On-Site Ion Exchange Resin Cleaning via Portable Chemical Recirculation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ion exchange resins used in power plants become fouled due to organic materials and iron oxides, leading to degraded kinetic properties, which results in increased impurities in effluent waters and high replacement costs, with existing regeneration methods being ineffective and requiring costly resin disposal, especially in nuclear power plants where on-site servicing is complicated by radiation and logistical challenges.
Innovation Solution
A portable system for on-site cleaning of ion exchange resins that includes a mixing tank, pumps, and a programmable logic controller (PLC) to create and recirculate a cleaning solution, using a sulfite solution and acid to remove fouling agents, and a resin vessel with eductors to enhance exposure to the cleaning solution, allowing for regeneration and neutralization of the cleaning solution, facilitating on-site restoration without removing the resins from service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional regeneration methods are used, then resin replacement is required, but this results in high costs and resin disposal issues
Solution Approach 1:
The patent applies parameter changes by using a multi-component chemical solution with specific pH range (2-4) and controlled composition (sulfite, surfactant, chelating agent) to transform the fouling agents on resin surfaces. This chemical treatment changes the physical-chemical parameters of the fouling layers, enabling removal of organic and iron oxide contaminants that conventional methods cannot eliminate, thereby restoring resin performance without replacement
Solution Approach 2:
The patent introduces a specially formulated cleaning solution as an intermediary substance that mediates between the fouled resin and the regeneration process. This solution contains multiple active components that work synergistically to break down and remove fouling agents, acting as a bridge that enables effective cleaning without direct mechanical intervention or resin replacement
2Ease of manufacture
If resin is removed for off-site servicing, then cleaning can be performed, but this causes excessive downtime and logistical challenges
Solution Approach 1:
The patent implements self-service by enabling the resin to be cleaned in-place within the existing vessel, eliminating the need for removal and off-site servicing. The portable cleaning system brings the necessary equipment and chemicals directly to the resin location, allowing the resin to service itself without being extracted from the system, thus minimizing plant downtime and logistical complexity
3Ease of operation
If portable cleaning system is used, then on-site servicing is enabled, but this requires transporting hazardous chemicals into the plant
Solution Approach 1:
The patent applies segmentation by dividing the cleaning system into portable, modular components that can be transported and assembled on-site. The chemical solution is segmented into multiple compartments within portable tanks, and the delivery system is divided into separate pumping and distribution units. This segmentation allows the system to be transported in manageable sections and assembled within the plant, reducing security and safety hurdles associated with transporting large quantities of hazardous materials
Solution Approach 2:
The portable containment system and controlled delivery mechanism act as intermediaries that safely manage the transportation and application of hazardous chemicals. The system includes features such as sealed containers, controlled dispensing, and spill prevention mechanisms that mediate between the hazardous nature of the chemicals and the safety requirements of the nuclear facility environment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively restores the kinetic properties of ion exchange resins, reducing impurity levels and extending resin lifespan, while minimizing downtime and costs by enabling on-site cleaning and regeneration, thus improving the efficiency and safety of resin maintenance in power plants.
Implementation Method 1
using a sulfite solution and acid to remove fouling agents
Implementation Method 2
a resin vessel with eductors to enhance exposure to the cleaning solution
Implementation Method 3
pumps, and a programmable logic controller (PLC) to create and recirculate a cleaning solution
Data Source
AI summary
A system and method for on-site cleaning of an ion exchange resin is disclosed. The system includes a mixing tank in fluid communication with a resin vessel, first and second chemical sources, first, second, and third pumps, and a deionized water source. The mixing tank and pumps are mounted on a portable skid. A cleaning solution is made within the mixing tank by displacing oxygen from the tank with a nitrogen blanket, and injecting a sulfite solution, an acid, and deionized water into the mixing tank. The third pump is configured to recirculate and mix the cleaning solution, drawing the cleaning solution from the mixing tank, past an instrument bank, and back into the mixing tank until mixed. The third pump is also configured to inject the cleaning solution into the resin vessel containing the ion exchange resin. The portable system is in fluid communication with a waste sump.