35 Ton per Hour Ultrapure Water System for China Spectrum New Materials

This project is a core supporting project for a newly built spectrum new material enterprise. The enterprise focuses on the R & D and production of high-end optical materials, and the production line construction needs to be equipped with an ultra – pure water system simultaneously. Due to the strict requirements of the core processes (such as coating and cleaning) of spectrum new materials on water quality purity, trace impurities in water will directly lead to product defects and a decrease in yield. In addition, the enterprise plans to put three production lines into operation simultaneously, so it is necessary to ensure the stable and sufficient supply of high-purity water. Therefore, the construction project of a 35 – ton/hour ultrapure water system was launched, taking into account production capacity adaptation, water quality compliance, and energy conservation requirements.

Project Challenges：

1. The water quality must be stable and the water production continuous to adapt to the continuous operation rhythm of the newly built production line.

2. The system needs to be advanced in synchronization with the enterprise’s plant construction and production line commissioning, with a tight construction period, and it is necessary to ensure the flexibility of subsequent expansion.

3. It is necessary to strictly control the initial investment cost and later operation and maintenance costs, require low energy consumption, and reduce the pressure of environmental compliance.

Process Flow：

  • Pretreatment Unit: It uses a multi-media filter to remove suspended solids and turbidity in water, an activated carbon filter to adsorb residual chlorine and organic pollutants, a water softener to reduce the hardness of incoming water and prevent scaling risks, and a 5-micron precision filter for terminal pretreatment. This unit can extend the service life of core components.
  • Reverse Osmosis Unit: A process of double-stage reverse osmosis + EDI configuration + UV sterilization + terminal microfiltration filter is adopted to remove more than 99% of ions and organic matter, and the produced water resistivity can reach more than 15 MΩ·cm. UV sterilization can ensure that the microbial indicators meet the standard, and terminal filtration ensures that there is no particle residue in the produced water.
  • Polishing Mixed Bed: A polishing mixed bed is added after the EDI to further deeply remove residual trace ions, colloids, and other impurities in the water, ensuring that the produced water resistivity stably reaches 18.2 MΩ·cm, which fully meets the extreme requirements of the production line for ultra – pure water.

Project Effects：

  • Water Quality Compliance: The produced water indicators fully meet the production requirements, ensuring that the defect rate of products from the newly built production line is controlled below 1.5%.
  • Production Capacity Adaptation: The continuous and stable supply of produced water supports the simultaneous commissioning of three newly built production lines, laying the foundation for the enterprise to achieve scheduled mass production.
  • Operation and Maintenance Costs: The initial cost and operation and maintenance cost of the project are within the controllable range calculated by the enterprise, reducing the pressure of equipment operation and maintenance.