A water softening system

Abstract: A water softening system has sampling pipes (21) and (22) in first and second water softeners (4) and (11). In use water to be treated first flows through the first water softener (4), and not through second water softener 11. Once the hardness component concentration of the treatment water sampled by sampling pipe (21) reaches a specified concentration, the watercourse selection of control valves (2, 6, 9, 13) are switched, causing water to flow through the second water softener (11) instead of the first. First water softener (4) is regenerated by salt water from a salt water chamber (14). The resulting water softening system prevents the leaking of hardness components, even with there is a fluctuation in the water quality of incoming water or when there is performance deterioration in the ion exchange resin.

Description: The present invention relates to a water softening system for making soft water by a softening treatment (hardness removal treatment) of hard water, that is water that contains hardness components. In particular, the present invention relates to a water softening system that continuously produces soft water by having at least two water softeners installed in parallel with water to be softened flowing alternately through these water softeners. As is well known, it is necessary to prevent the adhesion of so-called scale inside cooling and heating machinery such as boilers, water heaters, cooling devices and the like. As a result, devices that remove the hardness components contained in the supplied water are connected to the water supply lines of the cooling and heating machinery. Of these, an automatic regenerating water softener with a system of removing hardness components by using an ion exchange resin has been widely used. This type of water softener uses a Na + type of ion exchange resin. Metal cations such as Ca 2+ or Mg 2+ and the like are displaced with Na + to remove the hardness components. When the above resin becomes saturated by displacement with cations and the resin loses its ability to remove hardness components, the resin is flushed with a saline solution to regenerate its functioning. In this situation, because soft water cannot be supplied during the regeneration operation, two water softeners are used. Water passes alternately through these water softeners, and soft water is supplied continuously. With this conventional type of water softening device, the switching of the water supply from one water softener to the other is conducted by a timer. Due to errors or failures in the timer, there are situations where both softeners are being simultaneously regenerated, and a flow of softened water is not possible. Alternatively, there are situations where the untreated supplied water flows simultaneously through both water softeners with neither being regenerated. In order to overcome these shortcomings, in Japanese Laid Open Patent Publication Number 6-15265, a plurality of water softeners equipped with electromagnetic valves are connected in parallel. The water supply is treated alternately in these water softeners. After operating a water softener for a specified time, or after passing a specified amount of water, in order to regenerate the ion exchange resin, one of the electromagnetic valves is closed, and a signal is sent via a communication line to another electromagnetic valve to allow water to be treated in another water softener. The electromagnetic valve is opened to operate the water softener. After a specified amount of time has passed or after a specified amount of water has been passed, this water softener begins its regeneration operation, and this electromagnetic valve is closed, and the other or another electromagnetic valve is opened. Through the communication line, the water softeners after being regenerated are again automatically operated. With this water softener system, because the operating signal of one water softener is provided to a controller of the other or another water softener via a communication line, the regeneration operation and the soft water supply operation in each of the water softeners are never conducted simultaneously. With the control method of the water softening device of the above Japanese Laid Open Patent Publication Number 6-15265, the ion exchange resin is regenerated after operating the water softener for a specified amount of time or after passing a specified amount of water. As a result, if the water quality of the supplied untreated water fluctuates and the concentration of hardness components becomes higher, or if the properties of the ion exchange resin within the water softener changes (deteriorates with age for example), there is the risk that hardness components may pass through the system and be present in the treated, supposedly softened water. JP-A-10, 272, 370 discloses a water softening device having softening units installed in a parallel arrangement. One of the softening units may supply water when the other unit is being regenerated. The present invention seeks to provide a water softening device which overcomes the foregoing problems and to provide a water softening device that reliably treats the supplied water so that no hardness components pass through the system, that is it prevents the leakage of hardness components, even when there is fluctuation in the supplied water quality or when there are changes in the properties of the ion exchange resin. According to one aspect of the present invention, therefore, there is provided A water softening system, comprising first and second water softeners (4, 11); at least one regeneration chamber (14) for regeneration of each of the said first and second water softeners; a control device (19) for controlling the flow of incoming untreated water to each of the said first and second water softeners (4, 11) and for controlling regeneration thereof; and a hardness detection device for detecting the hardness of treated water in the water softener system; the control device (19) being operable to control the flow of untreated water and the regeneration of each of said first and second water softeners (4, 11) based on a hardness detection signal from the said hardness detection device, characterised in that that it further comprises a sampling mechanism (21, 22) that samples treated water from inside the first and second water softener (4, 11) at a specified distance from the outflow ports thereof to provide samples for hardness detection by the hardness detection device. A preferred emobidment of the present invention is a water softening system, comprising at least two water softeners placed in parallel so that water to be treated will flow alternately through them; a common regeneration chamber for regeneration of each water softener; a control device for controlling the switching of the flow of raw water to each water softener and for controlling regeneration; a hardness detection device for detecting hardness or a rise in hardness of treated water of the water softener; the control device controlling the switching of the flow of raw water and the regeneration of each water softener based on a hardness detection signal from the hardness detection device. In this invention, the hardness component concentration of the treated water of the water softener is detected and regeneration is conducted on the basis of this detected hardness component concentration. As a result, leakage of hardness is reliably prevented. With this, the hardness component concentration is detected for each pre-determined water collection amount. The current detection value and the previous detection value is compared, and the extent of the rise is calculated. Based on this rise in detection value, the switching of the flow is implemented. Leaks can be detected even with the deterioration of the detection device. The treated water from inside the ion exchange resin of the water softener is sampled and the switching of the flow to the water softener and regeneration is controlled based on the hardness of this treated water. With the water softening system of the present invention, a specified amount of ion exchange resin may still be present downstream from the treated water sampling site. As a result, by switching the flow of raw water and conducting regeneration when hardness components exceeding a specified value is detected from this sample water, the leakage of hardness components is prevented. Furthermore, with the present invention, in order to prevent the leakage of hardness components almost completely, or in other words, to prevent hardness leakage resulting from failure of the hardness detection device or from failure of regeneration of the water softener or the like, a non-regenerating polisher is preferably provided subsequent to the water softener. One embodiment of the present invention will now be more particularly described, by way of non-limitative example, with reference to the accompanying drawings, in which like reference numerals designate the same or corresponding elements, and in which: Fig. 1 is a system diagram of an embodiment of water softening device according to the present invention; Fig. 2 is a system diagram of a hardness component concentration measurement device; Fig. 3 is a system diagram of a salt water chamber used for supplying salt water; Referring now to Fig. 1, A water softener 4 and a water softener 11 are installed in parallel so that water can flow alternately through them. Untreated water is supplied from a pipe 1 and introduced into the first water softener 4 via a three-way valve 2, and a pipe 3. Water softening treatment takes place with the water softener 4 and soft water is removed via a pipe 5, a four way valve 6, a pipe 7, and a non-regenerating polisher 8. Untreated water can also be directed, from pipe 1 to a three way valve 9, a pipe 10, a second water softener 11, a pipe 12, and a four way valve 13 to the pipe 7 and the non-regenerating polisher 8. The inside of polisher 8 is also filled with a Na + type ion exchange resin. Because the hardness component load of polisher 8 is extremely small, it is possible for it to be non-regenerating. When, after an extended period of use the polisher becomes in need of regeneration the entire amount of ion exchange resin is replaced with new resin as needed. In order to regenerate the ion exchange resin inside the softeners 4 and 11, salt water, from a salt water chamber 14, is introduced into water softeners 4 and 11 via a pump 15, a pipe 16 and the four way valve 6 or the four way valve 13. In addition, in order to rinse the ion exchange resin with untreated water after regeneration with salt water, a pipe 17, which branches from pipe 1, is connected to each of its four way valves 6 and 13. In order to discharge the regeneration waste water, a discharge pipe 18 is connected to the three way valves 2 and 9 of pipes 3 and 10. These valves 2, 6, 9, 13, and pump 15 are controlled by a control device 19. A communication terminal 20, for sending control information to a control computer, is connected to control device 19. In order to determine the timing for regeneration, sampling pipes 21 and 22 are inserted inside water softeners 4 and 11 respectively. Sampling pipe 21 and sampling pipe 22 remove treatment water from the inside of the ion exchange resin layer at a specified distance from the outflow port of water softener 4 and 11. The hardness component concentration of the treated water sampled with sampling pipe 21 or sampling pipe 22 is detected by a sensor. The sampled treated water is checked for the level of hardness components reaching the sampling point. The sensor output signal is supplied to the control device 19. When operating this water softening device, on the one hand, initially untreated water is passed through the first water softener 4, but not through the second water softener 11. In this configuration valve 2 connects pipe 1 and pipe 3, and valve 6 connects pipe 5 and pipe 7. Valve 9 blocks the connection of pipe 1 and pipe 10, and valve 13 blocks the connection of pipe 12 and pipe 7. Soft water is taken from non-regenerating polisher 8. Once the hardness component concentration of the treatment water sampled by sampling pipe 21 reaches a specified concentration, the valves 2, 6, 9, and 13 are switched over so that the untreated water flows through the second water softener 11. Soft water is still taken from non-regenerating polisher 8. While untreated water is being passed through the second water softener 11, salt water from salt water chamber 14 is supplied to the first water softener 11 to effect regeneration of the ion exchange resin. To achieve this regeneration, valve 6 connects pipe 16 to pipe 5, and valve 2 connects pipe 3 to pipe 18. Pump 15 operates to pump salt water from the salt water chamber 14 through the first water softener 4. The ion exchange resin inside the first water softener 4 is regenerated by the flow of salt water and waste salt water is discharged via pipe 3 and pipe 18. Pump 15 is stopped after passing a specified amount of salt water. Then valve 6 is switched, to connect pipe 17 and 5 so that untreated water flows through the first water softener 4, and any remaining salt water inside first water softener 4 is flushed out via pipe 3 and pipe 18. This completes the regeneration process. After regeneration is complete, valve 2 and valve 6 are closed and the water softener 4 is in standby mode until next needed for soft water production. Unteated water continues to pass through second water softener 11, until the hardness component concentration of the teated water sampled by sampling pipe 22 reaches a specified concentration. The flow of untreated water is thus directed to the first water softener 4, and the second water softener 11 is regenerated. In order to regenerate the second water softener 11, as with first water softener 4, salt water from salt water chamber 14 is flushed through it from pipe 16 and pipe 12. The waste salt water is discharged via pipe 10 and pipe 18. When regenerating is complete untreated rinsing raw water is brought into second water softener 11 via pipe 17 and pipe 12, and residual salt water is flushed out via pipe 10 and pipe 18. After completing the rinse, the second water softener 11 is put in standby mode. In this way, the flow of raw water through water softener 4 and water softener 11 is conducted alternately. While one is conducting soft water production, the other is conducting regeneration of the ion exchange resin. The timing for the switching of this water softener 4 and water softener 11 is based on the hardness component concentration of the sampled water from sampling pipe 21 or sampling pipe 22. Even when the hardness component concentration of the sampling water reaches a certain value, ion exchange resin that is not broken down is still present between sampling pipe 21, sampling pipe 22 and the outflow ports of water softener 4 and water softener 11. As a result, the hardness components do not leak from water softener 4 or from water softener 11 during production of soft water. Even, if for some reason, some hardness components leak from water softener 4 or water softener 11, a non-regenerating polisher 8 is provided so that no hardness components leak from the output water of soft water. Through communication terminal 20, hardness information and water sampling information from each of the water softeners is sent to a control computer. At the control computer, the data for sampling amount and the hardness leakage amount is maintained in a time series. By doing so, trends in decreased sampling amount or the total amount of the ion load on the non-regenerating polisher in the later step can be estimated. The timing for exchanging the resin inside the water softener or the timing for exchanging the non-regenerating polisher can be estimated. Referring to Fig. 2, a device suitable for measuring the hardness component concentration of the treatment water sampled with sampling pipe 21 and sampling pipe 22 is described. Referring to Fig. 2, the sample water from each of sampling pipe 21 and sampling pipe 22 is brought into a water chamber 23 via a valve 21a and a valve 22a. Of course, when filling water from sampling pipe 21 into water chamber 23, valve 21a is opened, and valve 22a is closed. When filling water from sampling pipe 22 into water chamber 23, the opposite is done. This water chamber 23 is open to the atmosphere, and the soluble gases inside the soft water escape into the atmosphere. In addition, in this situation, the ends of pipe 21 and pipe 22 are placed at a position so that they do not contact the soft water inside water chamber 23. A blow pipe 25 that has a blow valve 24 is connected to the bottom of water chamber 23. From the output port at the bottom of water chamber 23, water from the inside of water chamber 23 is removed at a constant amount and constant pressure via a pipe 31 with a tube pump 30. This soft water is brought to a hardness component measurement device 40 via a heat exchanger 32 of a capillary format or the like. After measuring the hardness component, the soft water is discharged via a discharge pipe 33. The soft water, after measurement, is returned to a demand site from discharge pipe 33. This is preferred from the point of view of water recovery. Furthermore, a pipe 52 is connected to an intermediate point on pipe 31. Pipe 52 sends in a comparison standard solution from inside a comparison standard solution tank 50 via a pump 51. The detection signal of hardness component detector 40 is supplied to a signal processing circuit 41 where hardness is calculated. Depending on the result of this calculation, the control device 19 switches the flow of untreated water to water softener 4 or to the water softener 11 and controls regeneration of the other. Circuit 41 is connected to connection terminal 42. This connection terminal 42 sends data by cable or wireless transmission to a control computer (not shown). The transmitted data is stored as background information. In addition, alarms and the like can be communicated to the owner or the organization responsible for maintenance by any means such as electronic mail, fax, or mobile terminal or the like as necessary. With this arrangement, focused management can be conducted remotely. Furthermore, a level detector (not shown), which detects the water surface, is installed in water chamber 23. When a specified water level is reached, valve 21a and valve 22a, provided on sampling pipe 21 and sampling pipe 22, are closed, preventing the introduction of any more soft water. Water chamber 23 is emptied after the water quality has been measured by discharge valve 24. For the next measurement, new soft water is introduced up to the specified water level. When filling water chamber 23 with water from sampling pipe 21 or sampling pipe 22, it is preferable to have a repeated washing of one to ten times by filling water chamber 23 with water first and emptying the water by opening discharge valve 24. This is in order to erase any influence from the previous measurement. As described previously, the water chamber 23 is supplied to hardness component measurement device 40 by tube pump 30, which can supply the water at a constant pressure and constant flow rate. By doing so, errors are prevented when using an ion electrode sensor for hardness component measurement device 40. The ion electrode sensor can have fluctuations in the detection value due to flow rate or pressure variation. Furthermore, in order to maintain the test water at a constant temperature, heat exchanger 32 is installed in advance of hardness component measurement device 40. This heat exchanger is used to maintain the test water at a constant temperature. It is particularly effective if it is the same temperature as the comparison standard solution which is used to determine any deterioration in hardness measurement device 40. By having the test water which is supplied from water chamber 23 and the comparison standard solution which is supplied from the comparison standard solution tank at the same temperature, the measurement voltages of the test water and the comparison standard solution can be correctly compared. Heat exchanger 32 is of a material that can conduct heat such as a stainless steel capillary tube or the like. It is preferable to provide an extended contact surface by having corrosion resistant material in a coil-shape or the like. Hardness component sensor device 40 takes advantage of the fact that when the hardness component concentration rises, the voltage measured by the hardness ion electrode rises. From the voltage values detected at constant time intervals, a current measurement value is compared with the previous measurement value. When their difference exceeds a predetermined value, this is indicative of a so-called hardness leak, that is a predetermined amount of the hardness components of the untreated water are reaching sampling tube 21 or 22. At low concentrations of 1 ppm or less, the output voltage can fluctuate due to the various reasons described above, and the ion electrode (ion sensor) may not be able to differentiate between these fluctuations with certainty. As a result, the hardness leakage is detected based on changes in the trend by comparing the previous measurement value with the current measurement value. In other words, when the difference between the previous measurement value and the current measurement value exceeds a set standard value, this is recognized to be a hardness leak. With this method, it is not necessary to know the absolute value of the hardness component concentration. However, when the difference between the previous measurement value and the current measurement value is small, but the hardness leaking components are gradually rising, the hardness leak may not be detected. Because of this, it is preferable to add as a check a circuit that emits an alarm when the difference in the measurement voltages of the comparison standard solution and the test water exceeds a predetermined value. Because the detection part of the ion sensor can change with age, periodic measurement of the amount of change according to the standard solution (comparison standard solution) is necessary. Corrections are necessary based on this comparison. When the value falls below a predetermined standard value, replacement of the sensor film is necessary. As a result, a comparison standard solution tank 50 is provided with an internal water level measure and a liquid supply pump 51. By the control of a surveillance control device, solution is periodically sent to measurement device 40, and the standard value is corrected. In addition, the timing for replacement of the sensor film and the timing for supplementing the comparison standard solution is communicated to the information centre through the communication terminal, and periodic servicing is undertaken. In other words, for example, compared with the voltage detected using the comparison standard solution immediately after replacing the ion electrode film, when a subsequent detected voltage falls below some constant value, this is judged to be a deterioration in the hardness component measurement device. Maintenance, such as the replacement of the ion electrode film or replacement of the measurement device itself, is conducted. The comparison standard solution in the comparison standard solution tank 50 is maintained by a level sensor system installed in the tank. When the amount of solution falls below a predetermined value, there is a notification that supplementing of the comparison standard solution is necessary by an alarm and the like. With this hardness component concentration measurement device, the measurement of the hardness component concentration of the soft water production can be conducted automatically throughout the 24 hours. Furthermore, soft water is achieved without any hardness leaking through. With a system that can notify with regard to the maintenance timetable, such as for supplementing the comparison standard solution and the replacement of the hardness measurement device film and possibly also of the detector device itself maintenance is conducted reliably, and a stable operation of the device is possible. Referring now to Fig. 3, the salt water chamber 14 supplies saline solution (salt water) for regeneration to the water softeners via pipe 16 and pump 15. The untreated water for preparing the saline solution is brought into the chamber from pipe 1. Solid salt is precipitated and accumulated at the bottom of salt water chamber 14. In order to stir up this precipitated salt and to accelerate its dissolving, a diffuser 64 acting as an agitation device is installed at the bottom of the salt water chamber 14. Air is supplied from a compressor 66 to the diffuser 64 via an air pipe 65. In order to prevent direct contact between the undissolved salt and a concentration sensor 68, a mesh 67 is installed inside the salt water chamber 14. Concentration sensor 68 and a water level sensor 69 are provided within the region surrounded by mesh 67. For this concentration sensor 68, a float type is inexpensive and suitable. In this float type, the buoyancy increases as the salt water concentration increases, and when the buoyancy exceeds a specified value, an output signal is generated. Concentration sensor 68 can also be a Sodium ion electrode, a Chloride ion electrode, an inexpensive high performance electric conductometer, or the like. For water position sensor 69, a float type is inexpensive and suitable. In the float type, when the water level inside salt water chamber 14 reaches a specified water level, the float activates a limit switch or lead switch or the like. Water position sensor 69 can also be an electrode type, an optical type, or ultrasonic type. The output signals from sensor 68 and sensor 69 are supplied to a control device 70. Control device 70 provides a signal to compressor 66, a low concentration display device 71, and an alarm device 72. Furthermore, using a communication terminal 73, control device 70 sends data to a control computer and stores the operation history to this control computer. This data can be used for maintenance. Furthermore, various types, such as buzzers and lamps and the like, can be used for alarm device 72. For display device 71, various types, such as lamps, liquid crystal panels and the like, can be used. In order to have the water level detected by water level 69 at a specified water level, raw water is brought into this salt water chamber 14 from pipe 1 via a branching pipe (not shown). When water level sensor 69 outputs a signal signifying that the specified water level has been detected, control device 70 looks up the concentration of concentration sensor 68. When this concentration is lower than the specified concentration, low concentration display device 71 displays that the concentration is low. In addition, compressor 66 is operated for a specified time, and air is blown out of diffusion pipe 64, and the salt inside salt water chamber 14 is agitated by bubbling. After a specified amount of time has passed, compressor 66 is stopped, and the concentration at concentration sensor 68 is determined. Compressor 66 is repeatedly operated until the specified concentration is achieved. Compressor 66 can also be continuously operated until the specified concentration is reached. When the specified concentration is achieved, the display in the low concentration display device 71 is terminated. The salt water inside salt water chamber 15 remains until it is used for regeneration. Compressor 66 is preferably operated intermittently in order to prevent the consolidation of the precipitated salt. When the salt water inside salt water chamber 14 is sent out from pipe 16 in order to regenerate water softener 4 or water softener 11, the detected water level of water level sensor 69 becomes lower than the specified water level. Afterwards, raw water is supplemented, and the detected water level returns to the specified water level. Therefore, by detecting the lowering and the raising of this detected water level by a signal from water level sensor 69, it can be detected that salt water has been used for regeneration. Referring to Fig. 3, agitation by diffusion of air is used as a means for raising the salt water concentration. However, screw agitation by a motor or convection agitation by heating with a heater is also possible. With control device 70, when the salt water concentration that is sent out for regeneration is at a specified concentration, alarm device 72 is not activated. However, if the salt water is sent out when the salt water concentration has not reached the specified concentration (or when the specified concentration cannot be reached due to lack of salt), alarm device 72 is activated, and the person responsible is informed. As described above, with the water softening device of the present invention, even when there is fluctuation in the water quality of the raw water or when there is performance deterioration in the ion exchange resin, leaking of hardness components can be prevented.

Claims: A water softening system, comprising first and second water softeners (4, 11); at least one regeneration chamber (14) for regeneration of each of the said first and second water softeners; a control device (19) for controlling the flow of incoming untreated water to each of the said first and second water softeners (4, 11) and for controlling regeneration thereof; and a hardness detection device for detecting the hardness of treated water in the water softener system; the control device (19) being operable to control the flow of untreated water and the regeneration of each of said first and second water softeners (4, 11) based on a hardness detection signal from the said hardness detection device, characterised in that that it further comprises a sampling mechanism (21, 22) that samples treated water from inside the first and second water softener (4, 11) at a specified distance from the outflow ports thereof to provide samples for hardness detection by the hardness detection device. A water softening system according to Claim 1, characterised in that it further includes a non-regenerating polisher (8) downstream of said first and second water softeners (4, 11) with respect to the flow of water through the said water softening system. A water softening system according to Claim 1 or Claim 2, characterised in that the said first and second water softener (4, 11) are connected in a parallel arrangement with respect to water flow therethrough. A water softening system according to any preceding claim, characterised in that the said control device (19) controls the flow of water to be treated such that water flows alternately through said first water softener (4) and said second water softener (11); and the said control device (19) controls regeneration of one of said first and second water softener when the other has water flowing therethrough. A water softening system according to any preceding claim, characterised in that the said at least one regeneration chamber (14) is common to the said first and second water softener. A water softening method, comprising the steps of providing at least first and second water softeners (4, 11); regenerating each of said first and second water softener by using at least one regeneration chamber (14); controlling the flow of water to be softened to each of the said first and second water softeners (4, 11) by using a control device (19); controlling regeneration of each of said first and second water softener by said control device; detecting the hardness of water treated by the said water softener with a hardness detection device; and controlling the flow of water to be treated and the regeneration of each of the said first and second water softener on the basis of a hardness detection signal from the said hardness detection device, characterised in that it further comprises the steps of sampling treated water from within one of the said first and second water softener at a specified distance from the outflow port thereof to obtain a sample thereof; and detecting the hardness of the said sample of treated water. A water softening method according to Claim 6, characterised in that it further comprises treating water downstream of the said first and second water softener, with respect to the direction of flow of water through the said first and second water softener, with a non-regenerating polisher. A water softening method according to any of Claim 6 or Claim 7, characterised in that it further comprises directing water to flow alternately through the said first and second water softener; and effecting regeneration of one of said first and second water softeners when the other of said first and second water softeners has water flowing therethrough. A water softening method according to Claim 8, characterised in that the regeneration is conducted by delivering regeneration liquid from a regeneration chamber (14) common to the said first and second water softener.

Inventors: IIZUKA HIROSHI, KUROKAWA TUTOMU, YAMAMOTO AKIKAZU, IIZUKA, HIROSHI, KUROKAWA, TUTOMU, YAMAMOTO, AKIKAZU
Applicants: KURITA WATER IND LTD, KURITA WATER INDUSTRIES LTD.
Application year: 2001
Main classification: C02F1
IPC codes: B01J49, C02F1, B01J47