Softener Calculation

Softener Calculation
Step1 :- Get the water analysis. See that all analysis is ions are given as ppm CaCO3.
You can not add mg/l as ions and ppm as CaCO3. All ions should be in the same unit.
If not in the same unit ,first convert all ions to ppm CaCO3 and then feed in the
analysis shown below
Step 2 :- Decide on a Hardness leakage in the effluent and select the regeneration level
Step3 :- From the regeneration level select the Exchange capacity from the graph or
Table . Using correction factor you get the actual operation capacity
Step 4 :- Calculate the OBR required . OBR – output between regeneration is Service
flow rate *time the unit runs. There are many instances when OBR is given by the
customer but the flow rate is not known then OBR/time gives the flow (M3/Hr) If you
know the flow feed in the flow and service cycle duration otherwise feed the OBR .
Step 5 :-Calculate Resin Quantity
Resin quantity = Hardness load (ppm CaCO3)*OBR/ Operating capacity
Step6:- Finding the Area and diameter of the softener unit

Area = Volume/Height ( height is here is the Bed Depth )
Since we know the volume of resin and we select 1.2 M as bed depth
(Bed depth according to Resin manufacturer calculation should be between 750 mm to
2000mm .But for all practical purpose bed depth is kept between 1 to 1.5. for residential
purpose smaller bed depth may be used)
Area = Volume of Resin / Bed depth
Area = pD2/4 Where p =3.14 Therefore p/4 =3.14/4=0.785.
Area=0.785D2. Or D2 = sqrt (Area/0.785).
Step 7 :- Calculate the Salt Quantity required for Regeneration

Salt quantity in Kgs = Resin volume in M3 * regeneration Level gm/L
Step 8 :- Check linear and space Velocity

Check linear velocity. The value should be in the range of 10 – 25 M3/hr/M2. A slightly
lower value can be tolerated if the water is clear and slightly more if small increase in
the hardness leakage in the effluent can be tolerated
Linear Velocity = Flow /Area
If the Linear velocity is very high, reduce flow . For a flow of 10 M3/Hr and hardness
load of 110 ppm CaCO3 the linear velocity is very for a OBR of 120 M3 and service
Cycle of 12 Hours .Increase service cycle this will reduce the flow rate.
There are many instances where the Linear velocity is taken as a starting point for
calculation ( Click Here)
Taking the limit of 25 M3/Hr /M2 as Maximum velocity we can calculate the actual
number of regeneration per Day.
Linear Velocity = Flow /Area
Number of regeneration per day = Derived Linear velocity /Maximum Linear velocity
Say calculated linear velocity is 20 then
Number of regeneration per day =20/25 =0.8 i.e.1
Now let us consider that calculated linear velocity is 60
Number of regeneration per day =58/25 =2.32 i.e.2
Similarly if calculated linear velocity is 75 than
Number of regeneration per day =78/25 =3 .12 i.e.3
Actual Flow = (Actual Linear Velocity /N)* Actual area
Step 9 Check space velocity
Space velocity = Actual flowM3/Hr / calculated amount of resin in M3
Step10
Finding the correct OBR = OBR per Day in M3/Number of regeneration
Step 11 :- Calculate regenrant flow time and flow .
At 3M3/hr/M3 the regenrant flow in M3/hr is resin Quantity X Velocity.
Flow in M3/hr = 3 X M3 of resin
Volume in M3
Time = -------------------
Flow in M3/hr
There are times when the regenrant contact time is assumed to be 30 minutes minimum
and chemical injection flow rate is calculated on this basis.
Volume in M3 Volume in M3
Regenrant flow (M3/hr) = --------------------------- = --------------------------.
Time in hours 0.5 Hours
Step12:- Calculate Rinse timing :- Fast rinse in normally recommended between 12 –

16 M3/hr/M3 velocity. Let us be conservative and use 12 M3/hr/M3 for calculation
purpose which is normally taken by all designers.
Fast Rinse flow = 12 X Resin Qty
Volume of water per M3 of Resin
Fast Rinse period (minutes) = --------------------------------------------
Rinse Flow
Rinse volume is considered to be 5M3/M3 of resin. (5 bed volumes)
In this case = 5 X 1.071 = 5.355.
5* Resin Volume
Final Rinse period = ----------------------- X 60 = Time in Minutes
Rinse Flow rate
Step13 :- There are many instances when Slow rinse is done after Chemical injection .
This is done to flush out the excess chemical. The flow rate is same as that of injection
flow rate.
TECHNICAL DATA SHEET
Parameters Unit Values

Diameter of Vessel Meter
Diameter of vessel mm
Area of Vessel Sq. meter M2.
Bed Depth Meter
Unit HOS Meter
Resin Volume Cubic Meter
(M3)
Salt required Kgs
Hardness in influent As CaCO3
Output between M3
Regeneration(OBR)
Minimum Treatment Flow M3/Hr
Maximum Treatment flow M3/Hr
Normal flow M3/Hr M3/Hr
Period between regeneration Hours
Regeneration flow M3/Hr
Slow Rinse M3/Hr
Fast Rinse M3/Hr
Minimum pressure Kg/cm2
Maximum pressure Kg/cm2
Backwash Flow M3/Hr
Backwash period minutes
Note
1. There is no Backwash if the unit is upflow.
2. The direction of salt injection is from top to bottom in upflow units.
3. Minimum injection is taken as 30 minutes and regeneration flow rate is calculated on
this basis. Check Step no 11.

Softener Calculation

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Softener Calculation

Step6:- Finding the Area and diameter of the softener unit

Step 7 :- Calculate the Salt Quantity required for Regeneration

Step 8 :- Check linear and space Velocity

Step12:- Calculate Rinse timing :- Fast rinse in normally recommended between 12 –

Parameters Unit Values

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