CONDENSATE SYSTEM TROUBLESHOOTING AND OPTIMIZATION

Brian V. Jenkins
Nalco Chemical Company
Oak Brook, Illinois
ABSTRACT
Condensate is steam that has cooled and
condensed as a result of doing work (such
as heating a process or building, or driv-
ing a turbine). The purpose of this paper
is to outline benefits, guidelines, and
potential problem areas of condensate return
as well as tools available to optimize
proper treatment.
INTRODUCTION
One of the prime considerations in the
operation of a boiler is feedwater quality.
The better the feedwater, the less likely
it is that water related problems will
occur. There are many sources of feedwater:
raw, untreated water
zeolite softened water
demineralized water
lime soda softened water
and of course, returned condensate.
Of all of these sources, condensate is
usually the best economic choice. Conden-
sate, being condensed water vapor (steam)
is extreme1
6
pure. Since condensate is
usually 180 F (148 BTU/lb) or greater, less
fuel is needed to convert it back to steam
because 148 BTU's are in each pound of l80
0
F
condensate. And finally, because it is
water that the plant has already treated,
(ion exchange processed, scale/corrosion
treated, oxygen removed and evaporated to
produce steam) is represents a large
ment for a company. Therefore, recovering
and reusing this water becomes a matter of
good management.
Condensate return can help improve the
economics of boiler operation through:
Feedwater Temperature Increases - By
increasing feedwater temperature, less fuel
is required to produce a pound of steam
from a pound of water. Increasing the
amount of returned condensate increases the
feedwater temperature.
Concentration Increase (Blowdown
- Since condensate is low in
the more that is returned
the lower the concentra-
tion of feedwater solids. Boiler cycles of
concentration increase, blowdown decreases,
and so does the amount of heat lost through
the blowdown.
Reduced Make-Up Water Requirements - As
more condensate is recycled, less make-up
is required tor feedwater. Therefore, less
money is spent on make-up water treatment
(ion exchange regenerant, chemical treat-
ment) .
Now that reasons for returing condensate
have been established, it is necessary to
be aware of problems incurred in that area.
Almost all difficulties encountered in
condensate can be traced back to two
sources:
carbon dioxide
oxygen
1983 Nalco Chemical Company All Rights Reserved
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Proceedings from the Fifth Industrial Energy Technology Conference Volume II, Houston, TX, April 17-20, 1983
Carbon Dioxide
In boiler feedwater, some alkalinity is
present. Even in demineralized water,
some aklalinity is necessary to prevent
certain types of boiler scale. Under the
pressures and temperatures encountered in
the boiler, a portion of the alkalinity
breaks down to form carbon dioxide. Carbon
dioxide, being a gas, is carried out with
the steam. When steam condenses, some of
the carbon dioxide dissolves in the conden-
sate. This forms carbonic acid.
Carbonic acid, being a weak acid, will
cause four characteristic problems:
The pH of the condensate will drop
Dissolved iron content of the condensate
will increase
Total dissolved solids content of the
condensate will also increase
A trough-like thinning of the bottom
of the condensate pipe occurs. (Fig. 1)
Figure 1 - Carbonic Acid Attack on
Condensate Piping
What is the impact? Iron is dissolved by
low pH condensate and is then returned to
the feedwater.
Fe + 2H+ + 2HC0
3
Fe(HC0
3
)2 + H
2
t
When soluble iron mixes with alkaline
boiler water, iron hydroxide is formed
which is subsequently thermally aged to
various iron oxide compounds. These
amorphous iron oxides tend to agglomerate
on heat transfer surfaces. (Fig. 2)
Figure 2 - Boiler Tube with Iron Deposi s
Simply put, iron leaves one part of the
steam system (condensate piping) and
deposits in another area of the boiler
system (boiler heat transfer surfaces).
The results of carbon dioxide corrosion
include:
expensive replacement of condensate
piping
reduced boiler tube life and, in
cases,
unexpected boiler shutdown and
production losses.
The net result is an economic Jutlay fa
maintenance repairs for the condensate
network, acid or chemical cleaning for he
boiler, and a possible loss of plant pro u-
ction due to the unscheduled outage.
Oxygen
Also present in boiler feedwater, this as
is removed by conventional mechanical a d
chemical means.
Mechanically, oxygen content is reduced by
a deaerator, which atomizes the feedwat r
stream, and "scrubs" itwith steam. Th
steam increases feedwater temperature,
reduces oxygen solubility, and is relea ed
to the atmosphere. Typically, oxygen
concentration is reduced to below 10 pp
The rest of the oxygen (even at 10
oxygen is still capable of causing
corrosion) is scavenged chemically usin
one or more of the following oxygen
scavengers:
sulfite
hydrazine
other special reducing agents (i.e.
NALCO ELIMIN-OX or SUR-GARD)
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Usually, these two processes, mechanical
and chemical feedwater oxygen elimination
are sufficient to prevent oxygen from
flashing into the steam. However, in
large, extensive condensate systems, air
can be drawn in through condensate pumps,
improperly operating heat exchangers or
tank vents. This air-in-leakage brings in
both carbon dioxide and oxygen, causing
more corrosion problems than either gas
individually.
Oxygen attack is characterized by pitting
of the condensate pipe. (Fig. 3)
Figure 3 - Pitting of Condensate Pipe from
Oxygen Attack
The combined action of carbon dioxide and
oxygen can cause accelerated rates of
10-40 times the rate of either gas indi-
vidually. (Fig. 4)
2Fe(HC0 )2 + 02 + Fe 0 + 4C0
2
t + 2H 0
3 2 3 2
Figure 4 - Carbonic Acid and Oxygen Attack
of Condensate Pipe
The impact of oxygen attack is the same as
that of carbon dioxide - equipment damage,
expensive maintenance, unexpected boiler
shutdown, and possible costly production
losses.
PROBLEM PREVENTION
The best way of dealing with these two
corrosive gases is to prevent their entry
into the boiler system. Simple mechanical
measures include:
1. Good deaeration and properly operating
condensate pumps and tank vents can keep
oxygen and atmospheric carbon dioxide out
of the system.
2. Demineralization or split-stream
dealkalization can greatly reduce the
amount of alkalinity in boiler feedwater,
and thus, the amount of carbon dioxide
generated by alkalinity breakdown.
3. Condensate polishing, that is, using
ion exchange resin to remove and filter
hardness and corrosion products, is an
effective method of elimination of the
results of in-leakage and corrosion, but
not the causes.
Not all problems can be cured mechanically,
and due to budget constraints, chemical
treatment may be selected. There are
chemical answers to carbon dioxide and
oxygen corrosion in the condensate.
Neutralizing Amines - These products do
just what their name indicates: neutralize
carbonic acid formed in the condensate.
Since carbonic acid cannot exist above a
pH of 8.2, neutralizing amines are used.
Neutralizing amines are primarily charac-
terized in two ways: vapor/liquid (V/L)
distribution ratio, and pH/concentration
equilibria. Basically, the V/L ratio
refers to the amount of amine present in
the vapor (steam) phase versus the liquid
(condensate) phase. The V/L ratio is
pressure and temperature dependent, and
varies by amine. The pH/concentration
equilibria indicates what pH will be
obtained at a given concentration. Past
a certain pH, additional neutralizing
amine will do little to further increase
the pH.
Common neutralizers are morpholine, cyclo-
hexylamine, diethylaminoethanol (DEAE),
aminomethylpropanol (AMP), dimethyliso-
propanolamine (DMIPA), and methoxypropyl-
amine (MOPA). As mentioned earlier,
neutralizing amines neutralize carbonic
acid. Their impact on oxygen is
negligible.
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Filming Amines are used to protect cond-
ensate piping from oxyger and carbonic acid
attack. This is done b} laying down a very
thin film on the condensate pipe. (Fig. 5)
Figure 5 - Filming Amine Providing
Nonwettable Surface
In order for the filmer to work, the
condensate pH must be high enough for the
film form. Octadecylamine is a commonly
used fllmer, but the pH must be controlled
at a range of 6.5 - 8.0. Outside of this
range, the film strips off, and can cause
deposits in the steam traps and condensate
lines and even the boiler. Also, octa-
decylamine is very difficult to feed.
Anothe filmer, a proprietary compound
353) has a more stable pH range of
6.5 - 9.5, making it much easier to use,
and overall, a more flexible program. In
almost all cases, the filmer must be
supplemented with a neutralizing amine.
Filmers alone do not have enough neutral-
izing capability to buffer condensate pH
up into the range where filming can effec-
tively take place. Most of Nalco's
filmers are offered as a combination treat-
ment of filming/neutralizing amines to
alleviate this problem.
The fact that a filmer/neutralizing
program can provide protection at a lower
pH than a straight neutralizer may allow a
plant to use less neutralizer, and thus
reduce treatment costs. It should be
noted that the ultimate basis for this
decision is the individual plant's trea
ment performance and operating history.
Another benefit of filming amines noted
some users is an improvement in heat
transfer, due to the film promoting nuc
ate condensation.
-
by
e-
An alternative to filming amines for cond-
ensate oxygen corrosion protection is a
oxygen scavenger/metal passivator. (Fig 6)
Figure 6 - Passivated Pipe Surface
These compounds work by the same mechan sms
as the feedwater oxygen scavengers ment on-
ed earlier. The oxygen problem is addre sed
directly by using an oxgyen scavenger/
metal passivator in the steam/condensat
system. Passivation improves as conden ate
pH approaches 8.2, due to the absence 0
carbonic acid, which accelerates the de ra-
dation or inhibits the formation of the
passive magnetite film.
A combination of neutralizing amines an
metal passivator can be ideal for many
plants. However, if feedwater alkalini
ties are high, a neutralizer/filmer
program may be more econimical. The tr de-
off between ease of control (which favo s
neutralizer/metal passivator) and econom cs
(which favors neutralizer/filmer) is sys em
dependent.
There are several ways to tell if the c nd-
ensate system is being treated properly
Boiler and condensate line inspections re
the ultimate criteria. Are the condens te
clean and well passivated? Are tpe
bOller surfaces free of iron oxide and I
deposits?
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Proceedings from the Fifth Industrial Energy Technology Conference Volume II, Houston, TX, April 17-20, 1983
Condensate System Monitoring - A well admin-
istered program of condensate testing can
prevent small problems from becoming large
ones. Testing and monitoring that wil:
prove useful for system control include:
- Checking condensate pH at a number of
plant locations can insure that the entire
condensate network is properly treated for
carbonic acid attack. When sampling cond-
ensate, technique is extremely important
because of the high purity of the sample
involved. The sample should be taken
through a cooling coil at a temperature oi
less than 90
o
F. Higher temperatures will
cause flash off of carbon dioxide, oxygen,
and amine, and give false results. Also,
the sample coil should be throttled at the
exit and not the intake, to avoid drawing
air into the cooling coil and giving false
results. Generally, a pH below 8.2
indicates excessive corrosion for a neu-
tralizing amine program.
Iron Measurement - Dissolved, insoluble,
or total iron measurement is another good
way to track performance of condensate
treatment. Again, due to the nature of the
sample, sampling is extremely important.
Continuous flowing samples are best, but
when not available, flushing sample lines
and allowing them to run for a few hours
is satisfactory. If iron levels are above
50 ppb, excessive corrosion is taking place.
The following are tests that can be run on
condensate to determine iron content:
MilliporeQY Filters - This simple test can
measure insoluble particulate iron by
passing a liter of condensate through a
membrane filter and comparing the result
to a color chart such as the Babcock and
Wilcox comparison chart. (Fig. 7) Although
semi-quantitative, this test is also a
good tracking method, and can be quite
graphic.
Photometric Analysis - Laboratory tests to
determlne lron levels can give very accu-
rate results which are precise trend
indicators.
Gas Measurement - Detecting gases that
cause corrosion (oxygen and carbon dioxide)
can be the first step in determing if the
agents used to combat them are working.
There are tests for both carbon dioxide
(simple oxygen (Indigo
carmine or which are accurate
and reliable. Continuous oxygen meters
are also available. Generally, if oxygen
is above 50 ppb, corrosion is taking place.
Filming Amine Resiaual - Although a more
complex test, the filmer test can indicate
if all of the condensate system is being
filmed properly, or if the film is not
forming.
Oxygen Scavenger/Metal Fas"s"iVator: Test -
Usually a simple residual test. Here,
again, controlling the metal passivator in
a given range can insure optimum results.
Corrosion Coupons - (Fig. 8) Strips of
metal, usually the same metallurgy as the
system being monitored, are inserted into
condensate flow for a known length of time,
normally thirty days. The coupon is re-
moved, and its weight compared with its
weight at entry, then a corrosion rate is
calculated and expressed in mills per year.
These, like the Millipore filter pads,
provide semi-quantitative measurements,
but allow good system monitoring.
The previously mentioned tests and analyses
have been used for some time. Nalco is
able to offer two additional tools that
permit much more accurate condensate model-
ing and evaluation than conventional
methods.
10
71'
1000 100 2SO 100
Figure 7 - Babcock & Wilcox Membrane Charts (Courtesy of Babcock & Wilcox)
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Proceedings from the Fifth Industrial Energy Technology Conference Volume II, Houston, TX, April 17-20, 1983
Figure 8 - Corrosion Coupon
The first of these methods is called a
Nalco Selective Phase Condensate Extractor
(Fig. 9) (SPCE). This device, when attached
to a plant steamline, creates initial and
final condensate samples, representing
initial and final points of condensation in
the plant. The purpose is simple -- track-
ing amine and carbon dioxide behavior in
an entire condensate system from a single
steam sample. The benefits are many.
Troublesome pH areas can be pinpointed for
further analysis. The ability to hook up
to a single existing steam sample point
without having to shut down a process to
install sample taps is an added convenience.
Slight changes in the feedwater, amine feed
conditions, or other parameter changes can
be quickly evaluated since the SPCE deals
with on-line steam
OOo-r"T---c
w
=-',><I-,
TC,
I

"'"'",""",, [ ....f..om:
Gross Condensale w,
InilialCondensale Final Condensate
Fig. 9
Selective Phase Condensate Extractor (SPCE)
6Hl
The other innovative tool for condensat
analysis is the Nalco Condensate Comput r
Model.
The Condensate Computer Model was devel ped
to predict behavior of carbon dioxide and
amines in various types of condensate
systems. The model is a series of programs
designed by Nalco to evaluate various
of condensate systems. All programs
predict pH's at various plant locations; or
dosages of amines necessary to attain
desired pH results. The model uses dati on
carbon dioxide, amine thermodynamic beh'v-
ior, and plant condensate system config -
ration information to draw its conclusi ns.
Impact on corrosion rates by filmers is not
taken into account, since pH prediction is
the main goal of the program. Many of
Nalco's filmers are offered in COmbination
with neutralizing amines, so a pH range
appropriate to a combination treatment an
be selected, instead of a pH range appr,-
priate to a neutralization-only
Information on the condensate system,boller
and feedwater chemistry is gathered by he
Nalco salesman. Condensate pH data, if
available, is also recorded, along with
dosage information on the current amine
treatment. The Nalco salesman then
connects with a main computer at the Na co
Technical Center and uses the program
through a portable terminal.
using the model, the Nalco salesman can
Troubleshoot systems and help spot
process contamination or air in-
leakage by comparing actual vs.
predicted pH at key plant locations.
Examine a condensate corrosion
inhibitor and its impact on a
particular system at different
dosages.
Optimize dosage of a particular
condensate corrosion inhibitor to
attain a desired pH range.
Calculate dosages of inhibitors
for satellite feed.
Evaluate amine/carbon dioxide
behavior for multiple boiler systems
feeding steam to a common system,
as well as flashed steam (cascading)
systems, or thermocompressor systems
Examine multiple amine feeds.
ESL-IE-83-04-108
Proceedings from the Fifth Industrial Energy Technology Conference Volume II, Houston, TX, April 17-20, 1983
SELECTIVE PHASE CONDENSATE EXTRACTOR (SPCE)
CASE HISTORY
Due to the large area covered by the plant,
a Texas refining complex was having diffi-
culty providing adequate condensate
corrosion protection to all processes.
Many of the condensation points were in-
accessible for testing. Furthermore,
manpower and time restrictions prevented
sampling and testing of all accessible
condensate return sources.
The plant has 12 power boilers operating
from 450 to 1500 psig. There are also
seven waste heat boilers at 100-400 psig.
Condensate is the main feedwater source,
with sodium zeolite make-up to the high
pressure systems. The existing condensate
treatment program consisted of both
neutralizing and filming amines.
The Selective Phase Condensate Extractor
(SPCE) simulated the steam condensate
system at the complex. Use of the SPCE
uncovered areas where the existing amine
program was not protecting the system and
corrosion was occurring. By studying
these problem areas in greater detail,
types of amines and feed points were recom-
mended which further reduced corrosion in
these areas. Table 2 shows the average pH
at the gross, initial, and final stages of
condensation of various steam lines.
Since recommended condensate pH for a
combination neutralizer-filmer program is
generally in the range of 6.5-9.0, certain
areas were uncovered where corrosion was
occurring. There were six points in the
system that required additional amine
treatment.
TABLE 2 - pH at various sample points
Sample Point Gross Initial Final
and pressure pH pH pH
(psig)
I. 400 8.21 8.53 8.43
2. 150 7.77 8.13 8.00
3. 15 7.90 8.56 N.A.*
4. 400 8.73 9.16 6.98
5. 400 5.97 7.28 5.38
6. 400 6.21 8.36 5.62
7. 100 9.05 8.98 9.00
8. 50 N.A.* 5.66 5.60
9. 400 8.24 8.74 8.23
10. 250 7.22 7.29 7.08
II. 150 5.46 5.21 5.01
*Not Applicable
Note:
Gross pH: Fully condensed steam sample pH-
Indicates general corrosivity
Initial pH: ~ r s t stages of condensation
Final pH: Condensate formed at the end
points of a condensate system
Final condensate samples 5 and 6 required
additional cyclohexylamine-type corrosion
inhibitors to control corrosion in the
later stages of condensate formation. A
blend of neutralizing amines."asrecommended
to protect the total system of sample
points 8 and 11 because low pH's were found
in both initial and final condensates.
Since this study, supplemental amine treat-
ments have been initiated, and corrosion
in those previously unprotected systems
has been significantly reduced. Iron oxide
contamination of boiler feedwater has,
therefore, also been reduced, decreasing
the risk of costly tube failures from iron
oxide deposits.
CONDENSATE COMPUTER MODEL CASE HISTORY
MIDWEST PAPER MILL
Problem: A paper mill generating 500 psi
steam was experiencing low pH and high
iron levels in certain areas of its cond-
ensate system. The mill produces approxi-
mately 2.2 million pounds of steam per day,
using hot lime softened and filtered water
and returned condensate boiler feedwater.
Steam is used for process and building
heat, and to drive turbines.
The plant was using a combination treatment
of neutralizing amines, filming amines, and
oxygen scavenger. Due to the extensiveness
of the system, not all areas of the cond-
ensate network could be tested.
Program: The Nalco Condensate Computer
Model was used to model the plant's
condensate system. Results of the modeling
showed areas where condensate pH was too
low for film formation. Low pH and lack of
film formation were causinghighiron levels.
Results: Additional feed of neutralizing
amine was initiated to raise condensate pH
toa point where the filming amine could
work. ~ iron levels measured by
Millipore filters, dropped from 750 ppb
to 100 to 150 ppb. Additional work is
continuing to further reduce iron content
of the condensate. Condensate polisher
runs were doubled as well.
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Proceedings from the Fifth Industrial Energy Technology Conference Volume II, Houston, TX, April 17-20, 1983
Conclusion: Due to the use of the
Condensate Computer Model, corrosion rates
decreased drastically, condensate polisher
loading improved, and the amount of iron
being returned to the boiler decreased
significantly.
CONDENSATE COMPUTER MODEL CASE HISTORY
MIDWEST FOREST PRODUCTS PLANT
Problem: A forest products plant was
using 200 psi steam for its rosin heating
and hot press processes. Condensate cor-
rosion from both carbonic acid and oxygen
attack was experienced at the hot press
inlet.
The plant's boiler system uses sodium
zeolite softened water and returned cond-
ensate for feedwater. The neutralizing
amine program being used was not sufficient
to combat carbonic acid, formed by break-
down of alkalinity to carbon dioxide, which
left the boiler with the steam. Also,
the neutralizing amine did nothing to
address the oxygen problem. Iron levels
in the condensate were in excess of 100ppb.
Program: The Nalco salesman used the Nalco
Condensate Computer Model at this plant to
help him analyze and model the system.
Good correlation between actual and pre-
dicted pH's was shown. The model indicated
that the plant was feeding an excessive
amount of amine for a relatively small gain
in pH, and that changing programs could
give better results at less cost.
The Nalco Representative used his exper-
ience and the model in establishing a
filming amine program for the oxygen
problem, and a neutralizing amine program
for the carbonic acid attack.
Results: Iron levels dropped from over
100 ppb to 4 ppb, a decrease of 96%.
Total amine consumption dropped by
approximately 75%.
Conclusions: The Nalco Condensate Model
combined with the capabilities of the
Nalco representative cured a troublesome
corrosion problem for this plant.
CONDENSATE COMPUTER MODEL CASE HISTORY
WESTERN REFINERY/PETROCHEMICAL COMPLEX
Problem: A western refinery/petrochemical
boiler system was experiencing corrosion
in the outlying areas of their extensive
condensate network. Condensate pH's of
less than6 were not uncommon, with
Millipore filter tests showing 400-500 ppb
or iron in the far reaches ofthecondensat.e
system.
6113
,
The plant's 800 psi system generates
approximately 18 million pounds of stea
per day, using sodium zeolite, hot lime
softened water and returned condensate r
boiler feedwater. The steam is used fo
process heating, driving turbines, and
reboilers. A combination treatment of
neutralizing and filming amines with an
oxygen scavenger was in use.
Program: The Nalco Condensate Computer
Model was used by the Nalco
to determine why the complex was having I
problems. The model showed that a change
in feed point and an increase in dosage I
would produce uniform pH's throughout tJ
system. Prior to this, most of the pla t
pH's were in the range of 7-8, except i
the extreme ends of the condensate syste .
Results: Using the model, the Nalco rep-
resentative was able to optimize the dos ge
of amine to adjust pH range and reduce
corrosion rates. Iron levels have dropp d
more than 50%, and pH's throughout the
plant are more uniform.
SUMMARY
The rewards for increased condensate re rn
are many. Energy savings and improved
steam production reliability are the
primary potential benefits. Use of inno a-
tive modeling techniques such as the Nal
Condensate Computer Model, and a regular
monitoring program can help insure optim m
results and a well protected system wit
minimum energy wastage.
TRADEMARKS
(1) Millipore@ is a registered trademar
of Millipore Corporation.
(2) CHEMets@ is a registered trademark f
CHEMetrics Inc.
(3) NALCO ELIMIN-OX and SUR-GARD are al
registered trademarks of the Nalco
Chemical Company.
BIBLIOGRAPHY
(1) LaBombard, R.J., Troubleshooting A
Condensate System, August 1981.
(2) Kemmer, F.N., Editor, Nalco Water
Handbook.
(3) Kelly, J.A. and M. L. Palmer, Iron
Oxide Deposition - Complete System
Control, Proceedings of the 40th
International Water Conference,
October 3D, 1977, Pittsburgh, PA.
(4) Lin, M.L.; Internal Nalco Communica-
tions.
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Proceedings from the Fifth Industrial Energy Technology Conference Volume II, Houston, TX, April 17-20, 1983
(4) Christiansen, P.B.; Saving Energy Water Equipment Manufacturers' Association,
By Effective Water Treatment, Industrial Pollution Conference, March
Proceedings of the Water and Waste 1976, Houston, TX.

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Proceedings from the Fifth Industrial Energy Technology Conference Volume II, Houston, TX, April 17-20, 1983