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The prolonged use of hard water in industrial processes has consequences that can cause premature damage to expensive plants and equipment, due to limescale build-up. This is rather more prevalent in the UK, where public water is not suitable for industrial processes due to high levels of calcium and magnesium. An industrial water softener provides a good solution for reducing calcium and magnesium ions for industrial use. So why is there such a need to correct this hardness? The geographic formation of most areas in the UK is made up of sedimentary rocks, such as limestone, chalk, sandstone, and flint. These rocks have a high content of calcium and magnesium, and when rain falls on the rock surface, the minerals dissolve and form hard water. Therefore, in the case of industrial use, it causes limescale buildup that damages the equipment and reduces the efficiency of boilers, among other things. Industrial water softeners work by ion exchange processes to replace calcium and magnesium ions with sodium ions in two different types of systems: simplex and duplex. Simplex and Duplex water softeners During the ion exchange process, hard water passes through a pressure vessel that contains resin columns and resin beads charged with sodium ions. The sodium ions replace calcium and magnesium ions to reduce the content of these minerals to the required levels. The unfiltered wastewater (with a high content of calcium and magnesium) is flushed out into the drainage system. This is how both the simplex and duplex systems work. Over time, the resin beads become less efficient, requiring regeneration or rejuvenation. During the regeneration cycle, the resin column is supplied with saltwater (brine) to remove the calcium and magnesium ions, which are flushed out into the drainage system. The process takes about 60 to 120 minutes. During this time, there is a cut-off supply until regeneration stops. Difference Between the Simplex and Duplex Industrial Water Softeners There are distinct differences between the two systems, and they are as follows: Resin Columns The simplex type contains a single column responsible for the process of ion exchange, while the duplex type has two columns to complete the same process. Intermittent regeneration When the simplex type softener undergoes regeneration, the supply of soft water stops because, during this time, the vessels are not operational to clean and recharge the resins. On the other hand, with the duplex type, when the resins are nearing exhaustion and need to undergo regeneration, the second tank automatically picks up and continues feeding the industrial processes. A continuous supply prevents any interruptions in the workflow. Application Because of the temporary cut-off supply of soft water, the simplex type is not suitable in commercial settings where there is a 24/7 supply requirement. It can only be suitable where the need is moderate, such as in light commercial applications or large residential buildings, for instance. The dual type, on the other hand, is suitable where a constant supply is a requirement. Get Expert Advice on the Correct System Soft water is a requirement in industrial settings to prolong the life of machinery and equipment. It doesn’t contain high levels of calcium and sodium, two minerals that cause damage to plants because of limescale buildup. Depending on the need for supply, you can choose between simplex and dual industrial water softeners, however, it is important to consult an expert company to recommend the type of system suitable for your needs. Author Plate Sean Clifford is an advisor at AllWater Technologies Ltd, a wholly independent company providing consultation and water treatment equipment, including deionised water system technology and effluent treatment plant. 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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