Starting up and maintaining ion exchange systems involves several critical steps to ensure efficient operation. During initial startup, regeneration cycles are essential, with careful attention to valve operations and brine concentration. The system’s controller setup is tailored to each system’s specifics. Shutdown procedures mirror startup steps in reverse, crucial for system longevity. Routine maintenance includes flushing the system regularly and conducting sample testing after backwashing to maintain system integrity. Monitoring and logging normal operating conditions are vital for troubleshooting, with various parameters like pressure, flow rate, and water quality closely monitored.

On the other hand, pellet softening systems are designed for continuous operation, reducing the need for frequent startups and shutdowns. Automation streamlines operations, with minimal manual intervention required. Maintenance for these systems is low due to automation and fewer moving parts, mainly scheduled for upgrades or comprehensive cleaning. Operational efficiency ensures a steady supply of softened water, with continuous monitoring of parameters like pH, hardness levels, and turbidity to maintain water quality. Waste management in both systems involves proper disposal of byproducts, emphasizing sustainability and environmental responsibility.

The risks associated with ion exchangers and pellet reactors encompass several key areas. Firstly, the presence of compounds in water leading to resin fouling can result in resin damage, necessitating frequent replacements. This risk is mitigated through pretreatment steps like chlorination and filtration to minimize oxidizing agents. Additionally, temperature fluctuations can harm resin beads, requiring careful monitoring and cooling measures to maintain optimal operation. Mechanism failures due to uneven liquid flow or blockages in pipes are addressed through regular maintenance and the use of distributor plates or physical filters.

Secondly, mechanical failures such as plugging, flow resistance, and fragmentation can lead to resin loss and migration, impacting system performance. Proper backwash procedures and routine water quality testing are essential to prevent these issues. Lastly, external damage to equipment during loading/unloading and improper chemical dosing can affect system efficiency, highlighting the importance of following protocols and conducting regular inspections and maintenance.

Imagine your water is hard like a rock. Pellet softening is like magic that turns that rock into a fluffy cloud! Instead of clumpy lime causing trouble, we use a cool system that makes the water softer. Hard water comes in, gets mixed up with special stuff like milk of lime or caustic soda, and swirls around in a bed of tiny particles. These particles attract the rock-like stuff in the water, turning it into soft, fluffy pellets. Once they’re big enough, they sink to the bottom, and we can scoop them out. It’s like turning hard water into a soft, fluffy dream!

This week our team has been putting in werk, my apologies work for our prototype inspection day and video. In the past, we have had comments that people do not understand what we’re selling. Thus, we thought to make a mini physical model of our solutions. Even though our project is more related to the system and cost, it is important to understand how it works. We used two fish tank pumps, one for each solution. The pellet reactor was composed of 75% a plastic water bottle with BBs to simulate the fluidized bed function of it. A fluidized bed is essentially when the solid particles in a reactor almost behave like fluid. We demonstrated this by pumping the water in from where the BBs were lying flat. With the water pumping up, the BBs shoot up and come doing in a repetitive motion. This represents the sand that gets shot up and interacts with the calcium in the water and then falls in a new pellet form. The physical model of the ion exchange tank is a little simpler: a plastic peanut butter jar was used with BBs. The water came in from the top of one side and came out the other end. The BBs sit in the bottom making up about half the jar with little to no movement. This is what would occur in an actual ion exchanger tank as the BBs represent resin beads that would absorb the calcium in the water.

In our recent project endeavors, we’ve achieved several milestones worth celebrating. Firstly, we efficiently allocated sections of the Final Design Report (FDR) to each team member, ensuring comprehensive coverage of the report’s requirements. Additionally, we meticulously prepared for the Prototype Inspection Day by outlining key presentation points and assigning specific sections to team members, culminating in the successful purchase of necessary materials for our physical model, including fish tank water pumps, hoses, and plastic containers. We also navigated Duke Energy’s filming restrictions for our upcoming plant visit, demonstrating adaptability and thorough planning. Looking ahead, our focus for the coming week includes identifying and mitigating key risks related to ion exchange and pellet softening, as well as progressing towards an 85% completion milestone for the initial draft of the Final Design Report. Furthermore, we are dedicated to finalizing our video and presentation materials for the Prototype Inspection Day scheduled for April 2nd. These accomplishments and plans reflect our commitment to excellence and strategic project management.

In the serene embrace of crystal clear waters, amidst the rhythmic melody of raindrops, our journey unfolds with the beauty of resilience amidst the raindrops. Just as nature’s elements intertwine, so do our accomplishments and plans. Like the delicate dance of rain meeting earth, we receive and integrate feedback, creating a harmonious outline akin to a final design report. We schedule moments of inspiration, setting filming dates to capture the essence of our journey, and crafting storyboards to plan our narrative’s flow. As we delve into the depths of creation, like 3D-printed sample tanks revealing intricate designs, we prepare for internal reviews with physical demonstrations, mirroring nature’s cycle of growth and evaluation. Looking forward, we navigate the currents of uncertainty, identifying risks akin to storm clouds on the horizon, compiling information for a risk register that acts as our compass in turbulent times. Despite slight delays, our journey remains on course, with drafts nearing completion and scripts ready for filming, echoing the resilience found in nature’s ever-changing landscapes.

Ready to set sail on the waves of progress, here’s a glimpse into our latest team updates! 

This week marked a significant milestone for us as we prepared for the Qualification of Quality Review Board (QRB).  Leading up to the event, we went over our financial report deliverable outline with our liaisons during our weekly meeting and got the approval to move forward with it. For that, the team met up and worked on refining our existing operations costs as well as the process flow diagrams for both ion exchange and pellet softening technologies. During QRB, the coaches present provided us with great feedback that was both constructive and affirming. 

In other news, a huge update on the continuous vendor response drawback, Karim, Jay and Manuel had a virtual meeting with 3 representatives from Veolia Water Technologies where they asked questions about their pellet softening system and reviewed the quote provided.  

With QRB behind us, we turn our focus to our next step – refining our cost estimates and delivering our financial report to Duke Energy. Stay tuned!  

Figure 2. Team Working diligently

Choo! Choo! The wheels are turning!!!

In recent accomplishments, the team successfully generated process flow diagrams and forwarded them to Duke Energy for estimating installation costs. Additionally, the sub-team focused on Ion Exchanger operations meticulously calculated the waste output from the ion exchange system. Furthermore, Camila held a productive meeting with a vendor contact from FCT Water to obtain a quote, anticipated to arrive between late this week and early next week. Meanwhile, Manuel and Karim engaged in a constructive phone discussion with a vendor representative from Veolia. Looking ahead to the upcoming week, the team aims to persist in researching and estimating operation costs for each system while continuing to pursue system quotes from vendors. Additionally, they plan to draft a comprehensive financial report and participate in a liaison update meeting scheduled for Monday, February 19th, at 2:00 PM on Teams. Notably, there are several open items pertinent to Duke Crystal River, including confirming attendance for the FDR presentation on April 23rd, providing pump specifications, detailing the disposal process for spent resin from the current ion exchanger, and contemplating system redundancy within the team’s designs. Regarding the project schedule, while refining cost estimates lags slightly due to delayed responses from vendors, the Maintenance and Operation Plan remains on schedule, slated to commence in mid-March.

Do you feel like a hard ion drifting through the water, wanting to start again? I know the calcium and magnesium ions in the Florida well water definitely do. 

This week our team continued our journey and struggles with vendors. For those of you just tuning into our blogs, our team has been contacting vendors of water softening systems to attain estimates of what a pellet reactor and cation exchanger would cost for our project. We have unfortunately had a few bumps in the road with regards to some vendors, and it has been a little scary regarding our internal deadline of March 1^st. However, we have been doubling down on vendors, persistence and annoyance is the key to success in this area. Additionally, our team has continued with the calculations on how much waste would be produced from each system in order to get better maintainance cost estimates.  As well as finalizing the current cost of the system currently in place in order to have an accurate number for comparison.