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Industrial Water Softener Plants

Automatic ion exchange systems for hardness removal - Protect your equipment from scaling

Capacity Range: 1 m³/hr to 500 m³/hr
Hardness Removal: >99% Fully Automatic Regeneration: Auto/Manual ISI & ISO Certified
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Industrial Water Softener System

Water Softening Technology

Cation exchange resin systems for effective hardness removal

Ion Exchange Principle

Hardness ions (Ca²⁺, Mg²⁺) are exchanged with sodium ions (Na⁺) from resin

2RNa + Ca²⁺ → R₂Ca + 2Na⁺ 2RNa + Mg²⁺ → R₂Mg + 2Na⁺

Regeneration Cycle

Resin regeneration with brine (NaCl) solution to restore sodium ions

R₂Ca + 2NaCl → 2RNa + CaCl₂ R₂Mg + 2NaCl → 2RNa + MgCl₂

Performance Parameters

Key specifications for optimal softener performance

Hardness Removal: >99% Resin Capacity: 50-60 g CaCO₃/L Outlet Hardness: <2 ppm

Water Softener System Types

Various configurations for different industrial requirements

Single Vessel Softener

Basic
Capacity: 1-50 m³/hr Regeneration: Time/Volume Operation: Semi-Auto

Applications: Small industries, commercial buildings, hotels, hospitals

System Components:

  • Mild Steel/FRP pressure vessel
  • Cation exchange resin
  • Brine tank with ejector
  • Multiport valve/Actuated valves
  • Control panel
1 m³/hr 5 m³/hr 25 m³/hr 50 m³/hr

Twin Alternating Softener

Continuous
Capacity: 20-200 m³/hr Operation: 100% continuous Control: Fully automatic

Applications: Medium industries, boiler feed water, process water

System Features:

  • Two softening vessels
  • Automatic lead-lag operation
  • Common brine system
  • No interruption during regeneration
  • PLC based control
20 m³/hr 50 m³/hr 100 m³/hr 200 m³/hr

Triple Unit Softener

High Capacity
Capacity: 100-500 m³/hr Duty: 2 Operation + 1 Standby Redundancy: Full backup

Applications: Large industries, power plants, refineries, municipalities

System Features:

  • Three softening vessels
  • 2 operation + 1 standby
  • Automatic switchover
  • Common brine system
  • SCADA integration
100 m³/hr 200 m³/hr 350 m³/hr 500 m³/hr

Compact Package Softener

Skid Mounted
Capacity: 0.5-10 m³/hr Footprint: Compact Installation: Plug & Play

Applications: Small industries, laboratories, commercial complexes, apartments

Package Includes:

  • Complete skid mounted system
  • Pre-piped and pre-wired
  • Ready for connection
  • FRP/SS vessels
  • Compact brine tank
0.5 m³/hr 2 m³/hr 5 m³/hr 10 m³/hr

Cation Exchange Resins

High capacity strong acid cation exchange resins for water softening

Gel Type Resin

Standard
Matrix: Styrene-DVB Capacity: 50-55 g CaCO₃/L Bead Size: 0.3-1.2 mm

Technical Specifications:

  • Type: Strong Acid Cation (SAC)
  • Ionic Form: Sodium (Na⁺)
  • Moisture Content: 45-50%
  • pH Range: 1-14
  • Max Temperature: 120°C
Applications: Standard water softening, industrial applications
25 kg bags 500 kg bags Bulk supply

Macroporous Resin

High Fouling Resistance
Matrix: Styrene-DVB Capacity: 45-50 g CaCO₃/L Fouling Resistance: High

Technical Specifications:

  • Type: Macroporous SAC
  • Ionic Form: Sodium (Na⁺)
  • Moisture Content: 50-55%
  • pH Range: 1-14
  • Oxidation Resistance: High
Applications: High organic content water, surface water, industrial wastewater
25 kg bags 500 kg bags

Food Grade Resin

FDA Approved
Matrix: Styrene-DVB Capacity: 48-52 g CaCO₃/L Certification: FDA

Technical Specifications:

  • Type: Food Grade SAC
  • Ionic Form: Sodium (Na⁺)
  • Extractables: Ultra low
  • pH Range: 1-14
  • Certification: FDA, KOSHER
Applications: Food & beverage, pharmaceutical, drinking water
25 kg bags Food grade packaging

High Capacity Resin

Premium
Matrix: Styrene-DVB Capacity: 60-65 g CaCO₃/L Efficiency: High

Technical Specifications:

  • Type: High Capacity SAC
  • Ionic Form: Sodium (Na⁺)
  • Moisture Content: 40-45%
  • pH Range: 1-14
  • Salt Efficiency: High
Applications: High hardness water, large systems, cost-sensitive operations
25 kg bags 500 kg bags Bulk supply

Pressure Vessels

High quality pressure vessels for water softener systems

Mild Steel Vessels

Rubber Lined
Sizes: 300-3000 mm dia Pressure: 3-10 kg/cm² Lining: Food grade rubber

Construction Details:

  • Material: IS 2062 MS plates
  • Lining: 3-5 mm rubber lining
  • Design: ASME/IS standards
  • Testing: Hydrotest, spark test
  • Finish: Epoxy painted exterior
Applications: Industrial water softening, cost-effective solutions
12" x 48" 24" x 72" 36" x 72" Custom

FRP Vessels

Corrosion Resistant
Sizes: 250-2500 mm dia Pressure: 3-7 kg/cm² Material: Fiberglass

Construction Details:

  • Material: Fiberglass reinforced plastic
  • Construction: Filament wound
  • Design: ASME RTP-1
  • Corrosion resistant
  • Light weight
Applications: Coastal areas, corrosive environments, drinking water
10" x 54" 18" x 65" 30" x 72" Custom

Stainless Steel Vessels

Premium
Sizes: 200-2000 mm dia Pressure: 3-15 kg/cm² Grades: SS 304/316

Construction Details:

  • Material: SS 304/316L
  • Construction: ASME Section VIII
  • Finish: Electro polished (optional)
  • No lining required
  • Hygienic design
Applications: Food & pharmaceutical, high purity water, corrosive fluids
8" x 44" 16" x 65" 24" x 72" Custom

Control & Automation

Advanced control systems for efficient softener operation

Time Based Control

Regeneration initiated based on pre-set time intervals

Simple operation Low cost Ideal for consistent flow

Volume Based Control

Regeneration triggered based on water volume processed

Water meter controlled Efficient salt usage Ideal for variable flow

Hardness Based Control

Regeneration based on outlet water hardness monitoring

Hardness analyzer Most efficient Optimal salt consumption

PLC Based Control

Fully programmable logic controller with touch screen HMI

Advanced automation Data logging Remote monitoring

Automatic Regeneration Cycle

1

Backwash

Reverse flow to expand resin bed and remove suspended solids

10-15 minutes
2

Brine Draw

Brine solution passed through resin for ion exchange

30-60 minutes
3

Slow Rinse

Slow rinse to displace brine through resin bed

30-45 minutes
4

Fast Rinse

Final rinse to remove residual brine from system

10-15 minutes
5

Service

System returns to service mode for normal operation

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Industrial Applications

Water softening solutions for various industries

Industry Hardness Requirement Recommended System Benefits
Boiler Feed Water 0-2 ppm as CaCO₃ Twin/Triple softener Prevents scaling, improves efficiency
Cooling Towers <50 ppm as CaCO₃ Single/Twin softener Reduces scaling, lowers chemical consumption
Textile Industry <10 ppm as CaCO₃ Single/Twin softener Better dyeing, reduces soap consumption
Food & Beverage <5 ppm as CaCO₃ Food grade system Improves product quality, prevents scaling
Hotels & Hospitals <10 ppm as CaCO₃ Package softener Soft water for bathing, laundry, kitchen
Chemical Industry <2 ppm as CaCO₃ Twin/Triple softener Process water quality, equipment protection
Pharmaceutical <1 ppm as CaCO₃ FDA approved system Purified water for manufacturing
Laundry <10 ppm as CaCO₃ Commercial softener Reduces soap consumption, better cleaning

WATER SOFTENER PLANT ENQUIRY

Get customized quotation and technical specifications

Water Treatment Experts

+91 97116 23131

Email

info@kdstechnologies.in