BOILER WATER TREATMENT

Boiler Water System

pre-treatment Feed
s s
Tanks

Feed pump
s Receiver

s
Water Condensate
Column
Boiler Plant Process s Sample point
s
s
 Water Quality affects
• Efficiency of the boiler
• Safe performance
• Quality of steam
• Boiler life time
TYPE OF IMPURITIES IN WATER
1. SUSPENDED IMPURITIES : Insoluble

2. DISSOLVED SOLIDS : Which gets dissolved in

water and ionised into
cations and anions

CATIONS - Positively charged

ANIONS - Negatively charged

These revert back to precipitate of insoluble form

depending upon solubility level in water. Solubility is
reduced in water due to changed behaviour.
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TYPE OF IMPURITIES IN WATER

3. COLLOIDAL : Tiny suspended particles which

keep floating normally do not
get filtered out

4. ORGANICS : Dissolved / undissolved form

which may give colour

5. MICROBIOLOGICAL : Algae, fungus and bacteria

growth

6. DISSOLVED GASES : Dissolved Oxygen, Carbon

dioxide, H2S, Ammonia etc.
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TYPE OF IMPURITIES IN WATER

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EFFECT OF SCALING, CORROSION,
CARRY-OVER ON BOILER SYSTEM
• Reduction in heat transfer
• Severe elevation of metal/tube temperature
• Promotes under deposit corrosion - pitting
• Loss of construction material
• Failure of boiler tubes
• Water losses
• Increased maintenance cost
• Unplanned shut downs
• Ultimately, increased operational costs and loss of
productivity.
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 Energy Loss Versus
Scale Thickness
7
6
Energy Loss (%)

5
4
3
2
1
0
1/64 1/32 3/64 1/16
Scale Thickness (Inches)

Iron & Silica High Iron Content "Normal" Scale

 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

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UNITS OF CONCENTRATION

 Parts Per Million (ppm)

1 kg in 1,000,000 kg (1,000 Tonnes) of water
 Milligrams Per Liter (mg/l)
1 mg in 1 liter of water

ppm
ppm == mg/l
mg/l
 Relative Density (each increase of 0.000 1 relative density at
15.5°C is approximately equal to 110)
 Conductivity (µS/cm)
TDS (ppm) = conductivity in µS/cm x 0.7

10
HARDNESS
• Total hardness is a measure of Ca & Mg cationic
2+ 2+

ions irrespective of present anions.

• Alkaline/carbonate/temporary hardness is
hardness associated with Bicarbonate of Ca & Mg
2+
2+

.
• Non-alkaline/Non-carbonate/Permanent hardness
is hardness associated with Sulphates, Chlorides
and Nitrates.
• All salts of hardness have inverse solubility w.r.t.
temperature.
• Bicarbonate of hardness decompose to
carbonates having low solubility.
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TOTAL DISSOLVED SOLIDS (TDS)
• Indicates total content of dissolved solids in water
• Represents all charged ions - cations and anions -
as well as uncharged and molecular species
• Summation of cations mainly calcium,
magnesium, sodium; anions mainly bicarbonate,
chloride, sulphate and silica.

Non Total
Total
Hardness Dissolved
Hardness
Salts Solids
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SILICA
• Dissolved in water in molecular form SiO2 or hydrolysed as
the acid H2SiO3 (silicic acid)
• Also present in water in undissolved state or colloidal form
as polymeric silica (SiO2)n or a complex colloid that
includes organic material and heavy metal ions
• Colloidal silica in water is converted to the dissolved state
under the action of high temperature and pressure as
experienced in a boiler or autoclave
• Colloidal silica is removed substantially by coagulation,
flocculation, sedimentation and filtration. It is totally
excluded in ultra filters.
• Maintain feed water pH > 9.4

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DEPOSIT FORMATION

• Caused by hardness salts ppting,- Reduced

solubility with increased temp.& increased conc.
due to steam formation
• Scale: occurs at the point of steam
generation sludge: occurs in bulk
water & deposit on metal surfaces
• Lowers thermal conductivity
• Reduces boiler efficiency
• Increases fuel consumption

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DEPOSIT FORMATION

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DEPOSITS - EFFECTS ON METAL

• Furnace temp. over 2500 deg F

• Metal deforms at 900 deg F
• Water temp 338 deg F (100 psig)
546 deg F (1000 psig)
• Deposits form insulating barrier, tolerance
depends on nature & heat transfer of deposit

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DEPOSITS - EFFECTS ON METAL

17
DEPOSITS - EFFECTS ON METAL
EXTRENAL TREATMENTS

• Ion exchange
– Base exchange

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 EXTRENAL TREATMENTS

• Reverse Osmosis
• Membrane allows only the water to pass through, not the impurities or
contaminates.
• These impurities and contaminates are flushed down the drain.

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DEMINERALISATION

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EXTRENAL TREATMENTS

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 ASME GUIDELINES
Table 1 - Watertube Boiler with Superheater/Turbine
All Pressures: FW dissolved oxygen < 7 ppb (with DA)
Feedwater pH: 8.3 - 10.0 (0- 900 psig) / pH 8.8 - 9.6 (> 901 psig)

Boiler Feedwater Boiler Water

Total Total Specific
Drum Hardness Silica alkalinity Conductance
Pressure Iron Copper ( ppm ) ( ppm ) ( ppm ) (mhos/cm)
(psig) (ppm Fe) (ppm Cu) CaCO SiO CaCO (Unneutralized)
3 2 3
0 to 300 0.100 0.050 0.300 150 350 3500
300 to 450 0.050 0.025 0.300 90 300 3000
451 to 600 0.030 0.020 0.200 40 250 2500
601 to 750 0.025 0.020 0.200 30 200 2000
751 to 900 0.020 0.015 0.100 20 150 1500
901 to 1,000 0.020 0.015 0.050 8 100 1000
1,001 to 1,500 0.010 0.010 0.000 2 - 150
1,501 to 2,000 0.010 0.010 0.000 1 - 100

Note: All limits are expressed “less than” the value specified (e.g., < 0.100 ppm)
CORROSION
Primarily caused by Dissolved oxygen and
dissolved carbon-di-oxide.
High temp & Pressure means even trace
quantities of oxygen are highly corrosive
Oxygen pitting

General Thinning due to H2CO3

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CORROSION CONTROL

• Removal of oxygen
– Mechanical Deaeration
– Scavenging by chemicals
• Neutralising carbon dioxide
– Free CO2 = 0 if pH > 8.3
– Target pH = 9 – 11
– BS 2486: pH 10.5 – 12 for shell boilers
pH 9 for large pressure boilers

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MECHANICAL DEAERATION

• Steam or Vacuum is used

• Design to remove gases depends on:- Solubility of
gases - Partial pressures
- Operating temperatures
• Technique employed : - To
reduce partial pressure -
Continuously extract evolved gases
• Solubility of O2 decrease with increasing
Temperature.

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OXYGEN SCAVENGERS

• Sulphites - Adds to boiler water TDS

– Na2SO3 + ½ O2 Na2SO4
• Hydrazine - carcinogenic
– N2H4 + O2 N2 + 2H2O
• Tannins - Used in low pressure boilers
– Absorbs O2 in alkaline condition.
• DEHA - Volatile
– Filming Amine
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 SAVING IN CHEMICALS BY
FEED WATER HEATING

• 8 ppm NaSO3 for 1 ppm of Oxygen.

• Increase of feed water Temperature from 65
ºC to 80 ºC can save 47 % cost saving on
sodium sulphite.

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 CAUSTIC EMBRITTLEMENT

• Under following conditions steel is subjected

to intercrystalline cracking :
• Boiler must be subject to high stress
• Boiler water must contain free NaOH

• Rivetted flanges & rolled-in tube ends are

more prone

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

Porous magnetite films, deposits, cracks allow

localised build up of OH in that cause damage.
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HYDROGEN DAMAGE
• Almost all The hydrogen
damage is associated with
Caustic Gauging

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 Carryover
• Carryover is any solid, liquid or vaporous
contaminant that leaves a boiler along with
the steam.
– Priming
– Foaming
PRIMING

• Ejection of boiler water into the steam take-

off
• Reasons:
– Too high drum water level
– Operating boiler below design pressure
– Operating at higher design capacity
• Controlled by strictly adhering to operating
conditions

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FOAMING
• Pure water does not foam & steam bubbles are
large & burst quickly
• Following causes foaming by altering surface
tension- reduce bubble size:
– High suspended solids
– High alkalinity
– High dissolved solids
– Contamination of oils &other surfactant
• 0.1 - 0.5 ppm antifoam (certain organic
compounds) cause bubbles to coalse
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BOILER BLOWDOWN
 FOAMING
 Pure water does not foam & steam bubbles are large & burst
quickly
 Following causes foaming by altering surface tension- reduce
bubble size:
 High suspended solids
 High alkalinity
 High dissolved solids
 Contamination of oils & other surfactant
 0.1 - 0.5 ppm antifoam (certain organic compounds) cause
bubbles to collapse
 DECIDING ON THE REQUIRED BOILER WATER TDS.
Maximum TDS tolerated Maximum TDS
by boiler type (ppm)

Lancashire 10,000

2-Pass Economic 4,500

Package and 3-Pass Economic 3,000-3,500

Low Pressure Water Tube 2000-3000

Medium Pressure Water Tube 1,500

Coil Boilers and Generators 2,000

 The above figures are offered as a broad guide only

 The boiler maker should always be consulted for specific recommendations.
THE EFFECT OF TOO HIGH TDS IN THE BOILER
Contamination of
High TDS and/or Control Valves
suspended solids. Fouling of Heat
Exchangers

Boiler

Blockage of Steam Traps

 KEEPING THE STEAM CLEAN
Pure steam to
plant

Feed water Surface Blowdown

with
impurities
Build up of
impurities in
the boiler

Bottom Blowdown
CALCULATING BLOWDOWN QUANTITY
Let:

F = Feed water TDS (ppm)

B = Boiler target TDS (ppm)

S = Boiler steaming rate (kg/h)

FxS
Amount to be blown down =
B-F

This equation is valid for any consistent

units eg lb/h, S/cm
 CONTROLLING BLOWDOWN RATE
Orifice Plate
Orifice size determined based on
 Flow rate
 Pressure drop

Limitations
 Cannot adjust with steaming rate
 Flashing – erosion & wiredrawing
 Possibilities to restrict / block
 CONTROLLING BLOWDOWN RATE

Continuous Blowdown Valves

 Outer circumference defined by valve
seat
 Inner by the needle

Limitations
 Small clearance
 Flashing – erosion & wiredrawing
 Higher possibilities to block
 CONTROLLING BLOWDOWN RATE
ON/Off Blowdown Valves
 Small boilers – correctly sized solenoid valve
 Large boilers – sophisticated valve
 Have adjustable stroke – to select blow down rate
CLOSED LOOP ELECTRONIC SYSTEM

Manual B/D

Automatic B/D
 PROJECT BOILER
10,000 kg/h
steam to plant

Feed water Maximum

with 250 ppm allowable boiler
impurities TDS = 2,500 ppm

Boiler operating pressure = 10 bar

Saturation temperature = 184 oC
HEAT RECOVERY FROM BLOWDOWN
 Rate of blowdown ?
 Energy flow rate in blowdown?
 Quantity of flash steam generated @ 0.5bar g?
 Energy flow rate in flash steam?
 Energy available in residual water ?
 Total energy recovered?
HEAT RECOVERY FROM BLOWDOWN
Condensate
Deaerator Head
Steam

Blowdown valve Hot well

Flash
vessel
Heat
exchanger

Boiler Trap

Feed pump To drain Cold

make-up
HEAT RECOVERY FROM BLOWDOWN
Deaerator Head
Cold
make-up
Steam
Condensate

Blowdown valve Hot well

Flash
vessel

Boiler Trap

Heat
Feed pump To drain exchanger
 BOTTOM BLOWDOWN
 Suspended solids fall to the bottom when boiler stops
 Short sharp blast to remove this sludge
 Major influences on rate of blowdown
 Boiler pressure
 Size of the blow down line
 Length of the blow down line
 If equivalent length of blow down pipe less than 7.5 m,
vessel should size to higher flow
 BOTTOM BLOWDOWN
 Energy content of blow down (10 bar boiler, 40 NB
valve)

 Change in volume due to flashing (3 second blow down)

 BOTTOM BLOWDOWN
 UK standards covers boiler blowdown
 Factories act (1961)
 Health and safety at work act (1974)
 Public health act (1936)
 Pressure systems and transportable gas containers
regulations (1989)
 The European pressure equipment directive (2002)
 What about Sri Lanka ?
BOTTOM BLOWDOWN VALVE
 BLOWDOWN VESSELS
 Alternative to blow down pit
 Tangential inlet / radial blow down line
 Pressure vessel – Provision for inspection
 Design Pressure – 25% of the boiler pressure
 Design Temperature – minimum equal to saturation
temperature
 Volume – overflowing water should not exceed
allowable temp
 Vent – limit pressure inside to 0.35 bar
 BLOWDOWN VESSELS SIZING
 Factors affect the selection and sizing
 The boiler pressure
 Number of boilers
 Duration of blowdown
 Blow down line size
 Length of blowdown line
 BLOWDOWN VESSEL SELECTION
 Calculate the equivalent straight length of blow down line
 If equivalent length < 7m, multiply pressure by 1.15
 Establish the volume of standing water in the selected vessel
 If it is not sufficient, select a larger vessel
 Select the correct vent head
BLOWDOWN VESSELS
BLOWDOWN VESSELS
SAVING FROM AUTO BLOWDOWN
Given Information

F = Feed water TDS (ppm) = 250 ppm

B = Boiler target TDS (ppm) = 2,500 ppm

S = Boiler steaming rate (kg/h) = 10,000 kg/h

Amount to be blowdown = F x S
B-F

250 x 10,000
= 2,500 - 250

= 1,111 kg/h
HOW MUCH IS THE ACTUAL BLOWDOWN?
Given Information

Ba = Actual Boiler TDS (ppm) maintained = 2200 ppm

Amount actually blown down = FxS

Ba - F

250 x 10,000
= 2,200 - 250

= 1,282 kg/h

Amount of excess blowdown = 1282 - 1111

= 171 kg/h
 NET SAVING
Net Savings =Saving in blowdown x Sensible heat lost x Cost of fuel
GCV of fuel x Efficiency of boiler x Sp. gravity of fuel (if oil)

171 x 24 x (184 - 25) x 90 x 100

=
10200 x 80 x 0.88

= Rs. 8,178.50 per day

Total Saving = Rs. 212,641 per 26 days

BOILER BOTTOM BLOWDOWN RATE

Flow
Rate
(kg/s)

Pressure (bar g)