Iron Removal System

Iron removal is a water treatment technology designed to remove excessive iron (Fe) content from water. High iron content in water can cause a variety of problems such as an unpleasant metallic taste, brownish stains on sanitary equipment, clothing, and can damage piping systems and industrial equipment. Iron removal technology has become very important in various water treatment applications for industrial, commercial, and domestic purposes.

Sources of Iron Contamination in Water

Iron is one of the most abundant elements in the earth's crust and can be naturally dissolved in groundwater. Iron contamination in water can come from various sources:

Dissolution of natural iron minerals in rocks and soil
Corrosion of water distribution pipes and equipment
Industrial effluents containing iron
Groundwater in contact with iron ore deposits
Seepage from landfills and mining areas

How Iron Removal Systems Work

Iron removal from water involves several processes that can be applied separately or in combination, depending on the characteristics of the water and the concentration of iron present. Here are the main methods used:

1. Oxidation and Filtration

This process is the most common method used to remove iron from water. The steps include:

Oxidation: Dissolved iron (Fe²⁺) is oxidized to undissolved iron (Fe³⁺) which forms ferric hydroxide precipitates [Fe(OH)₃].
Oxidizing agent: May use oxygen (aeration), chlorine, ozone, potassium permanganate, or hydrogen peroxide
Filtration: The iron precipitates formed are then separated using filter media such as sand, anthracite, Inversand, or Jacobi media.

2. Specialized Filter Media

Some specialized filter media are designed for efficient iron removal:

Greensand: Media coated with manganese dioxide that acts as a catalyst to oxidize iron
Birm: A lightweight media that uses dissolved oxygen to oxidize iron
Catalytic Media: Media such as Clack Filter AG or Imerys that accelerate the oxidation reaction.
Pyrolox/Manganese Dioxide: Natural or synthetic media that oxidizes iron

3. Ion Exchange

For low to moderate iron concentrations, ion exchange systems can be used:

Ion exchange resins such as Purolite or Trilite capture iron ions and exchange them with another ion (usually sodium).
Effective for iron concentrations up to 5 mg/L
Often used in water softener systems that use Fleck or Autotrol control valves

4. Reverse Osmosis

For drinking water treatment with low iron content:

DuPont Filmtec or CSM Reverse Osmosis systems can remove dissolved iron.
Usually requires pre-treatment to prevent membrane fouling
Effective for small to medium scale water treatment

5. Aeration System

Aeration is an effective and economical method:

Injects air into the water to oxidize dissolved iron.
Can use air compressors, mechanical aerators, or aeration towers
Usually followed by sedimentation and filtration processes

Main Components of Iron Removal System

A comprehensive iron removal system usually consists of the following components:

Pre-treatment system: Removes sediment and other contaminants that may interfere with the iron removal process
Chemical injection system: Uses an LMI or HydroPro dosing pump to add oxidant or coagulant
Contact tank: Provides sufficient reaction time for iron oxidation
Filter tank: Pentair or HydroPro FRP tank containing filter media
Control valve: Runxin, Siata, or Pentair to regulate the backwash and regeneration process
Monitoring system: Create or HydroPro instruments to monitor water quality
Disinfection system: HydroPro or Wedeco UV systems to ensure water is free of microorganisms

Iron Removal System Applications

Iron removal technology is used in a wide range of industrial sectors and applications:

Industrial Applications

Food and Beverage Industry: Removing iron to prevent changes in taste, color, and product quality
Textile Industry: Prevents stains and discoloration in textile products
Chemical Industry: Provides iron-free process water for sensitive chemical reactions
Power Generation: Prevents corrosion and scaling in boilers and cooling systems
Electronics Industry: Provides ultrapure water for production processes
Pharmaceutical Industry: Meets stringent water quality standards for the production of pharmaceuticals
Paper Processing: Prevents discoloration and quality of paper

Commercial Applications

Hotels and Restaurants: Improves water quality for cooking, washing, and guest use
Laundry: Prevents browning stains on clothes and linen
Healthcare Facilities: Meet water quality standards for medical equipment and patient needs
Shopping Centers: Improve water quality for sanitizing and cooling systems
Office Buildings: Protects plumbing systems and equipment from iron damage

Residential Applications

Household Water Treatment Systems: Removes iron to prevent stains on sanitary equipment and clothing
Drinking Water Systems: Improves the taste and clarity of drinking water
Pentair Under-sink System: Provides high quality drinking water at the point of use
Home Appliance Protection: Extends the life of washing machines, water heaters and other appliances

Specialty Applications

Well Water Treatment: Removes iron commonly found in groundwater
Desalination: Pre-treatment for desalination systems to prevent membrane fouling
Wastewater Treatment: Removes iron prior to discharge or recycling
Aquaculture: Maintains water quality for the culture of fish and other aquatic organisms

Advantages of Iron Removal Systems

The implementation of an iron removal system provides various advantages:

Operational Advantages

Prevents damage and corrosion to piping systems and equipment
Extends the service life of other water treatment systems such as RO membranes
Reduces frequency of equipment cleaning and maintenance
Improves operational efficiency of the water treatment system
Reduces consumption of cleaning and disinfectant chemicals

Quality Advantage

Removes metallic taste and odor from water
Prevents brownish stains on sanitary ware, clothing, and equipment
Improves water clarity and aesthetics
Improves end product quality in industrial applications
Meets regulatory and industrial water quality standards

Economic Advantages

Reduced equipment maintenance and replacement costs
Lower consumption of detergents and cleaning agents
Improves energy efficiency of water heating systems
Reduces production downtime due to water quality issues
Provides quick return on investment (ROI) especially for industrial applications

Iron Removal System Design Considerations

In designing an effective iron removal system, several important factors must be considered:

Raw water characteristics: Iron concentration, pH, alkalinity, turbidity, and other parameters
Form of iron: Dissolved iron (ferrous) or undissolved iron (ferric)
Presence of other contaminants: Manganese, sulfur, hardness, and organic matter
Flow rate and system capacity: Determines tank size and filter media
Treated water quality requirements: Industry standards or regulations that must be met
Available space and infrastructure: Influences the choice of technology and system configuration
Operational and maintenance costs: Including energy consumption, chemicals, and media replacement

Iron Removal System Maintenance

To ensure optimal performance and long service life, iron removal systems require regular maintenance:

Filter backwashing: To remove accumulated iron precipitates and prevent channeling
Media regeneration: For media that require regeneration such as greensand with potassium permanganate
Water quality monitoring: Using Create measurement instruments to ensure system effectiveness
Media replacement: In accordance with manufacturer's recommendations or when effectiveness decreases
Dosing system check and calibration: To ensure proper dosing of oxidant or coagulant
Cleaning of tanks and components: To prevent microbial contamination and maintain efficiency

Our Iron Removal Solution

We offer comprehensive iron removal solutions tailored to your specific needs. Our systems incorporate high-quality components from leading manufacturers including Clack, Jacobi and Inversand filter media, Pentair filter tanks, Fleck and Runxin control valves and HydroPro monitoring systems.

Our technical team provides expert design, installation and maintenance services to ensure optimal and long-lasting system performance. We also offer water quality testing and monitoring services to validate system performance and compliance with regulatory requirements.

Contact our team today to discuss your iron removal needs and discover how our solutions can help you achieve your water quality goals.

Iron Removal System from Water