Res-Kem Zeo-Tech Industrial Water Softeners are available in a wide range of self-contained packages configured in single, double, triple, and multiple unit arrangements to remove calcium and magnesium hardness from your water. Res-Kem Zeo-Tech Softeners are used for municipal, institutional, and industrial water softening applications. Single units are rated for flows up to 680 gpm. For larger flow rates, contact Res-Kem to determine whether larger or multiple units would be appropriate.

Economical and efficient, Res-Kem Zeo-Tech Softeners can be equipped for manual, semi-automatic, or full-automatic operation. Regardless of the set up, only limited technical expertise is required for operation. Res-Kem Zeo-Tech Softeners will integrate into a complete water treatment system without expensive custom field engineering and programming.

STANDARD FEATURES:

• Single Unit Flows up to 680 gpm
• FDA Approved Epoxy Lined Steel Tanks with 100 psig Design Pressure
• Top Mounted Manway
• Schedule 80 PVC Hub and Lateral Distributors
• Factory Assembled Diaphragm Valve Nest
• Steel External Piping
• Time Clock Regeneration
• Automatic Brine Float Valve
• Backwash Flow Controller

ADVANTAGES:

• Materials and Coatings Selected to Withstand Corrosive Environments
• Reliable, Low Restriction Valves
• Non-Clogging Distributors Allow Operation Over Wide Flow Rate Range and for Even Distribution
• Standard Designs Reduce Cost and Delivery Time
• Simple Operation Reduces Operator Training Requirements

OPTIONS:

• ASME Code Vessel
• Stainless Steel, Fiberglass, or Galvanized Steel Pressure Tank
• Stainless Steel, Copper, PVC, or Galvanized External Piping
• Stainless Steel, Polypropylene, Steel, CPVC, or Galvanized Internal Piping
• Differential Pressure Switch
• Pre-piped and Wired Skid
• Interconnecting Piping Between Multiple Units
• NEMA 12 or 4XFG Control Housing
• Manual Unit Isolation Valves
• Allen Bradley PLC

Why use an Industrial Water Softener?

Calcium and magnesium are hard scale forming minerals that build up on piping, heat exchangers, water heaters, boilers, and any steam equipment. This buildup results in costly repairs, increased energy consumption, plugged heat exchangers and boiler tubes. The following facilities are examples of ideal applications for water softening equipment:

• Beverage Plants
• Municipal Water Plants
• Boiler Feedwater
• Hospitals
• Laundries
• Manufacturing Plants
• Food Processing Plants
• Institutions

Case Study No. 13 – Fluoride Ion Monitoring in Drinking Water and Water Applications (or non Acid/Etching Wastewater)

Online Fluoride Ion Monitoring for Water Districts and other Water Authorities

• Simple to use inline fluoride ion monitoring system operates just as easily as any inline low flow pH system
• Reliable menu driven Industrial Ion Selective Analyzer calibrates, displays, outputs and controls all in fluoride ppm units
• Inline fluoride ion sensor is completely sealed from both sides and requires no chemical addition -- unlike many popular competing sampling fluoride analyzers

The Problem
A water district was required to monitor the levels of fluoride in the city drinking water supply. If the levels were too low, fluoride was required to be added. If fluoride levels were too high, fluoride must be removed. Because of the natural temperature variance at the measurement point, the existing sampling fluoride analyzer gave erratic results. The constant requirement of adding reagents to the sampling analyzer placed a high burden on the busy maintenance staff, and resulted in reduced plant efficiency. When the problems with the sampling fluoride analyzer could not be addressed, grab sample analysis was used. The use of constant grab sample during times of problems with the online equipment created an undue burden on the maintenance staff, and defeated the purpose of having an online fluoride monitoring system.

Since multiple measurement points were required, a complex system of piping was installed to deliver sample to the few sampling analyzer available. One a few sampling analyzer were installed due to their prohibitively high cost. This caused the two fold problem of a delay in the measurement due to the piping of the sample to the analyzer (not real time) and the centralization cause the entire system to go down at once when problems occurred with any of the few analyzers that were installed.

The Solution
An inline fluoride ion selective sensor, specially engineered to water and wastewater application was chosen, with a rugged fluoride mono-crystal ion sensing element, and a virtually maintenance solid state reference system. In order to optimize the stability of the inline fluoride sensor measurement, a low flow sample bypass system was employed. A menu driven, simple to use, industrial ion selective transmitter and analyzer that was capable of calibrating, displaying, outputting and controlling in ppm units was selected. A convenient bayonet style twist lock inline installation style was selected for its ease of removal, facilitating the required calibration and cleaning. Calibration solutions were formulated that were ten fold (one decade) apart in value and would bracket the target concentration range. The calibration solutions were designed to closely mimic the expected ionic background of the measured solution. The calibration system simplified the validation of the online fluoride analysis system and reduced the need for grab sample calibration all while replacing the cumbersome sampling fluoride analyzer.

The Fluoride Sensor Used:
Model: AB 8100-100-10 Fluoride Ion Selective Sensor
Description: 1" MNPT Twist Lock (Quick Disconnect) ULTEM Bodied Fluoride Ion Selective Sensor; Integrated 100 Ohm Platinum Temperature Element; 10 feet cable to connect directly to Rosemount 54e-ISE Analyzer/Transmitter/Controller

Case Study No. 7 – Total Ammonia Analysis in Wastewater

Total Ammonia Determination through online ammonium ion and pH monitoring

• Industrial grade ammonium ion selective membrane and application engineered solid state conductive polymer reference can withstand the rigors of industrial process lines
• Ammonium calibration system has been optimized to yield reproducible results in a variety of wastewater systems
• Ammonia gas resistant pH sensor delivers the accuracy needed for total ammonia computation via a PLC or DCS from the ammonium ion and pH input values

The Problem
A sweetener manufacturer wanted to control the total nitrogen content in their process. This was a difficult proposition since they had a mixture of dissolved ammonia gas and ionized ammonium ions in solution. Fluctuation of process pH did not allow for a simple mathematical correction or computation, and made real time control arduous. The complex process solution necessitated significant interaction between ASTI and the customer to develop the proper custom calibration solutions. The total nitrogen must be calculated based upon an equation whose variables are pH and ammonium activity. Creating an accurate calibration system is a challenge in a complex system, whose primary function is not to determine simple activity, but rather a computed or derived total concentration. Common TISAB (total ionic strength adjustment buffer) solutions are often inadequate ISE standards for industrial calibrations because they do not accurately reflect the ionic strength and pH of the process solution. This application then necessitated not only determining the proper multi-point calibration for both pH and ammonia/ammonium, but also developing an interactive curve and standard ion buffer background which accurately reflected the process. Getting agreement and consistency between laboratory titrations and on-line measurement or process values was accomplished by using custom calibration solutions as the common reference standard for both the laboratory and process measurements.

The Solution
The solution was a ammonia gas resistant pH sensor and an industrial grade organic polymer ammonium ion selective sensor. Both the pH and ammonia sensor were sealed against any dissolved ammonia gas which may attack the reference element at lower pH. The reference element was designed to be insensitive to the interferences experienced by the ammonium polymer membrane. The ammonium ion analyzer, in combination with the PLC, was capable of computing the total nitrogen concentration via a multi-parameter algorithm. The multi-point calibration developed for this application allowed the PLC to create an accurate curve at any point along the operating pH range. The total ammonium analysis system was able to deliver reproducible and accurate results, replacing slow and inaccurate grab sample laboratory analysis.

The Ammonium Ion Sensor Used:
Model: AB 6410-873DPX-25 Ammonium Ion Sensor
Description: ¾"- 1" MNPT Immersion ULTEM Bodied Ammonium Ion Selective Sensor with integrated 100 Ohm Platinum Temperature Element, Stainless Steel Solution Ground and Foxboro 873DPX compatible preamplifier; 25 feet cable to connect directly to Foxboro 873DPX (Dual Channel Auto pH Compensation) pH/ISE Analyzer/Transmitter

The pH Sensor Used:
Model: PNA 6031-873DPX-25 pH Sensor
Description:¾"- 1" MNPT Immersion ULTEM Bodied Dissolved Ammonia Gas Resistant General Purpose pH Sensor with integrated 100 Ohm Platinum Temperature Element, Stainless Steel Solution Ground and Foxboro 873DPX compatible preamplifier; 25 feet cable to connect directly to Foxboro 873DPX (Dual Channel) pH/ISE Analyzer/Transmitter

Case Study No. 15 – Sodium & Calcium Ion Analysis for Water Softener Systems

Calcium (Ca++), Magnesium (Mg++) & Sodium (Na+) Ion Analysis

• Before and After Water Softener to determine Water Quality Feed to Boilers
• Industrial grade sodium ion selective membrane and application engineered solid state conductive polymer reference can withstand the rigors of industrial process lines
• Sodium calibration system has been optimized to yield reproducible results in a variety of boiler water systems

The Problem
A company wanted to automate the water quality testing on their water softener used to feed their boilers. When the softener ceased to function properly, the water softener needed to be regenerated. A delay in this service may cause damage to the boilers, eventually leading to a shutdown to clean and repair the boilers. The existing manual sampling routine or online sampling analyzers were slow and expensive, respectively. In addition, the delay caused by not having an accurate real-time online method to determine the effectiveness of the water softener could cause hard water to spread throughout the plant, leading to operational difficulties.

The Solution
ASTI's online ion selective sensors can be used to measure the effectiveness and state of the water softening system, although this measurement must be performed indirectly. The customer indicated a desire to measure the activity of calcium (Ca++) ion at a point after the water softening system. This measurement is not feasible due to the degree of excess of sodium present. The permissible ratio of excess of sodium (interfering) ion to calcium (analyte) ion for our calcium ion selective sensors is 100 fold (on a molar basis), whereas the lab analysis revealed an excess of 2600 fold (also computed on a molar basis). This then indicates that the concentration of sodium is 26 times too high to perform the calcium measurement after the water softener. ASTI found an excellent and feasible method to indirectly measure calcium after the softener and determine the effectiveness of the softening system as a whole. .

Typical Concentrations Before Softener
Sodium - Na+ = ~ 48 ppm
Calcium - Ca++ = ~ 160-250 ppm.

Typical Concentrations After Softener
Sodium - Na+ = ~ 300 ppm
Calcium - Ca++ = ~0.200-0.600 ppm.

The ion exchange system is clearly replacing calcium ions with sodium ions. If the ion exchange system fails or deteriorates, the sodium ion activity at the post softener location is changed from about 300 ppm to about 48 ppm. This is almost a step change in concentration. Measurement of such a change is an appropriate use of an inline ion selective sensor. At the post softener position, all concentrations of interfering ions for the sodium ion selective sensor are within the permissible range. The sodium ion activity as measured prior to the water softener can provide a valuable baseline sodium ion (Na+) level. The magnesium ion (Mg++) contribution to water hardness is ignored because it will be also be converted to sodium ion, which will be analyzed at the after softener measurement position. In addition, the concentration of magnesium is often five to ten (5-10) times less than calcium and usually occurs at a fixed ratio to calcium.

When the softener is functioning properly, the sodium ion (Na+) levels as measured after the softener will be quite high (~300 ppm), corresponding to a lack of calcium ion (Ca++) in the softened water (see abbreviated water analysis above). When the softener fails to work properly, the sodium ion levels at the post softener measurement point will return to the low levels as measured at the before softener measurement point (~30-50 ppm). This provides a very simple method to use the ion selective system as an alarm and indicator as to the state of the water softening system. In addition, the ion selective analyzer can automatically switch the water (via a relay) to a functioning secondary water softening system to avoid any downtime. A Rosemount 54e industrial sodium ion selective analyzer was employed to conveniently calibrate and operate in familiar ppm units. This ion selective analyzer had the necessary 4-20 mA outputs (scaled in ppm) and relays (also set in ppm) to enable the automation of this implicit water hardness (Ca++ & Mg++) determination for water quality analysis of the water softening system.

The Industrial Sodium Ion Selective Sensor Used:
Model: AB 8430-100-10 Industrial Sodium Ion Selective Sensor
Description: 1" MNPT Twist Lock Quick Disconnect ULTEM Bodied Industrial Sodium Ion Selective Sensor with integrated 100 Ohm Platinum Temperature Element; 10 feet cable to connect directly to Rosemount 54e Ion Selective (ISE) Analyzer and Transmitter

Choosing the Correct pH/ORP Sensor
1. Choose a sensor body type that suits the physical parameters of the installation (refer to the Configurations Portion of pH/ORP and Ion Selective webpages).
2. Choose a sensor that suits the process application, temperature, chemistry, and physical parameters of the installation (refer to Sensor Selection Guides and call factory or local sales agent for support)
3. Choose a sensor housing material that is compatible with the process chemistry, temperature & pressure (refer to Chemical Resistance Charts as posted under the Technical Documents portion of the website).
4. Select suitable temperature compensation element, solution ground & integrated preamplifier based upon the mating pH/ORP Instrument (refer to Electrochemical Instrumentation Page & ask for factory support).
5. Specify the required cable length based upon installation location (refer to Part Numbering Guide).

* Subject to application qualification and review by an approved ASTI sales agent and/or factory. Performance guarantee is posted on the ASTI online application questionnaire page.
** See list of supported pH/ORP/ISE Instruments webpages as posted on the ASTI website.
*** Completion of Application Questionnaire form is required. Other restrictions may apply.

Organic Membrane Ion Selective (ISE) Sensors

• Tetrafluoro Borate (BF4+)
• Hydronium (H3O+ - pH)
• Primary Amines (R-NH3+ Cl-)
• Ammonium (NH4+)
• Barium (Ba+2)
• Calcium (Ca+2)
• Carbonate (CO-3)
• Cesium (Cs+)
• Chloride (Cl-)
• Lithium (Li+)
• Magnesium (Mg+2)
• Nitrate (NO3-)
• Nitrite (NO2-)
• Potassium (K+)
• Perchlorate (ClO4-)
• Silver (Ag+)
• Sodium (Na+)

Solid State Ion Selective (ISE) Sensors

• Bromide (Br-)
• Chloride (Cl-)
• Cyanide (CN-)
• Fluoride (F-)
• Iodide (I-)
• Silver (Ag+)
• Sulfide (S-)
• Thiocyanate (SCN-)

This environmentally friendly technology will prevent the formation of scale and remove existing scale. The original, patented ScaleWatcher™ Electronic Water Conditioner is the intelligent alternative for hard water in your business. Feel safe with a money back guarantee and a ten year extended warranty. Invest under $500 and save yourself $10,000.

Problems in Industry still being solved with chemicals:

Mineral Scaling: Scalewatcher is able to prevent scaling and to remove existing layers without chemicals. There are numerous examples in Industry with successful applications. Launching the product in 1991 initiated Universities to research this phenomenon which was at the time not really understood. Now the technology is widely accepted. Thanks to managers of companies in Industry who in the early days, were not afraid being laughed at while evaluating the performance of Scalewatcher in the field. Physical water treatment has pushed back the use of chemicals, and will continue to do so.

Rust: An amazing side effect of the product on iron pipes with oxygen containing water is that rust is not

formed anymore; rust will be removed and replaced by a very thin black protective layer, called Magnetite. There are chemicals creating the same effect; Scalewatcher does it in a natural way using harmless magnetic and electric fields, without the burden of recurring costs and without polluting the environment.

Slime: A side effect to be expected is that biofilm fouling in process water will dramatically be reduced due to the cleaning effect of Scalewatcher. The breeding ground of bacteria disappears, so will the bacterium. This effect is noticeable in swimming pools but also in cooling towers. A cooling tower can run without chemicals to inhibit scale, corrosion and the growth of biofilm, when using Scalewatcher.

Water Disposal: In the civilized world Industry has to pay for its disposal of water. Blow down of steam boilers or cooling towers are examples. As most of this equipment uses automatic blow down based on the electrical conductivity of water, it is easily seen why water can be saved. The longer it takes before a certain conductivity level is reached the fewer blow downs. Adding chemicals to water will increase the conductivity. And in addition the tower can run on a higher cycle of concentration. Savings of at least 50% in water usage is possible. The total savings on water usage, cost of water disposal and cost of chemicals gives an extremely quick return on a one time investment.

These are the various types of water filtration media stocked by Res-Kem:

Anthracite Filter Coal, Anthrafilt®
Commonly used as sub-fill and as a component of multi-media filters, anthracite is a durable media with long life and a wide temperature range. It contains no silica to interfere in the production of ultra pure water.

Filter Sand and Gravel (May also be called Torpedo Sand - Coarse Sand - Support Gravel - Filter Gravel - Pea Gravel )
The filter sand and gravel we stock and distribute is 99% silica and mined in New Jersey. The sub-angular shape of silica sand enhances the mechanical filtration properties of multi-media filters. It is a dense media at 100 pounds per cubic foot and acts as perfect sub-fill for non-silica sensitive applications such as water softeners and dealkalizers.

Garnet
At 126 pounds per cubic foot garnet is typically used in multi-media filters as the sub-fill or bottom layers of the filter. Although its density requires high backwash rates combining fine mesh garnet with other media such as sand and anthracite significantly increases the filtration capacity of a system.

Filter Lite or Filter Ag®
A low-density media typically used in multi-media filters to enhance the capacity of the filter to remove smaller micron particles. At 24 pounds per cubic foot it sits as the top layer in a multi-media filter.

Catalox
A granular manganese dioxide media used primarily in potable water residential applications for the removal of hydrogen sulfide, iron and manganese. Chlorine is often used during regeneration cycle to insure full capacity.

Manganese Greensand
A dense media at 85 pounds per cubic foot. In addition to its filtration properties is can remove soluble iron, manganese and hydrogen sulfide from well water supplies.

GreensandPlus
The second generation of greensand, this media is more rugged than the original but has identical operating characteristics. GreensandPlus is a purple-charcoal filter media used for removing soluble iron, manganese, hydrogen sulfide, arsenic and radium from well water supplies.

KDF 55 & 85 KDF (Also known as a redox alloy)
KDF55 is used for the efficient removal of chlorine and mercury remediation. It is universally applied from the smallest of water filters to large municipal and industrial equipment. KDF85 removes iron, hydrogen sulfide and chloramines removal.

Neutralizing Media
Calcium Carbonate is commonly used to raise pH in residential well water supplies. Brand names include Georgia Marble or Water Neutralizer. To enhance the neutralization process the addition of magnesium oxide, Flo-Mag, may be required.

Birm®
A granular filter media commonly used for the reduction of iron and/or manganese from residential raw water supplies.

MTM®
A granular manganese dioxide used for reducing iron, manganese and hydrogen sulfide from residential water supplies.

R3 Water Technologies offers complete integration of incoming water and wastewater treatment for industrial applications for all of North America. Systems controls are designed to provide the information the customer desires (Internet monitoring, recordability, tie-in to other systems, etc.).

We offer production water pretreatment (softeners, carbon filters, bag filters, cartridge filters, etc.), Reverse Osmosis systems, holding and process tanks, complete plumbing packages, water recycling for near zero or zero discharge, and waste treatment for industrial wastestreams.

We employ our own people for design, manufacture and installation to assure our customers a timely installation of quality equipment

Resin Traps/Media Traps from Res-Kem Corp. are essential protection devices for water treatment systems. Res-Kem Corp. supplies resin traps/media traps for water lines to protect against complete loss of ion exchange resin, activated carbon media, filter media, greensand media, sand, and multimedia from an underdrain, lateral or strainer failure.

A resin trap is used on service outlet and backwash lines on:

• Cation, anion, mixed bed, and selective ion exchange resin systems
• Commercial and industrial water softeners
• Activated carbon filters
• Greensand, multimedia, sand, anthracite, etc. media filters.

The resin trap holds back escaping media at the onset of a failure. Visual monitoring will alert the operator to underdrain, lateral or strainer damage prior to catastrophic failure and extensive loss of media. An unmonitored resin/media trap will collect the ion exchange or media in the resin trap until the water flow is completely blocked, but it will still protect the downstream product, process, equipment and/or pumps from damage and contamination.

Resin Trap Benefits

• Saves your downstream product, process, equipment and/or pumps from damage and contamination
• Eliminates mass resin/media loss into piping distribution system
• Prevents loss of resin during backwashing
• Visual detection of minor resin/media losses prior to catastrophic failure of major equipment

Resin Trap Features

• PVC and stainless steel construction
• Clear acrylic tube for unobstructed viewing
• Available in 2", 3" and 4" pipe sizes
• End connection options: threaded, socket or flanged
• Resin/media blowdown valve for trap cleaning and media retrieval
• High flow rates with low pressure loss, clean trap pressure drop is < 2.0 psig