In previous post, I shared briefly about design of water softener. Water softener is used to eliminate ions that form scale, which are mainly calcium and magnesium. Key design calculation for water softener are already described in the post. It included resin volume requirements, vessel geometry, and required salt mass for regeneration. In this post, I want to share with you the water softener calculation using Plutocalc Water free software.
In this post, I want to share with you water softener design and preliminary sizing calculation of water softener.
In industrial Water Treatment Plants (WTP), a water softener is a critical ion-exchange unit designed to eliminate ions that form scale, which are primarily Calcium (Ca²⁺) and Magnesium (Mg²⁺). If left untreated, hard water leads to severe scaling in downstream boilers, cooling towers, and Reverse Osmosis (RO) membranes, drastically degrading thermal efficiency and shortening equipment life. Water softeners utilize Strong Acid Cation (SAC) resin beads saturated with Sodium (Na⁺) ions. As raw water passes through the pressurized resin bed, Ca²⁺ and Mg²⁺ ions displace the Na⁺ ions on the resin functional groups, delivering softened effluent to the plant.
