Steam boiler system treatment

The quahty of feed water required depends on boiler operating pressure, design, heat transfer rates, and steam use. Most boiler systems have sodium zeohte softened or demineralized makeup water. Feed-water hardness usually ranges from 0.01 to 2.0 ppm, but even water of this purity does not provide deposit-free operation. Therefore, good internal boiler water treatment programs are necessary. 

At the strategic level, boiler water treatment practice is essentially the planned, actioned, and documented management of the waterside of pre-boiler, boiler, and post-boiler plant equipment and systems. A key objective is to identify, obtain, and maintain operational and economic benefits for the plant owners, including maintaining the cleanliness and structural integrity of the boiler, its various water-steam cycle auxiliaries, and other components for a specified (long-term) period and to some quantifiable standard. 

In practice, however, it is often the case that for small LP steam heating boiler systems with a very high percentage of CR, and in those regions of countries where soft water is supplied, no water softener is provided or deemed necessary. Instead there is merely a reliance on internal chemical treatments (or sometimes magnetic devices or other types of gadget ). A good rule of thumb is ... 

Figure 23.2 shows a schematic representation of a boiler feedwater treatment system. Raw water from a reservoir, river, lake, borehole or a seawater desalination plant is fed to the steam system. However, it needs to be treated before it can be used for steam generation. The treatment required depends both on the quality of the raw water and the requirements of the utility system. The principal problems with raw water are1,2 ... 

The deaerated treated boiler feedwater then enters the boiler. Evaporation takes place in the boiler and the steam generated is fed to the steam system. Solids not removed by the boiler feedwater treatment build up in the boiler, along with products of corrosion. These are removed from the boiler by taking a blowdown (purge) from the boiler. The steam from the boiler goes to the... 

As discussed under boiler feedwater treatment, boiler blowdown is required to prevent the build up of solids in the boiler that would otherwise cause fouling and corrosion in the boiler. Carry over of solids from the boiler to the steam system via tiny water droplets should also be avoided. Total dissolved solids (TDS) and silica (SiC>2), as measured by the conductivity of water, are both important to be controlled in the boiler3. Dissolved solids carried over from the boiler will be a problem to all components of the steam system. Silica is a particular problem because of its damaging effect on steam turbines, particularly the low-pressure section of steam turbines where some condensation can occur. Blowdown... 

Improving the energy efficiency to reduce steam demand and hence reduce the wastewater generated by the steam system through boiler blowdown, boiler feedwater treatment and condensate loss (see Chapter 23). 

Increasing condensate return for steam systems to reduce makeup water requirements, reduce aqueous waste from boiler feedwater treatment and boiler blowdown (see Chapter 23). 

Waste from steam systems. If steam is used as hot utility, then inefficiencies in the steam system itself cause utility waste. Figure 23.2 shows a schematic representation of a boiler feedwater treatment system. The constant loss of condensate from the steam system means that there must be a constant makeup with freshwater. This makeup causes utility waste ... 

Power Production. Steam cycles for generation of electric power use various types of boilers, steam generators, and nuclear reactors operate at subcritical or supercritical pressures and use makeup and often also condensate water purification systems as well as chemical additives for feedwater and boiler-water treatment. These cycles are designed to maximize cycle efficiency and reliability. The fuel distribution of sources installed in the United States from 1990—1995 are as follow coal, 45% combined cycle, 27% miscellaneous, 14% nuclear, 11% solar, oil, and geothermal, 1% each and natural gas, 0.3%. The 1995 summer peak generation in the United States was 620 GW (26). The combined cycle plants are predominantly fired by natural gas. The miscellaneous sources include bagasse, black liquor from paper mills, landfill gas, and refuse (see Fuels frombiomass Fuels fromwaste). 

Recirculating water-cooling systems should have water treatment to control hardness to near zero and to prevent oxygen corrosion. If there is a steam boiler nearby, a common water treatment may be possible, but this should be explored with care. The cooling-water temperature rise should not exceed 20°F (11°C), and steaming... 

The wastewater from a hydrogen plant typically consists of only the blowdovm from the boiler system. The boiler feedwater that feeds the steam generation system has small amounts of impurities such as sodium, chlorides, silica, and organic carbons. These impurities will accumulate within the boiler system and create sludge, scaling of the boiler tubes, and possible carryover of solids into the process steam. Blowdown of the boiler water is performed to prevent these issues from affecting the operation of the steam system. The blowdown is typically sent to the sewer or the on-site waste treatment plant for treatment and disposal. 

Steam systems. Copper and copper alloys resist attack by pure steam, but if carbon dioxide, oxygen, or ammonia is present, condensates can be quite corrosive to copper alloys. Modem power utility boiler feedwater treatments commonly include the addition of organic amines to inhibit the corrosion of iron components of the system by scavenging oxygen and increasing the pH of the feedwater. These chemicals tend to release ammonia, which can be corrosive to some copper alloys. 

Corrosion of boiler systems will be controlled by water treatment externally or internally, or both, as required. The term external treatment (pretreatment) is usually applied to clarification, softening, or demineralizing equipment, whereas the term internal treatment usually refers to treatment injected into the deaerator, feedlines, boiler, or steam condensate systems. 

Water-side deposits are of many types. Hardness (calcium and magnesium)-based deposits and iron oxide are the most common water-side deposits and often affect boUers and cooling systems. Process and oil leaks can foul boilers and cooling systems. BiofouUng, mud, and debris are often found in cooling systems. Treatment chemicals, if not properly controlled, can add to deposits and scales. Silica can form hard, adherent deposits in boUers, steam turbines, and cooling systems. Corrosion products can add to deposits. 

Water Treatment. Water and steam chemistry must be rigorously controlled to prevent deposition of impurities and corrosion of the steam cycle. Deposition on boiler tubing walls reduces heat transfer and can lead to overheating, creep, and eventual failure. Additionally, corrosion can develop under the deposits and lead to failure. If steam is used for chemical processes or as a heat-transfer medium for food and pharmaceutical preparation there are limitations on the additives that may be used. Steam purity requirements set the allowable impurity concentrations for the rest of most cycles. Once contaminants enter the steam, there is no practical way to remove them. Thus all purification must be carried out in the boiler or preboiler part of the cycle. The principal exception is in the case of nuclear steam generators, which require very pure water. These tend to provide steam that is considerably lower in most impurities than the turbine requires. A variety of water treatments are summarized in Table 5. Although the subtieties of water treatment in steam systems are beyond the scope of this article, uses of various additives maybe summarized as follows ... 

In lower pressure boilers a variety of additional treatments may be appropriate, particularly if the steam is used in chemical process or other nonturbine appHcation. Chelants and sludge conditioners are employed to condition scale and enable the use of less pure feedwater. When the dmm pressure is less than 7 MPa (1015 psia), sodium sulfite may be added direcdy to the boiler water as an oxygen scavenger. It has minimal effect on the oxygen concentration in the system before the boiler. 

Pressure vessels and appurtenances should be constructed of stainless steel or other corrosion-resistant materials. Ideally, these steam generators should receive hot demineralized FW to minimize chemical treatment requirements. Alternatively, where a main boiler plant is installed, 100% steam condensate provides a good source of FW. In practice, it is very difficult to accurately control the correct amount of chemical feed. Chemicals are typically restricted to potable grade, deposit control agents such as polyacrylates, and other materials listed under the Code of Federal Regulations, CFR 21 173.310, or National Sanitary Foundation (NSF International) approval system. These boilers may be electrically heated or gas-fired. 

However, the source of MU water for higher pressure steam-raising plants is important because it is generally the case that no matter the origin of the water, it will not be entirely suitable for the purpose and some form of water conditioning will be required. This conditioning requirement necessitates the provision of a (pre-boiler section) water pretreatment plant system (external treatment/external conditioning) to render the water fit for purpose. 

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