Boiler Water Treatment

08 December, 2015

Vinod Desai
Thermax - Chemical Division

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 Contents
Water Chemistry w.r.t. Boiler
Problems associated w.r.t. Water chemistry
Objective and importance of boiler water treatment
Various programs in boiler water treatment
Dosing of chemicals and monitoring

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Water Chemistry

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 IMPURITY

GASEOUS PROBLEM CAUSED

Dissolved Oxygen Pitting Corrosion

Carbon Dioxide Condensate Corrosion

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 IMPURITY

SOLUBLE/IONIC PROBLEM CAUSED

Calcium/Magnesium Scaling

Sodium/Potassium Corrosion

Chloride/Sulfate Corrosion

Carbonates/Bicarbonates Scaling/Foaming

Hydroxides Scaling/Foaming

Silica Scaling/Deposition
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 IMPURITY

INSOLUBLE/NONIONIC PROBLEM CAUSED

Suspended Solids/Silt Fouling

OTHERS

Oil/Organics Foaming / carryover

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Water- impurities related problems in Boiler

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 SCALING

Location - Boiler water tubes

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INADEQUATE MAKE UP WATER QUALITY
SCALING

SCALE FORMING IONS

Ca ++,Mg ++,CO3--,HCO3 --,SiO3
OVER HEATING OF TUBES

Ca +2 HCO3 CaCO3 + H2O + CO2 REDUCTION OF HEAT TRANSFER

Ca + SO4 Ca SO4 CALLS FOR SHUT DOWN
Ca + SiO3 Ca SiO3
Mg + SiO3 MgSiO3 RESTRICTION OF WATER FLOW

CONTAMINATED CONDENSATE LEAKAGE

OF TURBINE CONDENSORS/ PROCESS LEAKS
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 CORROSION

METAL LOSS,PITTING
LOSS OF PROTECTECTIVE OXIDE FILM
LOW pH (DESIRED PROTECTECTIVE FILM IN BOILER
DISSOLVED OXYGEN
IS MAGNETIC IRON OXIDE, Fe3O4. OXYGEN
DESTRUCTS THE PROTECTIVE OXIDE FILM)
Fe3O4 + O2 --> 6 Fe 2O3

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 CORROSION

CAUSTIC CORROSION / EMBRITTLEMENT

HIGH CAUSTIC Fe3O4 + 4NaOH = 2 NaFeO2 + Na2FeO2 + H2O
ALKALINITY (Sodium ferroate)
Fe + NaOH = Na2FeO2(Sodium Ferrite) + H2

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 CORROSION

CONDENSATE CORROSION
BICARBONATES + HEAT CO2
CARBONDIOXIDE CO2 + H2O H2CO3 ( CARBONIC ACID)
Fe + H2CO3 Fe (CO3)2

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 MECHANICAL
HIGH WATER LEVEL
INCOMPLETE SEPARATION
OF STEAM& WATER
HIGH STEAMING RATE CARRYOVER
BOILER DESIGN
UNEVEN FIRE DISTRIBUTION
LOAD FLUCTUATIONS

AFTER BOILER DEPOSITS

PLUGGED VALVES AND

TRAPS
EFFECT
DEPOSITION ON TURBINE
BLADES

CHEMICAL
HIGH TDS (TOTAL DISSOLVED
SOLIDS)
HIGH ALKALINITY
LEAKAGE OF OIL /
ORGANICS
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 TURBINE DEPOSITS

Corroded blades Deposits on turbine before cleaning

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 TURBINE

CORROSION CARRYOVER
MU

CORROSION
SCALING
DEAERATOR
BOILER BD
CORROSION
FW

WATERSIDE PROBLEMS IN BOILER SYSTEM

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Types of boiler feed water treatment

External treatment

Internal treatment

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 EXTERNAL TREATMENT

INSOLUBLE SOLUBLE GASEOUS

OXYGEN CHLORINE
SETTLING CLARIFICATION
DEAERATOR ACTIVATED
FILTERATION CARBON

SOFTENING DEMINERALISATION

RO

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 INTERNAL TREATMENT - OBJECTIVE

Malfunctioning In External Treatment

- RO / FILTERS / DM PLANT / DEAERATOR

Change in Inlet Water Quality

Increase in Inlet Water Quantity

Decrease in Resin Exchange Capacity

Improper Regeneration of Resin

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 Internal Treatment - Need

External treatment is supported with internal

treatment
To take care during upsets in water quality

To maintain the BFW/BW & Steam quality

as per specified norms.

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INTERNAL TREATMENT- INSURANCE

TO MINIMISE REPLACEMENT COST

Very low compare to replacement cost of equipment

TO AVOID POOR HEAT TRANSFER DUE TO

SCALING ISSUES
Increases Fuel Consumption / Cost of Steam

TO AVOID PRODUCTION LOSS

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 Internal Treatment
Steam
MU

Safety,
Reliability
Efficiency
DEAERATOR
BOILER CBD

Longer Life FW IBD

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Internal Treatment - Various Programs

Phosphate Hydroxide Program

Polyphosphate-Polymer Based
Coordinated Phosphate control
Oxygen scavengers
Neutralizing amines
All volatile treatment

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Oxygen Scavenger

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Features of oxygen scavenger

Oxygen scavenging

Metal Passivator

Volatile compound

Organic Treatment
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Blend of Neutralizing
Amines

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Different types of Amines

Morpholine

Cyclohexylamine

Diethyl-aminoethanol ( DEAE )

Methoxypropylamine

Amino Butanol

Dimethyl amino ethanol ( DMAE )

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 Function of Neutralizing Amines

to maintain the pH of the feed water

to maintain the pH of condensate water

Ensuring corrosion protection of pre (feed water

section) and post boiler (condensate water
system)

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While selecting any neutralizing amine program, three factors
are to be considered.

Distribution ratio- It indicates how much of the amine will go with

the steam and how much remains in the condensate.

Basicity- It indicates the capacity of the amine to neutralize the acidity

Thermal Stability- Is a measure of ability of the amine to be used in

modern high temperature and pressure boilers without degradation.

Usually a blend of 2 or 3 different types of amines are used to provide

protection to entire condensate system.

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 Standard boiler water treatment

Combination of

Tri Sodium Phosphate + Di Sodium

Phosphate

Oxygen scavenger

Neutralizing amine

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 DOSAGE

OXYGEN SCAVENGER
- Based on Feed water temperature
SCALE / CORROSION INHIBITOR
- Based on PO4 residual to be
maintained in boiler/ on blowdown
NEUTRALIZING AMINE
- Based on pH of BFW/BW/Condensate
water

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 Boiler Treatment recommended Chemical Feed Points

1 S
3
MU

DEAERATOR
2 BOILER BD

FW
Phosphate - 3
OS - 2
Amine - 1 or 1 and 2

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ALL VOLATILE TREATMENT

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 FUNCTION OF AVT

Filming amine

Dispersing amine

Neutralization amine

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 PROTECTIVE FILM BARRIER
AMINE FILM

N R
N R
N R

WATER
METAL
SURFACE
LEGEND
N R = AMINE MOLECULE
N+ = AMINO GROUP
R- = ALKYL GROUP

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 NEUTRALIZING REACTION

R - NH2 + H2CO3 -----> RNH3 + HCO3

Neutralizing amine Carbonic acid Amine Bi-carbonate

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 BENEFITS OF AVT

Forms Protective Film Can be dosed through

preventing O2 pitting LP dosing section
Neutralizes CO2 completely Ease in monitoring - less
& prevents carbonic acid parameters
Corrosion Liquid formulation - ease
Disperses loose corrosion of handling
deposits Elimination of Phosphate

BETTER EASIER
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 LIMITATIONS OF AVT
Primarily used in Power boilers where make water is 99%
steam condensate ( Pure water)
High purity Feed water is mandatory MB-DM Make up and
non-contaminated condensate
Increases load on CPU and reduces life of Resin
Excess level of Ammonia accelerate Copper corrosion
Low boiler water pH ( 8.4 to 8.8 ) - chances of Silica carry
over to turbine
No protection from Chloride attack as no buffer alkalinity is
available
Non acceptance of pH range of 8.4 to 8.8 by boiler
manufacturer
No authenticated recommendation by boiler manufacturers,
Boiler Regulatory Authorities.
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Dosing Procedure

All the chemicals are to be dosed on continuous basis ( 24 hrs )

with the dilution in water .

Recommended 10 % dilution. However, it can vary according to

dosing system capacity

All the dosages are based on feed water quantity

Qty required in kg /day = Dose in ppm X FW quantity in MT X 24

----------------------------------------------
1000

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Blow-down
CBD ( Continuos blowdown )
- To remove concentrated water continuously
- Located in the area of highest boiler water concentration
Preferred way of blowdown as minimal loss of water
and heat recovery of heat content by use of blowdown
flash tank

IBD( Intermittent blowdown )

- To remove sludge from the boiler
- Located in the bottom part of lowest boiler drum

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One has to select the appropriate chemicals from mentioned list
to use it as program

The selection of the program would be based on

Boiler pressure
Application of the steam
Feed water pre-treatment
Feed water quality
Boiler operating conditions (like feed water
temperature, % blow down, etc.)
Customer requirement

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Monitoring
.
Monitoring of the treatment consists of

Drawing and analyzing all the water samples including

condensate water for defined parameters at decided
interval on continuous basis

Based on the analysis, take necessary actions to maintain

the desired water parameters in defined limits

Record the analysis and actions taken

In case of upset in the treatment, frequency of analysis

to be increased till system comes to normal

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WATER ANALYSIS

Correct frequency of water analysis

Follow standard analytical procedures

Calibration of instruments

Correct sample analysis

Accurate water analysis

Corrective steps incase of upset

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 Parameters to be analyzed

pH
Conductivity/TDS
Phosphate
Sulfite/Hydrazine
Silica
Alkalinity
Chloride
Iron
Residual Amine (incase of AVT)

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Preservation

Wet preservation ( Boiler under shut for approx. less than month )

- By maintaining Sodium Sulfite @ 200 ppm in water and pH 10.5

in case of low pressure boiler

- By maintaining Hydrazine @ 200 ppm in water and pH 10.5 in

case of high pressure boiler

Dry preservation
After complete drying either of the following desiccants to be used
- Quicklime @ 6 lb / 100 ft3 of boiler volume
- Silica gel @ 17 lb / 100 ft3 of boiler volume
- Activated alumina @ 27 lb / 100 ft3 of boiler volume

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