Ion exchange regeneration plant

Claim 2

A process for the regeneration of at least partially exhausted cation exchange material and at least partially exhausted anion exchange material, which comprises: feeding at least partially exhausted cation exchange material to a first enclosed regeneration zone to form a bed thereof therein; feeding at least partially exhausted anion exchange material to a second enclosed regeneration zone physically separate from said first enclosed regeneration zone to form a bed thereof therein; forming a dilute aqueous solution of hydrochloric acid by mixing concentrated hydrochloric acid and substantially deionized water in a first mixing zone located externally of said first enclosed regeneration zone; feeding said dilute aqueous hydrochloric acid into said first enclosed regeneration zone and flowing said dilute aqueous hydrochloric acid downwardly under a positive pressure and in contact with said bed of the cation exchange material contained in said first enclosed regeneration zone to a location at substantially the lower extremity of the bed of cation exchange material to effect regeneration of said at least partially exhausted cation exchange material; flowing said dilute hydrochloric acid from said location at substantially the lower extremity of the bed upwardly through the bed of cation exchange material out of physical contact therewith to an outlet from the first regeneration zone above the upper extremity of the bed; recovering regenerated cation exchange material from said first enclosed regeneration zone; forming a dilute aqueous solution of sodium hydroxide by mixing concentrated sodium hydroxide solution and substantially deionized water in a second mixing zone physically separate from said first mixing zone and located externally of said second enclosed regeneration zone; feeding said dilute aqueous solution of sodium hydroxide into said second enclosed regeneration zone and flowing said dilute aqueous sodium hydroxide solution downwardly under a positive pressure and in contact with said bed of anion exchange material contained in said second enclosed regeneration zone to a location at substantially the lower extremity of the bed of anion exchange material to effect regeneration of said at least partially exhausted anion exchange material; flowing said dilute sodium hydroxide solution from said location at substantially the lower extremity of the bed upwardly through the bed of anion exchange material out of physical contact therewith to an outlet from the second regeneration zone above the upper extremity of the bed; and recovering regenerated anion exchange material from said second enclosed regeneration zone.

Claim 3

The process of claim 1 wherein said regeneration steps are effected substantially simultaneously.

Claim 4

The process of claim 1 wherein said at least partially exhausted cation exchange material and anion exchange material are obtained from a plurality of exhausted service demineralizers employing the mixed bed principle, in which each service unit is filled with a mixed bed of exhausted anion and cation exchange materials.

Claim 5

The process of claim 3 wherein said mixed bed of ion-exchange material is subjected to the steps of: contacting the mixed bed with sodium chloride solution to ensure that said ion-exchange material is completely exhausted; contacting the mixed bed with a sanitizing fluid to kill any microorganisms in said bed; contacting the mixed bed with hydrochloric acid to effect stripping of calcium salts from anion exchange material and organic materials from anion and cation exchange material in said mixed bed and thereby to cause said anion exchange material to be in chloride form; and effecting substantially complete hydraulic separation of said anion exchange material from said cation exchange material while simultaneously effecting backwashing of said ion exchange material to remove particulates therefrom and wherein said hydraulically-separated ion-exchange materials are separately fed to their respective regeneration zones.

Claim 6

The process of claim 4 wherein each of said contact steps is followed by a washing step utilizing substantially calcium-free water to remove the chemical used in said contact step, and said hydraulic separation is effected using substantially calcium-free water.

Claim 7

The process of claim 4 or 5 wherein said hydrochloric acid used in said calcium and organic stripping step is constituted by partially spent hydrochloric acid from said cation exchange material regeneration.

Claim 8

The process of claim 1, 2 or 4 including: in said first enclosed regeneration zone prior to said regeneration of said exhausted cation exchange material, subjecting said exhausted cation exchange material to backwashing to remove therefrom particulate matter contained therein; and in said second enclosed regeneration zone prior to said regeneration of said exhausted anion exchange material, subjecting said exhausted anion exchange material to backwashing to remove therefrom particulate matter contained therein.

Claim 9

The process of claim 7 wherein said backwashing in both said first and second enclosed regeneration zones is effected using substantially calcium-free water.

Claim 10

The process of claim 7 including, in said second enclosed regeneration zone following said backwashing and prior to said regeneration of said exhausted anion exchange material, contacting said exhausted anion exchange material in the chloride form with sodium hydroxide solution to convert said exhausted anion exchange material in chloride form to hydroxyl form.

Claim 11

The process of claim 9 wherein said sodium hydroxide solution used in said chloride conversion is constituted by partially spent sodium hydroxide solution from said anion exchange material regeneration.

Claim 12

The process of claim 10 wherein said hydrochloric acid used in said calcium and organic stripping step is constituted by partially spent hydrochloric acid from said cation exchange material regeneration.

Claim 13

The process of claim 11 including: collecting partially spent aqueous hydrochloric acid solution from said cation exchange material regeneration; and collecting partially spent aqueous sodium hydroxide solution from said anion exchange material regeneration.

Claim 14

The process of claim 12, including: forwarding partially spent aqueous hydrochloric acid solution used in said calcium and organic stripping step to a neutralization zone, forwarding partially spent aqueous sodium hydroxide solution used in said chloride conversion step to said neutralization zone, forwarding any partially spent aqueous hydrochloric acid solution not used in said calcium and organic stripping step to said neutralization zone; forwarding any partially spent aqueous sodium hydroxide solution not used in said chloride conversion step to said neutralization zone; monitoring the pH of the solution resulting in said neutralization zone from said forwarding steps, and adding neutralizing chemical as required to said resulting solution to effect substantial neutralization thereof for discharge.

Claim 15

The process of claim 3 including mixing said regenerated anion exchange material and said regenerated cation exchange material to form a mixed bed thereof in desired proportions, and charging said mixed bed to empty service units.

Claim 16

The process of claim 14 including passing said mixed bed into a pressure vessel, pressurizing said mixed bed in said pressure vessel using substantially deionized water, and effecting said charging of said empty service units by flowing a slurry of said mixed bed into said units under the pressure of said substantially deionized water.

Claim 17

The process of claim 1, 5, or 15 wherein said substantially calcium-free water and said substantially deionized water are formed by the steps of: subjecting municipal water supply to filtration to remove particulates therefrom and activated carbon bed treatment to remove organic material and chlorine therefrom, subjecting part of the treated water resulting from said filtration and carbon bed treatment steps to contact with ion exchange material in the sodium form to remove calcium ions therefrom and form said substantially calcium-free water, and subjecting the remainder of said treated water to deionization to form said substantially deionized water.

Claim 18

The process of claim 17 wherein said remainder of said treated water is heated prior to said deionization.

Claim 19

The process of claim 1 wherein said regeneration of said cation exchange material and said regeneration of said anion exchange material are each followed by rinsing the respective material with substantially deionized water to remove regeneration chemical substantially completely therefrom.

Claim 20

A regeneration apparatus for the regeneration of at least partially exhausted cation exchange material and at least partially exhausted anion exchange material, which comprises: a first upright enclosed regeneration vessel for effecting regeneration of exhausted cation exchange material therein; a second upright cylindrical enclosed regeneration vessel for effecting regeneration of exhausted anion exchange material therein; first vacuum aspirator means; first conduit means connecting a first inlet to said first vacuum aspirator means to a concentrated acid regenerant chemical storage vessel and second conduit means connecting a second inlet to said first vacuum aspirator means to a source of deionized water; third conduit means connecting an outlet from said first vacuum aspirator means to an inlet to said first regeneration vessel located in a top closure thereof for feeding dilute acid regenerant chemical formed by mixing said concentrated acid regenerant chemical and deionized water therein from said first vacuum aspirator means to said first regeneration vessel to effect regeneration of exhausted cation exchange material therein by flowing said dilute acid regenerant chemical downwardly through and in contact with a bed of cation exchange material supported in said first regeneration vessel; said first regeneration vessel including conduit means extending downwardly from an outlet in said top closure to a location adjacent the bottom thereof to receive and convey therein spent acid regenerant chemical to said outlet and screen means located at said location adjacent the bottom of the vessel for supporting said bed of cation exchange material in said first regeneration vessel for contact with acid regenerant chemical; said first regeneration vessel further including second inlet means located in a lower closure of the regeneration vessel below said screen means and connected to a source of calcium-free water to enable said calcium-free water to flow into the first regeneration vessel, though the screen means and through and in contact with said bed of cation exchange material to a second outlet located adjacent said top closure to effect backwashing of the exhausted cation exchange material to remove particulates therefrom prior to contact with the acid regenerant solution; said first regeneration vessel further including a third inlet located above said screen means and above the intended height of the cation exchange material in the bed for feeding a slurry of exhausted cation exchange material to the first regeneration vessel, a fourth inlet located in said top closure connected to a source of deionized water for feeding deionized water to said first regeneration vessel to effect washing of regenerated cation exchange material free of acidic regenerant chemical, a third outlet located in the lower closure for discharge of spent deionized water from the first regeneration vessel and a fourth outlet located adjacent the lower closure for discharge of regenerated cation exchange material from the first regeneration vessel as a slurry in the deionized water; second vacuum aspirator means; fourth conduit means connecting a first inlet to said second vacuum aspirator means to a concentrated alkaline regenerant chemical storage vessel and fifth conduit means connecting a second inlet to said second vacuum aspirator means to a source of deionized water; and sixth conduit means connecting an outlet from said second vacuum aspirator means to an inlet to said second regeneration vessel located in a top closure thereof for feeding dilute alkaline regenerant chemical solution formed by mixing said concentrated alkaline regenerant solution and deionized water therein from said second vacuum aspirator means to said second regeneration vessel to effect regeneration of exhausted anions exchange material therein by flowing said dilute alkaline regenerant chemical solution downwardly through and in contact with a bed of anion exchange material supported in said second regeneration vessel; said second regeneration vessel including conduit means extending downwardly from an outlet in said top closure to a location adjacent the bottom thereof to receive and convey therein spent alkaline regenerant chemical to said outlet and screen means located at said location adjacent the bottom of the vessel for supporting said bed of anion exchange material in said second regeneration vessel for contact with said alkaline regenerant chemical; said second regeneration vessel further including second inlet means located in a lower closure of the regeneration vessel below said screen means and connected to a source of calcium-free water to enable said calcium-free water to flow into the second regeneration vessel, through the screen means and through and in contact with said bed of anion exchange material to a second outlet adjacent said top closure to effect backwashing of the exhausted anion exchange material to remove particulates therefrom prior to contact with the alkaline regenerant solution; said second regeneration vessel further including a third inlet located above said screen means and above the intended height of the anion exchange material in the bed for feeding a slurry of exhausted cation exchange material to the second regeneration vessel, a fourth inlet located in said top closure connected to a source of deionized water for feeding deionized water to said second regeneration vessel to effect washing of regenerated anion exchange material free of alkaline regenerant, a third outlet located in the lower closure for discharge of spent deionized water from the second regeneration vessel and a fourth outlet located adjacent the lower closure for discharge of regenerated anion exchange material from the second regeneration vessel as a slurry in deionized water.

Claim 21

A regeneration apparatus for the regeneration of at least partially exhausted cation exchange material and at least partially exhausted anion exchange material, which comprises: a first upright enclosed regeneration vessel for effecting regeneration of exhausted cation exchange material therein; a second upright cylindrical enclosed regeneration vessel for effecting regeneration of exhausted anion exchange material therein; first vacuum aspirator means; first conduit means connecting a first inlet to said first vacuum aspirator means to a concentrated acid regenerant chemical storage vessel and second conduit means connecting a second inlet to said first vacuum aspirator means to a source of deionized water; third conduit means connecting an outlet from said first vacuum aspirator means to an inlet to said first regeneration vessel located in a top closure thereof for feeding dilute acid regenerant chemical formed by mixing said concentrated acid regenerant chemical and deionized water therein from said first vacuum aspirator means to said first regeneration vessel to effect regeneration of exhausted cation exchange material therein by flowing said dilute acid regenerant chemical downwardly through and in contact with a bed of cation exchange material supported in said first regeneration vessel; said first regeneration vessel including conduit means extending downwardly from an outlet in said top closure to a location adjacent the bottom thereof to receive and convey therein spent acid regenerant chemical to said outlet and screen means located at said location adjacent the bottom of the vessel for supporting said bed of cation exchange material in said first regeneration vessel for contact with acid regenerant chemical; said first regeneration vessel further including second inlet means located in a lower closure of the regeneration vessel below said screen means and connected to a source of calcium-free water to enable said calcium-free water to flow into the first regeneration vessel, though the screen means and through and in contact with said bed of cation exchange material to a second outlet located adjacent said top closure to effect backwashing of the exhausted cation exchange material to remove particulates therefrom prior to contact with the acid regenerant solution; said first regeneration vessel further including a third inlet located above said screen means and above the intended height of the cation exchange material in the bed for feeding a slurry of exhausted cation exchange material to the first regeneration vessel, a fourth inlet located in said top closure connected to a source of deionized water for feeding deionized water to said first regeneration vessel to effect washing of regenerated cation exchange material free of acidic regenerant chemical, a third outlet located in the lower closure for discharge of spent deionized water from the first regeneration vessel and a fourth outlet located adjacent the lower closure for discharge of regenerated cation exchange material from the first regeneration vessel as a slurry in the deionized water; second vacuum aspirator means; fourth conduit means connecting a first inlet to said second vacuum aspirator means to a concentrated alkaline regenerant chemical storage vessel and fifth conduit means connecting a second inlet to said second vacuum aspirator means to a source of deionized water; and sixth conduit means connecting an outlet from said second vacuum aspirator means to an inlet to said second regeneration vessel located in a top closure thereof for feeding dilute alkaline regenerant chemical solution formed by mixing said concentrated alkaline regenerant solution and deionized water therein from said second vacuum aspirator means to said second regeneration vessel to effect regeneration of exhausted anions exchange material therein by flowing said dilute alkaline regenerant chemical solution downwardly through and in contact with a bed of anion exchange material supported in said second regeneration vessel; said second regeneration vessel including conduit means extending downwardly from an outlet in said top closure to a location adjacent the bottom thereof to receive and convey therein spent alkaline regenerant chemical to said outlet and screen means located at said location adjacent the bottom of the vessel for supporting said bed of anion exchange material in said second regeneration vessel for contact with said alkaline regenerant chemical; said second regeneration vessel further including second inlet means located in a lower closure of the regeneration vessel below said screen means and connected to a source of calcium-free water to enable said calcium-free water to flow into the second regeneration vessel, through the screen means and through and in contact with said bed of anion exchange material to a second outlet adjacent said top closure to effect backwashing of the exhausted anion exchange material to remove particulates therefrom prior to contact with the alkaline regenerant solution; said second regeneration vessel further including a third inlet located above said screen means and above the intended height of the anion exchange material in the bed for feeding a slurry of exhausted cation exchange material to the second regeneration vessel, a fourth inlet located in said top closure connected to a source of deionized water for feeding deionized water to said second regeneration vessel to effect washing of regenerated anion exchange material free of alkaline regenerant, a third outlet located in the lower closure for discharge of spent deionized water from the second regeneration vessel and a fourth outlet located adjacent the lower closure for discharge of regenerated anion exchange material from the second regeneration vessel as a slurry in deionized water.

Claim 22

A process for the regeneration of at least partially exhausted cation exchange material and at least partially exhausted anion exchange material obtained from a plurality of exhausted service demineralizers employing the mixed bed principle in which each service unit is filled with a bed of exhausted anion and cation exchange materials, which comprises: contacting the mixed bed with sodium chloride solution to ensure that said ion-exchange material is completely exhausted; contacting the mixed bed with a sanitizing fluid to kill any microorganisms in said bed; contacting the mixed bed with hydrochloric acid to effect stripping of calcium salts from anion exchange material and organic materials from anion and cation exchange material in said mixed bed and thereby to cause said anion exchange material to be in chloride form; effecting substantially complete hydraulic separation of said anion exchange material from said cation exchange material while simultaneously effecting backwashing of said ion exchange material to remove particulates therefrom, separately feeding the hydraulically-separated at least partially exhausted cation exchange material to a first enclosed regeneration zone and the hydraulically-separated at least partially exhausted anion exchange material to a second enclosed regeneration zone physically separate from said first enclosed regeneration zone, subjecting said exhausted cation exchange material to backwashing in said first enclosed regeneration zone to remove particulate matter therefrom, subjecting said exhausted anion exchange material to backwashing in said second enclosed regeneration zone to remove particulate matter therefrom and contacting said exhausted anion exchange material in the chloride form with sodium hydroxide solution to convert said exhausted anion exchange material in chloride form to hydroxyl form, forming a dilute aqueous hydrochloric acid solution by mixing concentrated hydrochloric acid and substantially deionized water in a first mixing zone located externally of said first enclosed regeneration zone; feeding said dilute aqueous hydrochloric acid into said first enclosed regeneration zone to effect regeneration of said at least partially exhausted cation exchange material; recovering regenerated cation exchange material from said first enclosed regeneration zone; collecting partially spent aqueous hydrochloric acid solution from said first enclosed regeneration zone, passing at least part of said collected spent hydrochloric acid to said calcium and organic stripping step as the hydrochloric acid utilized therein, and forwarding the hydrochloric acid so used and any collected hydrochloric acid not so used to a neutralization zone; forming a dilute aqueous sodium hydroxide solution by mixing concentrated sodium hydroxide solution and substantially deionized water in a second mixing zone and located externally of said second enclosed regeneration zone; feeding said dilute sodium hydroxide solution into said second enclosed regeneration zone to effect regeneration of said at least partially exhausted anion exchange material to effect regeneration of said at least partially exhausted anion exchange material; recovering regenerated anion exchange material from said second enclosed regeneration zone; collecting partially spent aqueous sodium hyroxide solution from said anion exchange material regeneration, passing at least part of said collected spent sodium hydroxide to effect said chloride conversion step, and forwarding the sodium hydroxide solution so used and any collected sodium hydroxide solution not so used to said neutralization zone, monitoring the pH of the solution resulting in said neutralization zone from said forwarding steps, and adding neutralizing chemical as required to said resulting solution to effect substantial neutralization thereof for discharge.

Claim 23

A process for the regeneration of at least partially exhausted cation exchange material and at least partially exhausted anion exchange material obtained from a plurality of exhausted service demineralizers employing the mixed bed principle in which each service unit is filled with a bed of exhausted anion and cation exchange materials, which comprises: contacting the mixed bed with sodium chloride solution to ensure that said ion-exchange material is completely exhausted; contacting the mixed bed with a sanitizing fluid to kill any microorganisms in said bed; contacting the mixed bed with hydrochloric acid to effect stripping of calcium salts from anion exchange material and organic materials from anion and cation exchange material in said mixed bed and thereby to cause said anion exchange material to be in chloride form; effecting substantially complete hydraulic separation of said anion exchange material from said cation exchange material while simultaneously effecting backwashing of said ion exchange material to remove particulates therefrom, separately feeding the hydraulically-separated at least partially exhausted cation exchange material to a first enclosed regeneration zone and the hydraulically-separated at least partially exhausted anion exchange material to a second enclosed regeneration zone physically separate from said first enclosed regeneration zone, subjecting said exhausted cation exchange material to backwashing in said first enclosed regeneration zone to remove particulate matter therefrom, subjecting said exhausted anion exchange material to backwashing in said second enclosed regeneration zone to remove particulate matter therefrom and contacting said exhausted anion exchange material in the chloride form with sodium hydroxide solution to convert said exhausted anion exchange material in chloride form to hydroxyl form, forming a dilute aqueous hydrochloric acid solution by mixing concentrated hydrochloric acid and substantially deionized water in a first mixing zone located externally of said first enclosed regeneration zone; feeding said dilute aqueous hydrochloric acid into said first enclosed regeneration zone to effect regeneration of said at least partially exhausted cation exchange material; recovering regenerated cation exchange material from said first enclosed regeneration zone; collecting partially spent aqueous hydrochloric acid solution from said first enclosed regeneration zone, passing at least part of said collected spent hydrochloric acid to said calcium and organic stripping step as the hydrochloric acid utilized therein, and forwarding the hydrochloric acid so used and any collected hydrochloric acid not so used to a neutralization zone; forming a dilute aqueous sodium hydroxide solution by mixing concentrated sodium hydroxide solution and substantially deionized water in a second mixing zone and located externally of said second enclosed regeneration zone; feeding said dilute sodium hydroxide solution into said second enclosed regeneration zone to effect regeneration of said at least partially exhausted anion exchange material to effect regeneration of said at least partially exhausted anion exchange material; recovering regenerated anion exchange material from said second enclosed regeneration zone; collecting partially spent aqueous sodium hyroxide solution from said anion exchange material regeneration, passing at least part of said collected spent sodium hydroxide to effect said chloride conversion step, and forwarding the sodium hydroxide solution so used and any collected sodium hydroxide solution not so used to said neutralization zone, monitoring the pH of the solution resulting in said neutralization zone from said forwarding steps, and adding neutralizing chemical as required to said resulting solution to effect substantial neutralization thereof for discharge.