05/06/2026
Operational Data and Application of Anhui Sanxing Resin in a 18,000 m³/day Softened Water Project for a Large Petrochemical Complex in China
Softened water treatment is critical to the operational safety of large-scale refinery projects. This paper analyzes real-world operational data to explore the application and performance of Sanxing Resin’s 001×7 strong acid cation exchange resin in boiler water pretreatment and circulating water softening.
Project Background and Challenges
With a total investment exceeding $5 billion and a refining capacity of 10 million tons in north China, feedwater is surface water with high Fe and COD concentration. Hardness is 220-450ppm but during saltwater intrusion period, hardness may double. All these adversely affected resin service lives. To ensure continuous production and consistent effluent hardness, the facility imposes near-stringent requirements on the stability of the water softening system.
The specific softened water treatment process adopted by the refinery is as follows:
Raw Water
↓
Raw Water Tank
↓
Multi-Media Filter (MMF)
↓
Activated Carbon Filter (ACF)
↓
Fully Automatic Ion Exchange Softener
↓
Softened Water Tank
Key Challenges Before Adopting the Sanxing Resin Solution
Prior to implementing the Sanxing resin solution, the plant faced several common industry challenges:
Significant Fluctuations in Feedwater Quality:
Due to seasonal variations and upstream process influences, the hardness of incoming water fluctuated frequently. This resulted in a reduction in the effective working exchange capacity of the existing resin and shortened the service cycle of the system.
High Operating Costs:
Lower-quality resins required frequent regeneration, leading to substantial consumption of acid and water. In addition, high resin breakage rates contributed to consistently elevated annual operating costs.
Equipment Safety Risks:
Due to fluctuations in feedwater quality, the hardness of the treated water occasionally exceeded acceptable limits, posing a risk of boiler scaling and seriously threatening the safe operation of the integrated refining facility.
Product Stability: Utilizing the suspension polymerization process, Sanxing 001×7 delivers a working exchange capacity comparable to international brands and significantly exceeding other domestic products. In cases of influent water quality fluctuations—especially variations in hardness—the superior effluent quality of Sanxing resin safeguards the continuity and stability of downstream processes.
After 5 years of operation, the working exchange capacity of Sanxing resin remains similar to imported resins, decreasing from 1.2 eq/L in the first year to 1.1 eq/L in the fifth. In contrast, the initial capacity of low-end domestic brands is only 0.9 eq/L, dropping to 0.6 eq/L by the fifth year, at which point they lose all operational value and must be replaced.
Reduced Acid and Water Consumption:
Compared with international premium brands and Sanxing resin, lower-end domestic products consume significantly more acid and water. Over a five-year operating cycle, this results in more than one million RMB in additional regeneration costs.
Lower Procurement Cost:
Compared with imported brands, the procurement cost of Sanxing resin is approximately 58% of that of imported products. Although lower-end domestic resins cost around 49% of imported brands(the resin was replaced after five years of use due to breakage and low working exchange capacity).
How Sanxing Helped the Client Overcome Challenges
During project implementation, Sanxing Resin not only supplied high-quality products but also delivered full lifecycle technical support:
Precise Selection:
Optimized resin bed depth and flow rate reduced effluent hardness to near 0 mmol/L, ensuring safe boiler operation.
Cost Reduction:
Regeneration cycles increased by 25%–33%, saving over 1 million RMB annually in acid and water costs.
Reliable Support:
Full-process technical support with 24-hour response ensured stable system performance.
Conclusion and Outlook
Leveraging its successful application in a 10-million-ton refinery project in Northern China, Anhui Sanxing Resin has once again demonstrated its expertise in large-scale industrial water treatment. Moving forward, we remain committed to a "quality-first" philosophy, providing green and energy-efficient softening resin solutions for sectors like petrochemicals, power, and metallurgy to drive industrial sustainability.
For more solutions and technical support, please contact us.
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