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Treatment
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Handouts .
AGD 1
Boiler Water System
pre-treatment Feed
s s
Tank s
Feed pump
Condensate s Receiver
s
Water
Column
Boiler Plant Process s Sample point
s
s
Continuous Blowdown
Benefits Of Using Steam
High Heat Content.
Gives up heat at constant
temperature.
Produced from water which is cheap
and readily available.
It is clean, odourless and tasteless.
Can be used to generate power.
Can be easily distributed and
controlled.
3
Types 0f Boilers
Coil type
Smoke tube
Water tube
Spreader stroker
4
Major Problems
Scaling
corrosion
Priming / Foaming
Silica carryover
Caustic embrittlement / cracking
5
Problems Caused
By Impurities
Water
Impurities Problems
Hardness Scaling
Ca/Mg salts
Carbonates
Phosphates
Silicates
Precipitation of non-alkaline
hardness , by carbonate ,
alkali or orthophosphate
added for deposit control
Elevation of temperature
Control pH>9.4
12
3.0: System:Steam /
Condensate
Problems Causes Treatment
Deposits Carry over from Antifoam
drum
Limit SiO2 control
Silica Volatalisation pH>9.4 in the drum water
13
Boiler Water Treatment
No Scale: Heat transfer surfaces
. free from Scale, sludge,
. & deposits
No corrosion: Surfaces covered
. by film of magnetite
Pure steam:Elimination of
. carryover
Safe Operation: Prevention of
. sludge in the water
. level & blow down control
Deposit Formation
Deposit Formation
17
Thermal Conductivities
( BTU .ft / ft2.hr.deg F )
CaCO3 1.10
Ca3(PO4)2 2.20
CaSO4 0.90
Fe2O3 0.35
SiO2 (Quartz) 0.97
Carbon steel 30.0
Copper 218
18
Scale Deposition
Potential
Tonnes/Year Entering Boiler
4
3.5
3.0 10 ppm hardness
Tonnes
2.5
2.0 5 ppm hardness
1.5
1.0 2ppm hardness
0.5
Steam Production kg/hr
10,000 20,000 30,000 40,000 19
SCALE / DEPOSIT CONTROL
Deposit Control
Correct Pre-Treatment of Feed Water
Hardness Precipitation.
ppted as CO3-2 or PO4-3 in presence of alkali.
Add sludge conditioners-polymers.
Metal Oxides
Dispersed with phosphonate + polymer.
Silica
Mainly present as Silicic acid H2SiO3
Decomposes above pH 9.4 into ions
Treatment
pH>9.4
Keep below limits specified
21
pH and PO4 Concentration
10.8
Above curve
10.6
Free caustic present
10.4
10.2 Below curve
10.0
pH all alkalinity in the form of phosphate
9.8
9.6
9.4
9.2 PO4- conc in ppm
10 20 30 40 50 60 70 80 90
22
CORROSION CONTROL
Corrosion
Presence of Oxygen, causing ferric
oxide rust ,Fe2O3
Fe +2H2O ---> Fe(OH)2 + H2
Under favourable conditions oxide
reduces to magnetite,Fe3O4,a very thin
protective adherent film/layer
3Fe(OH)2 ---> Fe3O4 + 2H2O + H2
Magnetite film is most stable between
pH 10.5 - 11.5
24
Corrosion Control
Removal of oxygen
*Mechanical Deaeration
*Scavenging by chemicals
25
Mechanical Deaeration
Steam or Vacuum is used
Technique employed :
- To reduce partial pressure
- Continuously extract evolved gases
26
Vacuum Deaerator
Oxygen Scavenger
Reactions
Hydrazine
N2H4 + O2----------> N2 + 2H2O
Sulphite
2Na2SO3 + O2 ---------->2Na2SO4
Diethylhydroxylamine (DEHA)
C2H5
NOH + [O] --> 2CH3COOH + 2N 2 + H2O
C 2H5
28
Sulphite
Limitations:
Adds to boiler water TDS
Metal Passivator
6Fe2O3 + N2H4 -----> 4Fe3O4 + 2H2O + N2
Carcinogenic
30
Di-Ethyl-Hydroxyl-Amine
DEHA
Non-Toxic
LD50 values---> 2190 mg/kg
(RATS, ORAL)
-------> 59 mg/kg for N2H4
Volatile : Available in return condensate line
Does not impart any solids to Boiler Drum Water
1.24 ppm DEHA 1 ppm O2
Forms stronger magnetite film
31
Reaction Rates Of Oxygen
Scavengers At 700F And pH 8.5
10.0
Hydrazine
8.0
Catalysed Hydrazine
D.O. 6.0 DEHA
ppm
4.0 Sulphite
Catalysed DEHA
2.0 Catalysed Sulphite
10 20
Contact Time In Minutes
Reaction rates of oxygen
scavengers at 700F& pH 11
10.0
8.0
D.O.,ppm Catalysed Hydrazine
6.0
4.0
Catalysed DEHA
2.0
Catalysed Sulphite
0.8
ppm NH3 Hydrazine
Generated
0.6
per ppm
Product 0.4
0.2
DEHA
Iron8.0
reduced
from ferric
6.0
to ferrous
Uncatalysed Hydrazine
4.0-
Vegetable Tannins--Absorb O2 in
alkaline Condition
Tannins form metal complexes & act as
corrosion inhibitors
Decompose at high temp. Used in low
press. boilers
useful at low temp. ,for protecting
feedline
36
Carbon dioxide
Corrosion
Carbon dioxide is present both in free &
combined form
CO2 + H2O <---> H2CO3 ( H2O.CO2 )
. - +
H2CO3 <--->HCO3 + H (pK=4.2 )
. -2 +
HCO3 <---> CO3 + H (pK=8.3)
Free CO2 is zero above pH 8.3 ,BFW is
therefore neutralised to pH 8.5 ~ 9.0 37
Carbon Dioxide
Corrosion
CO2 is released on heating in the drum
_ _2
2HCO3 + Heat ----> CO3 + H2O +CO2
_2 _
CO3 + H2O + Heat ----> OH + CO2
38
Return Lines Corrosion
When steam condenses O2 & CO2
dissolve and produce dil.carbonic acid
containing O2
This codensate will corrode return
system
O2 causes pitting, while CO2 will
channel out as grooving
Corrosion products will deposit in traps
& strainers, and may block narrow-bore
returns 39
Return Line Corrosion
Protection
Pretreatment - De-alkalisation /
. De-mineralisation *
. Deaeration
Oxygen Scavenging (Volatile) - D.E.H.A
Use of Volatile Neutralising Amines to
keep BFW & condensate pH > 8.5
Filming Amines
*Softening Will not remove alkalinity
& should be avoided
40
Volatile Oxygen
Scavenging (V.O.S)
DiEthylHydroxylAmine (D.E.H.A)
Volatile hence passed into steam
(Distribution ratio 1.26).
Removes Oxygen directly from the
condensate
Reduces corrosion and also promotes
formation of an adherent magnetite film
which gives additional corrosion
protection.
41
Volatile Oxygen
Scavenger (V.O.A)
42
Neutralising Amines
45
Filming Amines
Filming amines contain a cationic amine
group & a long hydrocarbon chain
(hydrophobic)
Form an impervious, Non-Wettable film on
metal surfaces by attracting amine groups
Steam condenses as a film & insulates
heat transfer surfaces.
With filming amines the hydrophobic film
promotes condensation as droplets &
increases heat transfer ( Very useful on a
paper drying roller )
46
Primary Amines
47
Secondary Amines
48
Filming Amines
1.6
1.2
Silica , ppm Boiler water pH > 10.3
0.8
0.4
Boiler water pH<9.0
0.0 Press.,psig
1300 1500 1700 1900 2100 2300 2500
Caustic Embrittlement
52
Inhibition Of
Cracking
For HP & MP boilers - use zero caustic /
co-ordinated phosphate treatment
(normally stress relieved tubes are
used)
for LP boilers following chemicals may
be used:
*NaNO3 - keep NaNO3 / T.Alk as
CaCO3 ratio above 0.4
*Na2SO4 - keep Na2SO4 / NaOH ratio
above 2.5 53
Priming
Boiler Water
56
Shell Boiler Operating Parameters
Type of boiler Lancashire Verticak Fire Tube Economic/Vertical Wt. Modern Packaged
Cornish
Boiler pr 350
Bar PSIG 150 150 150
Feed water
----------------
pH ---- ------- ------ 8.5-9.5
Boiler water
------------------
Caustic alk. Min. 200 250 250 350
All reserves are as ppm. Hardness and alkalinity reserves are expressesd as CaCO3. The operating caustic alkalinity is 57
assumed to be half the maximum total alkalinity
Boiler Water Treatment
Programming
Calculations
58
Survey Data
Raw water analysis
Pretreatment
Feed water analysis
Feed water Temperature
Steam output and input pressure
water consumption
Condensate Return
Steam Applications
59
Calculation steps
!. Determine Feed water quality
2. Determine oxygen scavenger dose
3 . calculate the maximum permissible boiler
conc.
4. calculate Alkalinity demand
5. calculate phosphate requirement
6. calculate sludge conditioner dosage
7. calculate return line treatment requirement
8. Determine blow down rate
9. convert product dosage ppm to weight
10. calculate cost of programme 60
Determine Feed Water
quality
{ }
Condensate Return% = 1 - Feed water Cl x 100
. Makeup Cl
Hydrazine Requirement
[Feed water O2(ppm) X 1 ]
+Hydrazine Reserve/C
62
Feedwater Temp
0C Temp. 0Dissolved
F oxygen
D.O.ppm
100 212 0
95 203 0.8
90 194 1.6
85 185 2.2
80 176 2.9
75 167 3.4
70 158 3.9
65 149 4.3
60 140 4.7
55 131 5.2
50 122 5.6
45 113 6.1
40 104 6.6
35 95 7.1
30 86 7.5
25 77 8.1 63
20 68 8.8
Determine Maximum Permissible
Boiler Concentrations
64
Alkalinity Demand
Alkalinity Demand =
{(FWAlk - FW TH - Bisulphite Allowance) x Cmax}-
Alk Res
Alkalinity reserve is normally taken as 850
ppm for low pressure boilers
If demand is negative then no extra alkali is
required
Dose 0.8 ppm Sodium Hydroxide per 1 ppm
of Alkalinity demand
65
Determination of Phosphate
Requirement
66
Checking Sludge
conditioner dosage
Boiler Sludge Conditioner Dose =
Sludge Conditioner Conc ( 200ppm)
COC X Product Factor
67
Calculate Return Line
treatment requirement
68
Determination Of
Blowdown
%Blowdown = 100 X S
. T-S
Calculated as %of Evaporation rate
% Blowdown = 100 .
. C max
Calculated as % of Feed water
Feedwater rate.
S - Feedwater TDS
T - Boiler water Maximum TDS
69
Conversion of dose rates to kg
product per day
70
Water
Losses
71
Water Losses From Steam
System
Evaporation Of steam
Loss of Condensate
steam Boiler leaks
Blowdown
72
Uncontrolled water
Losses
Steam boilers
Waste water
Waste fuel
Waste chemical
Lead to poor control of inhibitor reserves
Lead to over running of pretreatment plant,
Fuel, increased chemical consumption
73