Need ultra-pure water for your process? Go Mineral-Free with a DM Plant!

A Demineralisation (DM) Plant is designed to remove dissolved salts, minerals, and ions from water, producing high-purity water suitable for industries like power generation, pharmaceuticals, and electronics manufacturing.
By using ion exchange technology, DM plants ensure consistent water quality for processes where even trace minerals can cause corrosion, scaling, or product quality issues.

Over 60% of industrial boiler and process equipment failures are linked to mineral scaling from untreated water.

Key Features

Two-Stage Ion Exchange System – Cation and anion exchange units for complete mineral removal.
High-Quality Resin Media – Premium-grade resins ensure long life and consistent output quality.
Automatic Regeneration – Reduces manual effort and chemical wastage.
Compact Skid-Mounted Design – Easy to install, transport, and maintain.
Corrosion-Resistant Construction – Made with FRP, PVC, or SS materials for durability.
Conductivity Monitoring – Real-time TDS and conductivity control to ensure water purity.

Produces ultra-pure water with conductivity as low as 0.1 µS/cm.
Prevents scaling, corrosion, and spotting in industrial processes.
Extends the lifespan of boilers, cooling towers, and RO membranes.
Low operational cost with chemical regeneration instead of cartridge replacement.
Ensures compliance with process and quality standards in critical industries.

Benefits

Applications

For boiler feed water and steam generation.
In formulations, rinsing, and sterile processes.
For semiconductor and PCB washing.
For chemical testing and sample preparation.
For blending and process water where mineral control is critical.

Working Principle

A DM Plant works on the ion exchange principle — where unwanted mineral ions are replaced with hydrogen (H⁺) and hydroxyl (OH⁻) ions to produce pure, demineralized water.
To ensure consistent output and protect the resins, the process starts with pre-treatment, followed by DM treatment, and is supported by an air compressor system for automation and backwashing.

Step-by-Step Process:

Pre-Treatment:
- Raw water first passes through a pressure sand filter (PSF) and activated carbon filter (ACF) to remove suspended solids, turbidity, and organic matter.
- A softener or iron removal filter is used if the inlet water has hardness or iron content — this prevents resin fouling and capacity loss.
Cation Exchange Unit:
- Positively charged ions (Ca²⁺, Mg²⁺, Na⁺) are exchanged with H⁺ ions using cation exchange resin.
- The result is acidic water (H⁺ rich) containing corresponding anions.
Anion Exchange Unit:
- Negatively charged ions (Cl⁻, SO₄²⁻, NO₃⁻) are exchanged with OH⁻ ions using anion resin.
- H⁺ and OH⁻ combine to form pure H₂O — demineralized water with conductivity <1 µS/cm.
Optional Mixed Bed Unit (if installed):
- A polishing stage with a mixed resin bed for ultra-pure water (<0.1 µS/cm).
Compressor System:
- The air compressor powers pneumatic valves and assists during backwash and regeneration cycles, ensuring smooth and automated operation.

Add-on:
Reverse Osmosis

The Reverse Osmosis (RO) Plant serves as an efficient pre-treatment add-on before the demineralisation (DM) system. It removes up to 95–98% of dissolved salts, hardness, silica, and organic impurities, significantly reducing the ionic load on the cation and anion exchange resins. By feeding low-TDS water to the DM unit, the RO system minimizes chemical consumption during regeneration, increases resin life, and ensures consistent production of high-purity demineralized water.

How to Operate

Ensure pre-treatment units (PSF/ACF/Softener) are clean and backwashed.
Check chemical tanks for acid (HCl) and caustic (NaOH) — required for resin regeneration.
Turn ON the feed pump and confirm proper pressure and flow.
Open inlet valves sequentially: Pre-treatment → Cation → Anion → Outlet.
Monitor outlet conductivity — the water should be within desired purity levels (<1 µS/cm).
When output conductivity rises, initiate regeneration:
Cation resin → regenerate with HCl.
Anion resin → regenerate with NaOH.
Rinse both columns until conductivity stabilizes again.
Compressor should remain ON during automatic valve operation and backwash.
After stabilization, the plant is ready for next production cycle.

Maintenance Guide

Daily:
- Check inlet pressure and conductivity readings.
- Inspect compressor air pressure (should be within recommended range).
Weekly:
- Backwash sand and carbon filters.
- Inspect chemical levels and refill as required.
Monthly:
- Check resin condition and regeneration efficiency.
- Inspect pneumatic valves, hoses, and compressor oil levels.
Quarterly:
- Calibrate conductivity meters.
- Check for any leaks or corrosion in tanks and piping.
Annually:
- Replace exhausted resin if output quality drops significantly.
- Perform chemical cleaning of the system if fouling is observed.

Pro Tips for Long-Term Performance

Always keep the pre-treatment units operational — untreated hardness or iron will damage the resins quickly.
Use RO or softener water as feed for best resin life.
Never skip the rinsing cycle after regeneration — residual acid or alkali can affect product water quality.
Regularly clean strainers and nozzles to maintain uniform flow.
Keep the compressor drain and filters clean to ensure smooth valve operation.
Store chemicals properly — away from direct sunlight and moisture.
Monitor the conductivity trend: a slow rise over days is normal; a sharp rise indicates resin exhaustion or channeling.