Condensate polishing units remove ionic impurities, suspended solids, and corrosion products from power plant condensate, ensuring ultra-pure feedwater quality for high-pressure boilers and HRSGs. Their internal components require regular replacement to maintain water quality.
AQ Process Systems sources and exports replacement resins, filter elements, analytical instruments, and vessel components for both internal and external regeneration condensate polishing systems used in thermal and combined-cycle power plants.
Condensate polishing is critical for supercritical and ultra-supercritical boilers where feedwater purity requirements are extremely stringent, sodium and silica levels must be maintained below 3 ppb to prevent turbine blade deposits.
| Component | Specification | Description |
|---|---|---|
| Resin & Media | ||
| Mixed Bed Resin | Nuclear-grade cation + anion | Uniform particle size | Mixed bed ion exchange resin for condensate polishing, nuclear-grade for maximum purity performance. |
| Cation Resin (Separate) | Strong acid cation | Gel or macroporous | H-form | Cation exchange resin for separate-bed condensate polishing configurations, removing cationic impurities. |
| Anion Resin (Separate) | Strong base anion | Type I | OH-form | Anion exchange resin for separate-bed configurations, removing silica, chloride, and sulphate. |
| Filtration | ||
| Pre-coat Filters | Powdered resin or cellulose | Pre-coat media | Pre-coat filter media for pre-coat type condensate polishers, powdered mixed bed resin or cellulose. |
| Cartridge Filters | 1-10 micron | Pleated or depth | PP or polyester | Pre-filter and post-filter cartridges protecting polishing vessels and downstream systems. |
| Resin Trap Screens | SS wedge wire | Retention screens | Outlet retention screens preventing resin bead carry-through into the condensate system. |
| Vessel Internals | ||
| Distribution Laterals | SS | Hub-and-lateral or header type | Internal water distribution systems, ensuring uniform flow through the resin bed for optimal polishing. |
| Strainer Nozzles | PP or SS | Slot or mesh type | Collector nozzles at the vessel base retaining resin while passing polished condensate. |
| Internal Linings | Rubber or epoxy | Corrosion protection | Internal vessel lining protecting the carbon steel shell from corrosive regeneration chemicals. |
| Instrumentation | ||
| Conductivity Analysers | Cation conductivity | ppb resolution | High-sensitivity cation conductivity analysers monitoring polisher outlet water quality. |
| Sodium Analysers | Online | ppb-level detection | Sodium analysers providing early warning of resin exhaustion, detecting breakthrough before conductivity rises. |
| Silica Analysers | Online | ppb-level detection | Online silica analysers ensuring polisher outlet silica remains below turbine manufacturer limits. |
Parts are matched to OEM material specifications and dimensional tolerances. Please provide the equipment manufacturer, model number, and serial number (if available) for precise part identification.
The main consumables are mixed bed resin (replaced every 3-7 years due to degradation), cartridge filters (replaced every 3-12 months), analytical instruments (probes replaced every 1-2 years), strainer nozzles (cracking or blocking), and regeneration valve seats and seals. Internal vessel linings may need refurbishment every 10-15 years.
Mixed bed resin life depends on condensate quality and regeneration frequency. In base-load power plants with clean condensate, resin lasts 5-7 years. In cycling plants or with condenser tube leaks, replacement may be needed every 2-4 years. Monitor resin kinetics and capacity during routine testing.
Cation conductivity measures the conductivity of condensate after passing through a cation exchange column, removing the masking effect of ammonia and amines. It provides a much more sensitive indication of impurity breakthrough (chloride, sulphate, sodium) than direct conductivity. Target is typically below 0.2 µS/cm.
Yes. We supply nuclear-grade mixed bed resins from Purolite, Dow, and Lanxess, these have uniform particle size, low ionic leachables, and high kinetic performance required for condensate polishing applications. All resins are supplied with certificates of analysis.
Yes. We supply online sodium analysers (ppb-level detection for early exhaustion warning) and silica analysers (critical for preventing turbine blade deposits) from Endress+Hauser, Hach, Mettler-Toledo, and other manufacturers. We also supply replacement reagents, electrodes, and calibration standards.
Share your equipment make, model, and part numbers, we respond within 24 hours.