Explosion-proof Quartz Sand Filter,activity Carbon Filter Teo Stage Reverse Osmosis Dosing Water tank Fully Automatic System

Product description

1、 Core Component Functions and Principles
1. Explosion proof Quartz Sand Filter
Structure and Explosion proof Design:
Adopting explosion-proof shell (such as stainless steel material+explosion-proof coating), the internal electrical components (such as backwash motor, solenoid valve) are all explosion-proof grade (such as Ex d IIC T6), suitable for flammable and explosive environments (such as chemical workshops, oil and gas fields).
Fill quartz sand filter material (particle size 0.5-1.2mm) to remove large impurities such as suspended solids, sediment, rust, colloids, etc. in the raw water through interception (turbidity ≥ 20NTU can be reduced to below 5NTU).
Workflow:
Filtration stage: Raw water enters from the top and passes through the sand layer from top to bottom, where impurities are intercepted.
Backwash stage: The PLC control system automatically triggers backwash, and the water flow backwashs the filter material in reverse to remove impurities (backwash intensity 15-20L/(m ² · s), taking 5-10 minutes).
2. Activated Carbon Filter
Function and explosion-proof compatibility:
The same explosion-proof structure is used, with fruit shell/coconut shell activated carbon (specific surface area ≥ 1000m ²/g) filled inside to adsorb residual chlorine, organic matter (such as benzene derivatives), pigments, and odors in water, protecting the subsequent reverse osmosis membrane from oxidative damage.
The adsorption efficiency of residual chlorine is greater than 99%, while reducing TOC (total organic carbon) to ≤ 2mg/L.
Maintenance points: Activated carbon needs to be replaced regularly (usually once a year) or restored for adsorption capacity through steam regeneration.
3. Two Stage Reverse Osmosis
First stage reverse osmosis (1st RO):
After pre-treatment, the raw water is driven by a high-pressure pump (explosion-proof type, pressure 0.8-1.5MPa) through a first stage reverse osmosis membrane (desalination rate 95% -98%) to remove most of the salt (such as NaCl), bacteria, viruses, etc., and the conductivity of the produced water is reduced to 5-50 μ S/cm.
Second stage reverse osmosis (2nd RO):
The first stage produced water enters the intermediate water tank and is then driven by the second stage high-pressure pump (pressure 0.6-1.2MPa) to pass through the second stage reverse osmosis membrane (desalination rate ≥ 99%), further desalinating to a conductivity of ≤ 1 μ S/cm, meeting the demand for high-purity water.
Membrane element selection: commonly used roll type composite membranes (such as Dow BW30-400), with a focus on high flux for the primary membrane and high desalination rate for the secondary membrane.

4. Dosing System
Dosing type and function:
Scale inhibitor: Add (such as polyphosphate) before the first stage RO to prevent calcium and magnesium ion scaling (concentrated water LSI index ≤ 0).
Reducing agent: If the residual chlorine in the raw water is greater than 0.1mg/L, add sodium bisulfite (SBS) to reduce the residual chlorine and protect the reverse osmosis membrane.
PH regulator: Sodium hydroxide (NaOH) can be added before the secondary RO to improve the efficiency of CO ₂ removal and reduce the conductivity of the produced water.
Control method: Automatic dosing (accuracy ± 1%) is achieved by linking the metering pump with online instruments such as conductivity meters and pH meters.
5. Water Tank
Intermediate water tank (primary RO production water):
The volume is designed based on the system’s water production capacity (for example, when the water production is 10m ³/h, the water tank volume is ≥ 20m ³), buffering the fluctuations of the first stage water production and providing a stable water source for the second stage RO.
Production water tank:
Storage of secondary RO water, equipped with liquid level control (such as ultrasonic level gauge) and air respirator (to prevent secondary pollution), suitable for continuous water supply scenarios.
6. Fully Automatic System
Explosion proof PLC control cabinet:
Adopting explosion-proof PLC (such as Siemens ET 200SP Ex), integrated human-machine interface (HMI), real-time monitoring of parameters such as pressure, flow rate, conductivity, pH, etc.
Automatic execution process: pre-processing backwash → softening regeneration → RO start stop → dosing adjustment → fault alarm (such as high-pressure pump overload shutdown).
Remote monitoring: Supports 485 communication protocol and can be connected to the factory DCS system to achieve remote parameter adjustment and equipment maintenance.
2、 System process and key points of explosion-proof design
1. Complete processing flow
plaintext
Raw water → Explosion proof quartz sand filter (to remove large particles) → Explosion proof activated carbon filter (to remove residual chlorine and organic matter) → Dosing device (scale inhibition/reduction) → Primary reverse osmosis (primary desalination) → Intermediate water tank → Secondary reverse osmosis (deep desalination) → Produced water tank → Water consumption point
2. Key details of explosion-proof design
Electrical equipment: All motors, sensors, and solenoid valves comply with explosion-proof standards (such as Chinese GB 3836 series and international ATEX certification) to avoid explosions caused by electric sparks.
Material and sealing:
The filter and water tank are made of 316L stainless steel, with a polished surface to prevent static electricity accumulation.
The pipeline interface adopts explosion-proof flanges (sealing level IP66) to prevent the leakage of flammable gases.
Ventilation and heat dissipation: The explosion-proof control cabinet is equipped with a built-in heat dissipation fan (explosion-proof type) to ensure that electrical components operate within a safe temperature range (<60 ℃).

3、 Application scenarios and performance advantages
1. Typical application areas
Petrochemical industry: Processing oily and saline water, producing circulating cooling water or boiler makeup water (conductivity ≤ 10 μ S/cm) to meet production needs in explosion-proof environments.
Natural gas treatment: Desalinate high salt wastewater (TDS>10000mg/L) generated from shale gas extraction, and reuse it through two-stage RO (TDS<100mg/L).
Pharmaceutical/Electronic Industry: Produce high-purity water (resistivity ≥ 15M Ω· cm) in explosion-proof workshops for drug preparation or chip cleaning.
2. Performance advantages
High desalination efficiency: The two-stage RO combined desalination rate is greater than 99.5%, and can treat raw water with TDS up to 5000mg/L.
Safe and reliable: The explosion-proof design meets the requirements of Zone 1/21 hazardous areas, certified by ATEX/IECEx, and can operate stably in hydrogen and dust environments.
Low operation and maintenance costs: Fully automated operation reduces manual intervention, reverse osmosis membrane lifespan can reach 5 years (under routine maintenance), and system water utilization rate ≥ 80%.
4、 Maintenance and troubleshooting
1. Daily maintenance
Check the pressure difference between the sand filter and carbon filter every week (backwash when>0.05MPa).
Monthly testing of residual chlorine adsorption capacity of activated carbon (replace filter material when residual chlorine in influent exceeds 0.1mg/L).
Perform chemical cleaning on the reverse osmosis membrane every quarter (acidic cleaning to remove carbonate scale, alkaline cleaning to remove organic matter).
2. Common faults and their solutions
Possible causes and solutions for the fault phenomenon
First stage RO water production decreases due to membrane fouling/high pressure pump failure, chemical cleaning of membrane/inspection of pump head
The conductivity of the secondary produced water increases, and the secondary membrane is damaged/the intermediate water tank is contaminated. Replace the membrane components/clean the water tank
Explosion proof control cabinet alarm pressure exceeding limit/electrical component failure inspection pipeline blockage/replacement of explosion-proof components
summarize
This set of equipment combines explosion-proof pretreatment, two-stage RO deep desalination, and fully automatic control, which not only meets the safety requirements in flammable and explosive environments, but also achieves efficient purification of high salt wastewater, suitable for industrial scenarios with strict requirements for water quality and safety. Its core advantages lie in multi-level filtration collaboration, reliable explosion-proof performance, and high degree of automation, making it an ideal solution for water treatment in industries such as petroleum, chemical, and energy.