Optimizing Steam and Cooling

Systems for Reliability and

Sustainability
Presented By: Kevin Emery
Kevine@chemtreat.com
804-317-2381

Optimizing Steam and Cooling Systems

for Reliability and Sustainability
Steam systems
Boiler Feedwater Pretreatment
Internal treatment and cycle control
Condensate System Treatment

Cooling System Failure Modes Balancing

Cycles vs. Risk

The Hydrologic Cycle

Fundamentals of Water
Why isnt water perfect for boilers?

AIR
EARTH

MINERALS

Calcium
Magnesium
Iron
Silica

Oxygen
Carbondioxide

Mud
Silt
Clay

Primary Boiler System Contaminants and

Issues
Contaminant

Issues

Hardness salts
Silica

Scaling and deposits

Turbine deposits and scale

Alkalinity and CO2

Foaming and carryover,

condensate corrosion
Boiler deposition
Deposition
Corrosion

Iron and manganese

Suspended solids
Oxygen

Boiler Scale
What is it?
Hardness = Calcium

& Magnesium
Calcium forms hard
calcium carbonate
scale in boiler.
Magnesium forms
magnesium silicate in
boiler.

Impact of Boiler Scale Percent Fuel Loss

Scale layer
Inches
1/64

Normal
Scale

High Iron
Scale

Iron and
Silica Scale

1%

1.6%

3.5%

1/32

2.0%

3.1%

7.0%

3/64

3.0%

4.7%

1/16

3.9%

6.2%

Impact of Scale

A boiler operating at 450,000 million Btus of

fuel for 8,000 hours at the rated capacity
of 45,000 pounds/hour of 150 psig steam.
If 1/32nd of scale is allowed to form and the
scale is normal. The fuel loss is 2%.
Assuming $5/million Btus
450,000M Btus/Year * $4 MBtu * 0.02 =
$36,000

Comparison of Common
Pretreatment Systems
Zeolite Softening Reverse Osmosis

Demin. Units

Removes

Calcium and
magnesium and
some iron

97% of salts, silica 99.9+% of salts,

and all TSS, gases silica, alkalinity
not removed
and CO2

Application

Low to medium
pressure boilers,
<600 psig

Across the board,

polishing required
for high pressure
applications

High pressure
boilers or silica
limitations

Cost and
Limitations

Low
Doesnt remove
alkalinity or silica

High cost
reject water

High cost
Acids and bases
for regeneration

Sodium Zeolite Softening?

How does it work?

Sodium Zeolite Softener

How does it work?
Calcium and magnesium from water are

transferred to the sodium zeolite resin via

chemical reaction.
Mg+
Ca++
Mg+
Ca++
Na
Na Mg+
Na
Ca++

Na

Na
Na

Na
Na

Na
Na
Na

Mg+

Sodium Zeolite Softener

Ca and Mg are exchanged for sodium
Mg+

Ca++

Ca++

Ca++ Mg+
Ca++
Ca++
Na+
Mg+
Na+Na+
Na+ Na+
Na+ Na+Na+
Na+ Na+

Mg+

Service

Backwash

Regeneration

Rinse

Sodium Zeolite Softening

How does poor operation affect the plant?
Increased scale

inhibitor demand
Increased energy
costs
Tube failures

Typical Softener Problems

Iron fouled resin: short runs

Leaking valves: hardness in boiler feedwater

Inadequate regeneration: short runs
Loss of resin: short runs
Channeling: hardness in boiler feedwater

Reverse Osmosis
Essentially molecular

filtration
~ 98% salt removal in
permeate
Dissolved gases are not
removed (CO2, etc.)
1025% of flow is
rejected as brine

Reverse Osmosis
Feed
200 ppm
calcium
carbonate

Permeate or
Product
Brine
788 ppm
calcium
carbonate

4 ppm calcium
carbonate

RO Pretreatment
Filtering

Dechlorination
Free available chlorine must be <0.05 ppm for composite
polyamide membranes
Activated carbon or sulfite (1.83.0 ppm sulfite per ppm
chlorine)
Antiscalants and dispersants
Most units are softened

pH adjustment

RO Troubleshooting
Leaking seals and O-rings: too much water

hammer
Fouling
Hardness and metals
Silt and colloids
Organics and microbiological

Membrane mechanical failure

Telescoping

Reliability in Plant Utility Systems

The deaerator is used to remove non-

condensable gases from the boiler feedwater:

Oxygen
Carbon dioxide

Ammonia

What is Oxygen Corrosion?

As temperature increases, the corrosivity of

dissolved oxygen in water doubles with every

18 F increase.

Can I Mix Condensate and Soft Water?

This is a common design flaw

The temperature of the condensate drives the

oxygen out of the soft water

In mild steel tanks the corrosion is severe
Iron transport to the deaerator and boiler
Pitting in the tank

Deaerator
What Do I Need To Know To Operate It?
Temperature in storage section should be less

than 3 F below the deaerator heating steam

temperature.
Ensure that the deaerator is properly vented
Inspect internals annually for oxygen pitting

Dissolved Oxygen Control

Common chemical oxygen scavengers and

metal passivators
Sulfite
Hydrazine
Carbohydrazide
Erythorbate/ascorbate
Methylethylketoxime/MEKO
Hydroquinone
Diethylhydroxylamine/ DEHA

Oxygen Scavenger Reaction Rates

Catalyzed sulfite is the

fastest
Ratio feed to BFW
Allow at least 2 minutes
Prevent ingress of oxygen in
standing equipment such
as pot feeders, sample
ports, etc.
Circulating some of the
boiler feedwater back to the
deaerator can improve
reaction rates and prevent
oxygen ingress

The Deaerator
What if it doesnt work properly?

A feedwater line subjected to excessive oxygen because of poor deaerator control.

Indications of Trouble
High oxygen scavenger use

Sudden changes in pressure

Maintain at least 2 psig unless under vacuum
18- to 24-inch discharge plume
Flooding of the tray or spray section
Poor inspections

Internal Treatment
The last stand
Program selection based on contaminants and

pressure
Iron deposition is a common contaminant in high
purity systems
Hardness contamination can be a concern from
the pretreatment system or condensate leaks
Provide buffering to prevent corrosion

Internal Treatment
Prevent corrosion
Low/high pH conditions
Destroy magnetite layer
Generate corrosion products

Generate hydrogen (low pH)

Underdeposit/concentrating film (formation of

acid phosphates/NaOH)
Localized metal loss
Gouging

Boiler Water Treatment

Prevent deposition
Iron oxide/scale/deposits lead to heat transfer
losses, underdeposit corrosion, tube failures from
overheating
On line cleanup of a dirty water tube boiler can
create chip scale and tube blockage.

Treatment
Programs

Precipitating
Phosphate

Chelant
Polymer

All
Polymer/Organ
ic

Coord.
Phos/ EPT

Application

Unsoftened
makeup with
90%
condensate
return
High purity
makeup
Softened
makeup

Consistent
quality
deaerated
water
Low iron
Low hardness

Consistent
quality
Low hardness
<25 cycles
Phosphonate/
Polymer for
Iron
Contamination
or variable
makeup

High pressure
High purity
makeup
No polymer
after 1,250 psig

Pressure

<900 psig

<600 psig

<900 psig

>900 psig

Feed Point

Drum or BFW

After BFW pump DA Storage

in BFW
BFW

DA Storage
BFW

Attention Level

Low

High

High

Low

Boiler Blowdown
Why do we blowdown?
To remove the dissolved solids that have

concentrated in the boiler due to evaporation

To prevent high alkalinity and steam
contamination due to foaming
To remove sludge
Cycles = Boiler feedwater /boiler blow down
Avoid >50 cycles in industrial boilers

Percent of Feedwater
that must Blowdown

How do Cycles of Concentration and

Blowdown Relate?
25
20
15

10
5
0
5

10 15 20 25 35 40 45 50 55 60 65 70 75
CYCLES OF CONCENTRATION

ASME Limits

How does Blowdown Affect Plant

Operations
Too much blowdown
Increased fuel costs
Increased water costs
Increased chemical costs

Over cycling the boiler

High TDS
Scaling and deposition
Underdeposit corrosion

Polymer breakdown
High alkalinity
Carry over
Turbine fouling

Boiler Bottom Blowdown

Purpose: To remove precipitated solids from

the bottom of the boiler

Procedure: Open valve 34 seconds only;
repeat 2 times
Frequency
Daily to once per shift with normal operation
34 time per shift during hardness problems

Limiting Factors for Boiler Cycles

Steam Purity and Separation Equipment
Silica is a major concern as is boiler alkalinity
Iron contamination from the condensate

system
Percent condensate return and feedwater
quality.
Polymer Residence Time

Condensate Treatment
Note the
groove
caused by low pH
corrosion

The Value of Condensate

Energy

Condensate
Return

Water
Makeup

Water can cost over $3.00 per 1000 gallon

Condensate is worth even more because it is pure

Value of Condensate 10 gpm

$54K per year or $5.4
Energy
180 F 80 F = 100 BTU/lb
10 gpm = 600 gph = 5004 lbs/hr
5004 lbs/hr x 100 BTU/lb x 24 hours day x 365
days/year = 4383 MM BTU
At $4/MM BTU = $17534/year in energy
Water, Sewer, and Pretreatment
10 gpm x 1440 mpd x 365 = 5256 K gallons/year
5256 x ($3/1000 gallon water + $2/1000 sewer) =
$26,280
5256 x $2/1000 gallons pretreatment costs = $10,512

Condensate Contamination
Problems
Significant scale potential
Boiler corrosion potential: organics
Foaming and carryover
Product contamination
Solutions
Find the source and repair, or
Dump condensate

Treatment Options
Mechanical
Deaeration
Dealkalizers
Demineralizers
Condensate polishers

Chemical
Filming amines
Neutralizing amines
Oxygen scavengers

Filming Amines
Advantages
Nonwettable barrier
ODA
Protection against
oxygen and carbon
dioxide
Feed at low level to
feedwater or steam
Low cost
FDA/USDA approval

Disadvantages
No good tests
Gunking
Distribution problems
Cannot use with
turbines
Feed separate

Ammonia
Advantages
Cheap
Rapid pH rise
Feed to feedwater,
boiler or steam
FDA approval

Disadvantages
Hard to control in
narrow pH range
Only high distribution
Potential for copper
Corrosion
Elevates pH

Neutralizing Amines
Feed to feedwater, boiler, steam

Neutralize carbonic acid, pH control

No oxygen protection
Wide range for complex system
Distribution ratios
Basicity

FDA/USDA approvals

Morpholine
High boiling point 265 F

Low distribution ratio

Protection initial condensation
Not good alone in complex systems
Cannot exceed 10 ppm for FDA
2.4 ppm/ppm CO2

Cyclohexylamine
Low boiling point 205 206 F

High distribution ratio

Good blend for complex systems
FDA maximum 10 ppm
2.11 ppm/ppm CO2

Diethylethanolamine
Low boiling point 202 203 F

Moderate distribution ratio

Blend with other amines
FDA 15 ppm maximum
2.1 ppm/ppm CO2

Probability of Boiler Failures

Variable

Level of
Control

Potential for
Failure

Impact

Oxygen Pitting

Constant

High

Immediate
Pitting of
economizer

Polymer Levels

Changes
Slowly

Low

Gradual
Scaling

Hardness in
Feed water

Constant

High

Immediate to
Gradual
Scaling

Conductivity

Constant

High

Immediate
Carry over
Deposition

Monitoring Program
Focus on Critical Few
hardness, conductivity, sulfite, oxygen, silica, pH
Condensate purity
inhibitor
Mass balance (flow and inventory)
Results Based
Heat Rate
Boiler Inspections
Boiler Efficiency

Questions

What Determines Limits for Cooling Tower

Cycles?

Hardness: Scaling index

Cycled pH
TSS
Film fill vs. splash fill
Filtration

Silica and iron in makeup

Corrosion
Discharge limits
Inorganics: Chlorides, Zn
Phosphate

Application
Skin temperature
Low flow

Ammonia Evaporative Condenser

Safe Limits: Circulating Water

Silica <180 ppm
TSS <50 ppm: use more polymer above

30 ppm
LSI <2.5 is ideal, but 2.8 is possible
Chlorides <150 ppm
Calcium <1,000 ppm use LSI
Iron <3.0 ppm

Wichita Water Cycle Up

Cycles

pH

Cond

'M' Alk Calcium Magnesium Ortho PO4

Silica

Chlorides Sulfates

LSI

pHs

1.0

7.8

634

111

83

56

19

92

67

0.3

7.5

1.5

8.0

951

130

125

84

29

138

101

0.7

7.2

2.0

8.2

1,268

173

166

112

38

184

134

1.2

7.0

2.5

8.4

1,585

216

208

140

48

230

168

1.6

6.8

3.0

8.5

1,902

260

249

168

57

276

201

1.9

6.7

3.5

8.7

2,219

303

291

196

67

322

235

2.1

6.5

4.0

8.8

2,536

346

332

224

76

368

268

2.3

6.4

4.5

8.9

2,853

390

374

252

86

414

302

2.5

6.3

5.0

9.0

3,170

433

415

280

95

460

335

2.7

6.3

5.5

9.0

3,487

476

457

308

105

506

369

2.9

6.2

2000 gpm tower with 10 delta T

$3/1000 water $2/1000 sewer
140,000.00

120,000.00

100,000.00

Cost

80,000.00
Inhibitor
Water
Sewer

60,000.00

40,000.00

20,000.00

0.00
2

Cycles

10

Failure Mechanisms
Over cycling/high pH: Mineral

scale deposition
Poor biological control:
Deposition, under-deposit
corrosion, disease
Under cycling: Water waste,
corrosion, chemical waste
Overfeed of halogen
Low pH: Corrosion
Low inhibitor: Corrosion +
deposition
Low flow: Corrosion+ deposition

Mechanical Oversights
Chemical Feed and Control Systems
Design for high and low load

Location of Tower
Avoid Air Intakes, Dusty Roads, Trees, Exhausts

Exchanger added to end of the line

System changes (water source, temperature, flow)

Metallurgy
Dont use galvanized towers with high alkalinity waters

Film Fill vs. Splash Fill

No filter to remove TSS

EXCESSIVE AND POOR USE OF

OXIDIZERS

Overfeed of Halogen
High oxidant feed

rates cause copper

pitting
Copper plates out
on steel and pits
steel

Probability of Failure
Level of
Control

Potential for
Failure

Impact

pH

Constant when
required

High

Immediate

Inhibitor levels

Changes Slowly

Low

Gradual

Biological control

Constant

Depends on
system

Immediate

Conductivity

Constant

High

Immediate

Variable

Cooling System Monitoring Program

Focus on the critical few
pH, conductivity, oxidant, inhibitors
Mass balance (flow and inventory)
Results based
Corrosion rates
Temperatures and heat transfer
Biological growth
Appearance
Water use and flow
Chiller efficiency
Data Management: Trend graphs, statistics, reports to

management

Questions?