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Zeolite Softener Regeneration Issues

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Posted by James on May 18, 2011 at 11:56:01:

I have 2 Bruner Sodium Zeolite Water Softeners. 617,500 grains / tank, throughput capacity between regenerations of 123,500 gallons / tank, 60 GPM flow rate each tank.

Due to short run cycles we recently changed out both resin beds with same in kind high temp resin. After the resin change out, we noticed that as many as 3 additional fast rinses are now needed to “cleanup” (3 ppm hardness) the beds after regeneration and prior to placing either of the softeners in service. Since we use treated water for our rinse, this increase is quite expensive and time consuming. On occasions we have put the softener in service with hardness as high as 10 ppm, and have noticed that after doing so, the softener will “cleanup” to < 1 ppm hardness in a matter of about 15 – 20 min.

We opened the softeners to check for channeling and all appeared good (also, the laterals were inspected prior to the new resin being added and they were in excellent condition).
We sent resins samples to a laboratory for analysis and the results came back “good”, like new resin.
We have conducted elution studies and adjusted all of our cycle times, but still cannot figure why we are now requiring these additional rinses to clean up the resin. Any help would be greatly appreciated.

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