (m3) 5.00 10.0 15.00 20.00 30.00 50.00 70.00 100.00 150.00 200.00 250.00 300.00 400.00

Capacity at 300ppm (m3) 4.175 8.30 12.525 16.70 25.05 41.75 58.45 83.50 125.25 167.00 208.75 250.50 334.00

Capacity at 350ppm (m3) 3.575 7.10 10.75 14.30 21.50 35.75 50.05 71.50 107.25 143.00 178.75 214.50 286.00

Capacity at 400ppm (m3) 3.125 6.25 9.375 12.50 18.75 31.25 43.75 62.50 93.75 1250.00 156.25 187.50 250.00