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Advance Techniques in Boiler Chemical Cleaning

Chemical Cleaning of Boilers with EDTA (Ethylene Diamine Tetra Acetic Acid)

By: BRIJRAJ ENGINEER (ABHIJEET PROJRCTS LTD,

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Agenda
1 2 3 4 5 Need for Chemical Cleaning of Boilers? What is EDTA Cleaning? BHELs Experience with EDTA Cleaning EDTA Cleaning Process EDTA vis--vis HCl Cleaning Advantages Conclusion

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Need for Chemical Cleaning of Boilers?

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Need for Chemical Cleaning of Boilers?

Pre-operative
Maintaining steam quality in the system.

Minimizing corrosion of the metal surface of the boiler.

Post-operative
Improving heat transfer in the system. Enhancing efficiency of the power plant. Minimizing under-deposit corrosion of the metal surfaces of boiler. Minimizing plant outage due to boiler tube failures.

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Need for Chemical Cleaning of Boilers?

Pre-operative Chemical Cleaning System

Evaporator System Economizer Down comers Bottom Ring Header Water Walls Boiler Drum (Only water touched surface)

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Need for Chemical Cleaning of Boilers?

Iron metal surface with Corrosion layer

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What is EDTA Cleaning?

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What is EDTA?
EDTA or Ethylene Di-amine Tetra acetic Acid is a strong chelating agent having ability to form stable complexes with metal ions present in the boiler such as of Iron and Copper etc.

C10H16O8N2

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EDTA and EDTA-Fe Complex Structure

EDTA EDTA-Fe Complex

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EDTA Pickling & its Reaction

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Magnetite Layer
Fe + O2 FeO

4FeO + O2 2Fe2O3
6Fe2O3 + N2H4 4Fe3O4 + N2 + 2H2O A protective layer of Magnetite (Fe3O4) is formed on the water touched metal surfaces in the steam generator. Magnetite layer is coherent in nature that stops further corrosion of the base metal.

Magnetite is a combination of FeO and Fe2O3.

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BHELs Experience with EDTA Cleaning

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EDTA Process - World Scenario

EDTA process is at present executed by :

Dow chemical Co USA Halliburton Services UK Alstom, MHI, & Siemens

Process details & chemical formulations especially inhibitor for the process are being held under proprietary rights by these companies.

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EDTA Process - World Scenario

BHEL has marked the giant leap by developing its own inhibitors and chemical formulations for EDTA Cleaning Process.

BHEL has joined the select band of few companies in the world to possess & establish this advanced cleaning process.

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Inhibitors
EDTA Process developed by R&D Centre of BHEL-Trichy; involved in-house development of inhibitors: BHEL MAX BHEL SOL These inhibitors are patented by BHEL: Patent Nos.: 177 & 332 / 2004

These inhibitors act by forming an invariable layer between the base metal surface and the chemical solution as the deposits are removed.

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Experience with EDTA Cleaning

EDTA Cleaning Process was introduced in BHEL in 2003-2004. Chemical cleaning of boilers with EDTA completed in 43 projects of different ratings, till Feb 2009.
Year 2003 2004 2004 2005 2005 2006 2006 2007 2007 - 2008 2008 - 2009 2009 - 2010 2010 2011 No. of Projects 1 3 3 7 13 16 15 20
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Total

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Experience with EDTA Cleaning

Rating 500 MW 250 MW 210 MW 75 / 120 / 125 MW No. of Projects 24 26 10 8

Total

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Projects expected in 2009-10

Rating 500 MW No. of Projects 9

250 MW
210 MW 125 MW

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1 6

Total

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Exceptions during reigns of EDTA Process

Besides EDTA Cleaning, BHEL has also conducted HCl cleaning at following 7 projects during the same period.

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Rihand # 4 (500 MW)

Vindhyachal # 9 (500 MW) Vindhyachal # 10 (500 MW) Sipat # 4 (500 MW) Sipat # 5 (500 MW) Kahalgaon # 6 (500 MW) Kahalgaon # 7 (500 MW)

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EDTA Cleaning Process

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EDTA Cleaning Process

1. Alkali Flushing

2.

Alkali Flushing Hot Water Flushing Cold Water Rinsing EDTA Pickling & Passivation Treated DM Water Rinsing

EDTA Cleaning

3. 4.

Inspection SH Back Flushing

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EDTA Cleaning Process

1. Alkali Flushing Purpose

Alkali Flushing (TSP and DSP is used as alkali) Removes polar organic material such as oil, grease etc. from the metal surface. Alkali reacts with polar organic materials to form soluble glycerols and salts. Dirt & loose debris etc. are also removed. Hot Water Flushing Cold Water Flushing

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EDTA Cleaning Process

1. Alkali Flushing - Procedure

Alkali Flushing Alkali solution made by adding TSP(0.1%) & DSP (0.05%) with DM water. Solution is filled into boiler through bottom ring header & economizer drains up to drum NWL. Boiler is fired. Water temperature is raised to 140C and boiler tripped. Solution is forced cool till 95C and then drained.

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EDTA Cleaning Process

1. Alkali Flushing - Procedure (Contd.)

Hot Water Flushing System is filled with DM water and temperature raised to 140C and then forced cool to 95C and drained subsequently.
Cold Water Rinsing System is filled with DM water and drained. The process is repeated till phosphate level is less than 10 ppm and pH around 7 to 8.

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EDTA Cleaning Process

2. EDTA Cleaning

Preparing EDTA Solution

EDTA solution is prepared for total boiler volume by mixing. 1.Ammoniated EDTA (40%) 2.BHEL MAX (inhibitor) 3.BHEL SOL (inhibitor) 4.Hydrazine hydrate 5.Ammonia : : : : : 4% (approx.) 0.15-0.2% w/v 0.15-0.2% v/v 1000 ppm (min.) for achieving pH 9.5-9.8

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EDTA Cleaning Process

2. EDTA Cleaning EDTA Pickling and Passivation

The system is filled with EDTA solution up to 100 mm below NWL of drum. The boiler is lighted up and temperature raised to 140C and maintained for maximum 4 hours. Sample solution is checked for Iron, pH and EDTA concentration every 45 minutes. The boiler is tripped either on achieving 3 consistent consecutive readings of Iron concentration or completion of 4 hours, whichever is earlier. The solution is allowed to cool till 95C and drained.
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EDTA Cleaning Process

(Typical)

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EDTA Cleaning Process

EDTA Storage Tank

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EDTA Cleaning Process

EDTA Mixing Tank & Pumps

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EDTA Cleaning Process

Sample Analysis of EDTA Solution

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EDTA Cleaning Process

2. EDTA Cleaning Treated DM Water Rinsing

A solution of hydrazine (0.01-0.02%) and ammonia with DM water is prepared (pH 9.5 9.8) and the system is filled with this solution.

Boiler is fired and temperature raised to 120C.

Boiler is tripped and natural cooled. When the temperature comes down to 95C, the solution is drained.

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EDTA Cleaning Process

3. Inspection

4.

Boiler Drum and Coupons Bottom ring header (Only for 500 MW units)

Super heater back flushing

Super heater is filled with a solution of hydrazine (N2H4 > 0.005 %) & Ammonia (pH>9.5) in DM water through SH drain header. When the solution comes through SH openings in the drum, the back flushing is continued for 10-30 minutes and drained.

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EDTA Cleaning Process

EDTA Cleaning Results

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EDTA Cleaning Process

EDTA Cleaning Results

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EDTA Cleaning Process

EDTA Cleaning Results

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EDTA Cleaning Process

EDTA Effluent Pit

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EDTA Cleaning Process

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EDTA Effluent Treatment by Aeration

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EDTA vis--vis HCl Cleaning - Advantages

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EDTA vis--vis HCl CleaningAdvantages

HCl Cleaning Process
1. Preliminary Cleaning Alkali Cleaning
Hot Water Flushing Alkali Boil-out Cold Water Rinsing

2. Acid Cleaning
HCl Pickling DM Water Rinsing Citric Acid Rinsing DM Water Rinsing Neutralization Passivation (1st and 2nd Stage)

3. Inspection
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EDTA vis--vis HCl Cleaning Advantages

Technological Advantage

Parameter Iron pick-up mechanism

EDTA Cleaning

HCl Cleaning

Strong chelating agent Dissolution for metal ions action

Process Advantage

Parameter Viability for Green Field Project Cycle time

EDTA Cleaning Suitable as auxiliary steam is not required 5-6 days

HCl Cleaning Not suitable as auxiliary steam required 14-17 days Less adherent
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Magnetite layer More adherent

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EDTA vis--vis HCl Cleaning Advantages

Process Advantage (contd.)

Parameter Chemicals required DM Water consumption Fuel consumption Nitrogen & its systems Temporary pipes & tanks

EDTA Cleaning 7 chemicals Less Less Not required MS/CS piping and tanks required

HCl Cleaning 12 chemicals More (4 times) More Required Extensive piping and tanks required with Rubber lining
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EDTA vis--vis HCl Cleaning Advantages

Process Advantage (contd.)

Parameter Acid Handling Pumps Process Handling

EDTA Cleaning Not required Easy due to less hazardous chemicals Easy as volume of effluent is less and requires aeration only Economical

HCl Cleaning Required Difficult due to hazardous chemicals Difficult as volume of effluent is more and requires chemical treatment Costly

Effluent treatment

Process Cost

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Conclusion

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Conclusion
EDTA cleaning process ensures efficient cleaning and passivation of boiler internal surfaces. Inhibitors for EDTA cleaning process being used has been developed by BHEL. Inhibitors are patented as BHEL MAX and BHEL SOL.

EDTA Cleaning has obvious advantages over conventional HCl Cleaning with minimum effect on the base metal surface.

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Thank you

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