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The process of water softening is essential for a huge range of industrial applications. It tackles the issue of “hard water”— which has high levels of calcium, magnesium and other minerals. This can cause debilitating limescale build-up on boilers and other vital equipment, decreasing their efficacy and causing costly downtime and other operational expenses. The heart of a water softening system is a resin bed, where an ion exchange process takes place. Hard water passes through the bed, and the calcium and magnesium ions are exchanged for sodium ions (which are similar in composition) from a brine solution, creating “soft” water. Advanced softening can be as simple as installing a small standalone unit, or as complex as a fully integrated tailored system, depending on a company’s operational needs. Because every industry and every application have specific requirements, it’s essential that a solution is installed and maintained by a professional industrial water treatment company. Below is a simple explanation of the five stages of the process, in which salt brine flows to the resin bed and goes on to create the ion exchange that effectively removes the unwanted minerals. Stage One: Fill Water flows directly into a salt storage container. Inside the container, the salt dissolves and the liquid goes on to form the brine solution that’s needed for the resin bed to facilitate the ion exchange process. Stage Two: Brining Next, the brine is sent into the resin bed/tank, which contains resin beads. This is when the ion exchange occurs; the brine absorbs the calcium, magnesium and other minerals which cause the hardness, and replaces them with sodium ions. Stage Three: Slow Brine Rinse When a defined volume of the brine solution has been used (the amount depends on flow rate and other factors which should be determined by a professional industrial water treatment company), a valve will close and prevent any more from entering. The liquid then travels on to the next stage, without the brine, and the brine (along with the unwanted minerals) is discharged safely. Stage Four: Backwash In this next stage, the liquid travels upwards at a faster flow rate than previously, through a larger resin tank. This has the effect of removing any remaining dirt and sediment and flushing it out. Stage Five: Fast Rinse After the backwash is finished, fast rinsing happens, when liquid flows very fast through the resin tank. In this stage, any leftover brine is sent through the resin beads, which will cause it to adhere to them. This is the final part of the process, after which it will start all over again. Times will vary, but on average the five stages of water softening regeneration will be complete in around two hours — however this will depend on the type of system installed by the industrial water treatment company. High demand applications that require a continuous flow of softened water will use a complex system with two resin tanks; whereas for industries where continuous flow is not required, a standalone tank with automatic regeneration capability may be installed. Bespoke Solutions It’s imperative to install a system that is appropriate for the needs of your particular industry and application. A professional industrial water treatment company will consult on your individual needs and provide a customised solution to cater to your requirements. Not only that, they’ll set up a regular maintenance schedule, so you can rest assured your system and plant are working to their optimal ability at all times. Author Plate Sean Clifford is an advisor at AllWater Technologies Ltd, a wholly independent industrial water treatment company providing consultation and equipment, including reverse osmosis water systems. Bringing together a host of experience and specialist knowledge, the company is committed to building and maintaining long-term relationships and creating maximum value and benefit for their customers.
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