Technical Analysis of UMK-UV-3840 High-Flow Ultraviolet Disinfection System

The UMK-UV-3840 Ultraviolet Disinfection System is a high-flow disinfection equipment based on advanced post-treatment technology of membrane separation, specifically designed for industrial water treatment applications. Adopting a high-power ultraviolet lamp array, combined with an intelligent PLC control system and an automatic cleaning device, the system achieves efficient and chemical-free disinfection of water with a treatment capacity of 590m³/h. Its core advantage lies in inactivating microorganisms through physical means, avoiding chemical residue issues. It is particularly suitable for scenarios with high requirements for water quality safety, such as advanced drinking water treatment, industrial circulating water disinfection, and food processing water treatment.

The system has been successfully applied in international projects such as those in Uruguay. Through comprehensive testing and verification by the engineering team, all performance indicators meet the design requirements, demonstrating reliability for long-term stable operation.

1. Intelligent Control System Architecture

The system adopts a Programmable Logic Controller (PLC) as the control core, constructing a complete automated control system.

Control Function Modules:

• Operation Logic Control: Implements basic logic such as system start/stop, lamp preheating, and fault protection.

• Automatic Cleaning Program: The quartz sleeve wiper operates automatically according to a preset cycle or feedback from ultraviolet intensity.

• Real-time Monitoring System: Integrates ultraviolet intensity sensors, water temperature sensors, flow meters, etc., to achieve online monitoring of multiple parameters.

• Fault Diagnosis and Alarm: Equipped with multiple protection functions against overcurrent, overvoltage, lamp failure, abnormal water level, etc.

• Remote Communication Interface: Supports industrial communication protocols such as Modbus and Profibus, and can be connected to upper computers or DCS systems.

Technical Advantages:

• High degree of automation, reducing manual intervention.

• Fast fault response speed and strong system safety.

• Traceable operation data, facilitating maintenance and management.

• Supports remote monitoring, adapting to distributed application scenarios.

2. Technical Parameters of Ultraviolet Disinfection Unit

Lamp Configuration and Power Design:

• Number of lamps: 12

• Power per lamp: 320W

• Total power: 3840W

• Lamp type: Low-pressure high-intensity mercury lamp (or medium-pressure mercury lamp, subject to confirmation of specific models)

• Ultraviolet wavelength: 253.7nm

Cavity Structure Design:

• Material: 316L stainless steel

• Wall thickness: ≥3mm (designed according to pressure-bearing requirements)

• Internal polishing treatment: Ra≤0.8μm

• Sealing structure: Double O-ring seal, pressure resistance ≥0.6MPa

• Water inlet and outlet configuration: Designed for a flow rate of 590m³/h, with flow velocity controlled at 2-3m/s

Process Characteristics:

• 316L material contains molybdenum, exhibiting excellent corrosion resistance to chloride ions, suitable for chlorinated water environments.

• Precision welding technology ensures no dead corners in the cavity, preventing microbial growth.

• High surface finish reduces ultraviolet reflection loss.

• Reliable sealing structure ensures no leakage during long-term operation.

Automatic Quartz Sleeve Cleaning System

Control Mode:

Timed start or automatic trigger based on ultraviolet intensity attenuation.

Working Principle:

After long-term operation of the quartz sleeve, calcium and magnesium ions, organic matter, etc., in the water will form a fouling layer on the sleeve surface, leading to a decrease in ultraviolet transmittance. Under the control of the PLC, the automatic wiper starts automatically according to a preset cycle (e.g., every 4-8 hours) or when the ultraviolet intensity sensor detects that the light transmittance drops to a set threshold. The wiper blade moves reciprocally close to the surface of the quartz sleeve to remove fouling and restore ultraviolet transmittance.

Advantages:

• Maintains ultraviolet disinfection efficiency above 90%.

• Extends lamp service life (reduces overheating damage caused by fouling).

• Lowers the frequency of manual cleaning and maintenance costs.

• Ensures continuous compliance of disinfection effects.

Quartz Sleeve and Lamp Arrangement

Quartz Sleeve Characteristics:

• Material: High-purity fused quartz

• Light transmittance: ≥90% (at 253.7nm wavelength)

• Wall thickness: 1.5-2.0mm

• Temperature resistance: Capable of withstanding instantaneous high-temperature shocks

Lamp Arrangement:

Parallel or annular arrangement is adopted to ensure uniform illumination of water flow in the cavity. For high-flow systems with 590m³/h, multiple lamps are usually arranged in parallel. Through reasonable flow channel design, the water flow velocity around each lamp is ensured to be uniform, avoiding disinfection dead corners.

Performance Parameters and Operational Characteristics

Main Technical Parameters

Disinfection Performance Analysis

Ultraviolet Dose Calculation:

Ultraviolet dose (D) = Ultraviolet intensity (I) × Exposure time (T)

Wherein, exposure time T = Effective length of the cavity / Water flow velocity

For a flow rate of 590m³/h, the cavity design must ensure that the water flow stays in the ultraviolet irradiation area long enough to reach the target dose. A dose standard of 40mJ/cm² can effectively inactivate most bacteria and viruses, including Escherichia coli, Legionella, Cryptosporidium, etc.

Influencing Factors:

• Water quality transmittance (UVT): The clearer the water quality, the better the ultraviolet penetration effect.

• Lamp output intensity: Attenuates with operating time and requires regular monitoring.

• Cleanliness of the quartz sleeve: The fouling layer will significantly reduce ultraviolet intensity.

• Uniformity of water flow distribution: Avoids short-circuit flow.

Operational Energy Consumption and Economy

Energy Consumption Composition:

• Lamp power consumption: 3840W (continuous operation)

• Control system power consumption: Approximately 200W

• Wiper motor: Intermittent operation, power consumption is negligible

• Total: Approximately 4.2kW (calculated at maximum power)

Operational Cost Advantages:

• No chemical consumption, saving chemical costs.

• Relatively low power consumption, with power consumption per ton of water treatment approximately 0.007kWh/m³.

• Low maintenance costs: Lamp service life is 8000-12000 hours, and wiper blades are replaced 1-2 times a year.

• Automated operation, low labor costs.

4. System Integration and Engineering Applications

Pretreatment Requirements

To ensure the long-term stable operation of the ultraviolet disinfection system, the inlet water must meet the following pretreatment requirements:

Water Quality Index Control:

• Turbidity: ≤1 NTU (recommended ≤0.5 NTU)

• Suspended solids: ≤5 mg/L

• Iron content: ≤0.3 mg/L

• Manganese content: ≤0.1 mg/L

• Hardness: Evaluated according to scaling tendency

Recommended Pretreatment Processes:

• Multimedia filtration: Removes suspended solids and colloids.

• Activated carbon filtration: Removes organic matter and residual chlorine.

• Softening treatment: If the raw water hardness is high, softening or scale inhibitor dosing should be considered.

• Precision filtration: 5μm security filter.

Installation and Commissioning

Installation Notes:

• Install according to requirements to ensure stable water flow.

• Reserve sufficient maintenance space (≥1m at the front and rear).

• The power cord specification meets the power requirements, and grounding is reliable.

• Configure valves and pressure gauges for the inlet and outlet pipelines.

• Set up a bypass pipeline for easy maintenance.

Commissioning Steps:

1. Check the electrical connections to confirm correctness.

2. Conduct no-load testing of the control system functions.

3. Perform water flow testing to check sealing performance.

4. Start the lamps and monitor ultraviolet intensity.

5. Set parameters for the automatic cleaning program.

6. Record initial operation data.

Maintenance Procedures

Daily Inspection:

• Check the displayed ultraviolet intensity value.

• Observe the operation status of the wiper.

• Record the operating current and voltage.

• Check for pipeline leaks.

Regular Maintenance:

• Every 3 months: Inspect the wear of the wiper blade.

• Every 6 months: Manually check the cleanliness of the quartz sleeve.

• Every year: Conduct a comprehensive inspection of the electrical system and replace lamps (according to actual service life).

• Every 2 years: Replace the quartz sleeve (depending on wear conditions).

Troubleshooting:

• Low ultraviolet intensity: Check the lamp, cleanliness of the quartz sleeve, and water quality transmittance.

• Wiper not operating: Check the motor, control signal, and mechanical jamming.

• System alarm: Troubleshoot according to the PLC fault code.

5. Application Scenarios and Case Illustrations

Applicable Fields

Municipal Drinking Water:

• Advanced disinfection of water treatment plants

• Secondary water supply disinfection

• Pipeline direct drinking water systems

Industrial Water:

• Process water in the food and beverage industry

• Purified water disinfection in the pharmaceutical industry

• Ultrapure water systems in the electronics industry

• Bacteria and algae killing in circulating cooling water

Special Applications:

• Aquaculture water disinfection

• Swimming pool water treatment

• Reclaimed water reuse disinfection

The UMK-UV-3840 High-Flow Ultraviolet Disinfection System achieves efficient and stable disinfection of water with a capacity of 590m³/h through the optimized design of intelligent PLC control, automatic cleaning devices, and a precision 316L stainless steel cavity. The system has the advantages of no chemical residues, low operating costs, and a high degree of automation, and has broad application prospects in fields such as drinking water and industrial water. With the development of intelligent and energy-saving technologies, ultraviolet disinfection technology will play a more important role in the water treatment field.

Amanda & UMEK Team is a professional one-stop integrated water treatment service provider. As a 17-year professional international trade water treatment technology company, we supply a full range of industrial water treatment equipment and accessories, including various ultraviolet filters, water softening equipment and control valves, FRP tanks, reverse osmosis membranes, membrane housings, etc. Our technical personnel can design reasonable and effective system configurations according to your regional or industry conditions.

Contact Information:

Tel: +8619331305749

Email: sales@cnumek.com / sales@amandawatertech.com

Website: www.amandawatertech.com / www.cnumek.com