DOSHION – Boiler Feed Water Treatment

Contents
Page
Contents ................................................................................................................................................................ 1
1.0 Basics for Boiler Operation ............................................................................................................................... 3
1.1 Steam Boilers................................................................................................................................................... 3
1.1.1 Boiler Water Quality Requirements for Steam and Large Chamber Boilers .................................................... 4
1.2 Warm Water Boilers......................................................................................................................................... 5
1.2.1 Estimated Values for Low Pressure and High Pressure Warm Water Producers for Boiler Temperatures
above 100 °C................................................................................................................................................... 5
2.0 Boiler Feed Water Treatment ........................................................................................................................... 6
2.1 Feed Water Quality Requirements.................................................................................................................... 6
2.2 Softening.......................................................................................................................................................... 7
2.3 Soda Splitting................................................................................................................................................... 7
2.4 Decarbonization ............................................................................................................................................... 8
2.5 Reverse Osmosis ............................................................................................................................................. 9
2.6 Demineralization Plants.................................................................................................................................. 11
2.6.1 Cation Exchangers ...................................................................................................................................... 12
2.6.2 CO2 - Degasifier .......................................................................................................................................... 12
2.6.3 Anion Exchangers ....................................................................................................................................... 12
2.6.4 Mixed Bed Exchangers............................................................................................................................... 13
3.0 Degasifiers ..................................................................................................................................................... 14
3.1 Basics ............................................................................................................................................................ 14
3. 2 Thermal Degasifiers ...................................................................................................................................... 14
3. 3 Spray Degasifier ........................................................................................................................................... 15
3.4 Vacuum Degasifiers ...................................................................................................................................... 16
3.5 Removal of Oxygen by Ion Exchange............................................................................................................. 16
4.0 Dosing Systems ............................................................................................................................................. 17
4.1 Basics for Dosing............................................................................................................................................ 17
4.2 Dosing at salt-free Operation .......................................................................................................................... 17
4.3 Dosing in Food Operations ............................................................................................................................. 17

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DOSHION - Boiler Feed Water Treatment

4.4 Oxygen Binding Media....................................................................................................................................17

4.4.1 Sodium Sulphite ..........................................................................................................................................17
4.4.2 Hydrazine ....................................................................................................................................................17
4.4.3 Other Dosing Chemicals ..............................................................................................................................17
5.1 Condensate Filtration......................................................................................................................................17
5.2 Removal of Iron/Residual Hardness................................................................................................................17
5.3 Removal of Silicic Acid ...................................................................................................................................17
5.4 Condensate Deoiling.......................................................................................................................................18

Boiler Feed Water Treatment 2

DOSHION – Boiler Feed Water Treatment

1. Basics for Boiler Operation The water provided from the water In terms of boiler feed water, one
treatment plant is free from undis- talks about total hardness and car-
1.1 Steam Boilers solved matter, like iron, manganese bonate hardness, or the alkalinity of
etc. and is acceptable as drinking the water. When heating the water,
Why does boiler feed water have to water. But, in naturally available hardness precipitation and boiler
be treated? water different salts are dissolved. scaling occur from both hardness
That means they cannot be filtered forms. This precipitation leads to
Steam boilers have - as shown in mechanically. These salts enrich the formation of sediments at the
the diagram - a water chamber with concentrate in the boiler water, this heating surfaces in the boiler. It
a heating tube. By heating this tube is known as evaporation. Problems builds up on pipe walls and causes
the water is heated and evaporates. can develop, depending on the type plugging of the pipes, hinders the
of salts present in the feed water. heat transfer from the heating pipes
The arising steam consists of pure to the water and finally causes
water, i.e. H2O. Salts practically The most common salt types pre- overheating and destruction.
cannot dissolve in this steam. (Ex- sent in water are alkaline earths,
ception: SiO2 in high-pressure also called hardness formers. In order to avoid this, the boiler feed
boilers). water must have a hardness of 5 –
10 ppm.

STEAM BOILER
Steam Outlet

Feed Water Inlet

Sediment Outlet

Fig. 1 : Steam Boiler Schematic Drawing

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DOSHION - Boiler Feed Water Treatment

Neutral salts in the boiler water corrode the steam condensate The salt content and the alkalinity in
must be at a very low concentra- system. the boiler water can be reduced by
tion, since salt content of approx. The boiler water alkalinity is limited increasing blow-down and de-
5000-10000 µS/Cm can lead to to a p-value of max. 12 mg /lit. At sludging rates. The exact require-
particles being carried away in the higher alkalinity the boiler water ment for the boiler water can be
steam. These salt particles can tends to foam. taken from the following table.

1.1.1 Boiler Water Quality Requirements for Steam and Large Chamber Boilers

Pressure stage < 1 bar 1-22 bar 22-44 bar <36 bar <44 bar > 44 bar

Operation method salty feed Low salt salt free

water >
Boiler type combined flue quick steam combined flue
and smoke- producer and smoke-
tube boiler tube boiler
General demands colorless,
particle free

pH-value at 25°C pH 10.5-12 10.5-12 10.5-11.8 10.5-12 10.5-11.5 9.5-10.5

Acid capacity up to PH 8.2 mg/l 1-8 1-10 1-6 1-8 0.5-3 0.1-1
(p-value)
Conductivity (LF) at 25°C µ S/cm <5000 <6000 <5000 <5000 <2500 max <50
direct measuring 100-fold
Silicic acid mg/l - <150 <50 - 30+3xp <4
max 40
Phosphate mg/l 10-20 10-20 5-15 5-10 10-30 5-10

KMnO4-consumption mg/l <100 <150 <100 - <50 <30

Sodium sulphite mg/l 10-20 10-20 10-20 - 10-20 -

Hydrazine mg/l 0.2-0.5 0.2-0.5 0.2-0.5 - 0.2-0.5 0.2-0.5

Boiler Feed Water Treatment 4

DOSHION – Boiler Feed Water Treatment

1.2 Warm Water Boilers ity in the warm water boiler and in The water quality requirements for
the circuit is identical. Water treat- warm water boilers can be taken
Unlike a steam boiler there is no ment for this application should from the following table.
salting of boiler feed water in a produce water that is free of sedi-
warm water boiler. The water qual- ment and corrosion agents.

1.2.1 Estimated Values for Low Pressure and High Pressure Warm Water Producers for Boiler Tempera-
tures above 100 °C:

Operation Method low salt Saline

Estimated Values for Boil-

ers And Circuit Water
General Demands clear without
sediments

Electr. Conductivity µS/cm 0-30 30-100 100-1500

pH-Value at 25° C pH 9-10 9-10.5 9-10.5

Oxygen (O2 ) mg/l <0.1 <0.05 <0.02

Bound Carbonic Acid mg/l <25 <25 <50

Alkaline Earths (Ca+Mg) mmol/l <0.02 <0.02 <0.02

Phosphate Contents (PO4) mg/l 1-5 1-10 1 -15

Hydrazine (N2H4) mg/l 0.3-3 0.3-3 0.3-3

Sodium Sulphite mg/l -- -- <10

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DOSHION - Boiler Feed Water Treatment

2.0 Boiler Feed Water 2.1 Feed Water Quality salt operation (osmosis) and salt-
Treatment Requirements free operation (demineralization).

The boiler feed water quality re- The most important requirements
quirements depend on type of can be taken from the following
boiler, pressure stage and intended table.
use of the steam. The treatment
differs between the saline operation
(softening, decarbonization), less

Pressure stage < 1 bar 1-22 bar 22-44 bar <36 bar <44 bar > 44 bar

Operation method salty feed less salt salt free

water
Boiler type combined fuel quick steam combined fuel
and smoke- producer and smoke-
tube boiler tube boiler
General Demands colourless and free from
particles
pH-Value at 25°C pH >9 <9 <9 9-9.5 <9 <9

Acid Capacity up to PH mg/l >0.1 >0.1 >0.1 >0.1 >0.1 -

8.2 (p-value)
Alkaline Earths (Total mmol/l <0.015 <0.015 <0.01 <0.01 <0.01 <0.0051
Hardness)
Oxygen O2 mg/l <0.1 <0.02 <0.02 <0.1 <0.02 <0.1

Conductivity (LF) at µ S/cm - - <500 <5000 5-50 <5

25°C Direct Measuring
Bound Carbonic Acid mg/l <25 <25 <25 <50 <10 <1

Iron, total Fe mg/l - <0.05 <0.03 - <0.03 <0.03

Copper, total Cu mg/l - <0.01 <0.05 - <0.005 <0.005

Oil, Grease mg/l <3 <1 <1 <1 <1 <1

Silicic Acid mg/l only limit <2 <0.05

values for
Phosphate mg/l 10-20 10-20 5-15 5-10 10-30 5-10

KMnO4-Consumption mg/l <100 <150 <100 - <50 <30

Hydrazine mg/l 0.2-0.5 0.2-0.5 0.2-0.5 - 0.2-0.5 0.2-0.5

04/99 Boiler Feed Water Treatment 6

DOSHION – Boiler Feed Water Treatment

2.2 Softening One softener is in service while the The free carbonic acid in the boiler
second is in regeneration or stand- feed water becomes vapor and
Softening of the water is often car- by. goes with the steam into the con-
ried out by ion exchange via soften- densate system. The unbuffered
ers, as shown in the drawing below. 2.3 Soda Splitting condensate becomes acidic and
corrosion occurs. This corrosion is
These softeners exchange the By simple softening, boiler feed visible by brown condensate or
hardness formers of the water, i.e. water can be treated for high con- discoloured boiler water.
calcium and magnesium against densate backflow or if the inlet
sodium from the exchanger mate- water is of exceptionally good qual- In order to avoid corrosion in the
rial. ity. boiler and condensate, a maximum
concentration of bound carbonic
After a calculated throughput, de- For carbonate hardness greater acid of 25 mg/l is acceptable, ac-
pending largely on the raw water than 35 ppm this type of softening cording to regulations. This corre-
hardness, the ion exchanger resins is no longer sufficient. By simple sponds to a carbonate hardness of
must be regenerated. This is carried softening the carbonate hardness of approximately 35 ppm.
out with sodium chloride, NaCl. The the water is converted into sodium
regeneration media demand is bicarbonate. 1 mg/l of CO2 in the condensate
approximately 200 - 300% of the results in a pH of 5.5, which in turn
theoretical salt quantity. By the influence of pressure, tem- will result in corrosion of the con-
perature and time, free carbonic densate system. Unless the con-
This regeneration should be carried acid, caustic soda and sodium densate system is fabricated com-
out based on total throughput. carbonate (soda) are created from pletely of stainless steel a decar-
sodium bicarbonate. bonization or demineralization plant
In order to guarantee a continuous will have to be provided for treat-
water supply, softeners may be ment.
designed as 1 working and 1 SB.

Fig. 2

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DOSHION - Boiler Feed Water Treatment

By forming caustic soda in the treated by simple softening. The carbonic acid created. Therefore,
boiler water alkalinity is greatly decarbonization or demineralization all pipes downstream of the weak
increased. At an alkalinity of ap- of the water becomes necessary. acid cation unit must be designed to
proximately 12-15 ppm (p-value) resist corrosion. This also applies to
the boiler water tends to foam. Only 2.4. Decarbonization the decarbonization equipment.
by performing blow-downs or de-
foaming can the acceptable value Another common treatment process Regeneration of the weak acid
be maintained. is decarbonization followed by sof- cation exchangers is carried out
tening. If correctly used this treat- with dilute hydrochloric acid. It is
The required blow-down capacity is ment process is an excellent alter- absolutely necessary to avoid over-
directly proportional to the carbon- native to demineralization. regeneration of the resin, as other-
ate hardness in the raw water. The wise the aggressive mineral acids
blow-down capacity is, for example, By decarbonization of the water, can arise in the product water. The
at 90 ppm carbonate hardness through the use of a weak acid regeneration of the weak acid cation
approximately 14% and increases cation unit, only the hardness form- units is depenent on total through-
to 23 % of steam capacity at 180 ers bound to the carbonate are put.
ppm. removed from the water. (carbonate
hardness). Exchange of carbonate The regeneration media demand is
+
Dilution of the feed water by return hardness against H ions of the approximately 103-105% of the
condensate has a favourable effect exchanger media is carried out. The theory. The wastewater occuring
on the blow-down rate. The steam pure water still contains the hard- during regeneration has a pH of
condensate is practically salt-free ness components of the non- approximately 3 - 5 and may re-
water. carbonate hardness. quire neutralization.

In the case of low condensate re- The decarbonized water, however,

turn and high carbonate hardness, becomes acidic because of the free
the boiler feed water cannot be

Fig. 3

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DOSHION – Boiler Feed Water Treatment

As already mentioned, the hardness Unfortunately, it is not possible to For certain boiler types, e.g. quick
formers of non-carbonate hardness retrofit existing water treatment steam producers and sterile steam
are still available after the decar- plants that consist only of soften- producers, a salt concentration of
bonization. These are removed by ers. It is almost always necessary only 250 µS/cm is acceptable. The
installing a downstream softener. to replace the softeners as well, acceptable salt concentration in a
since these units are usually not normal three pass boiler can be in
By decarbonization and softening, designed for acidic conditions. the range of 3000 - 5000 µS/cm.
one achieves a soft, hardness-free Furthermore, the addition of degasi- This value depends on the manu-
water, the concentration of bound fier is likely required. facturer. In many regions, a salt
carbonic acid is well below 25 mg/l. concentration of 500 µS/cm in the
This treated water reacts aggres- raw water is common.
sively because of the high concen-
2.5 Reverse Osmosis
tration of free carbonic acid. The This means that if the salt concen-
Over the years, the use of reverse
free carbonic acid can be stripped tration in the boiler water is ap-
osmosis systems for boiler feed
from the water by a using down- proximately 3000 µS/cm then 14%
water applications has become
stream thermal degasifier or a CO2 of the boiler water must be blown-
more widespread.
decarbonator. down. For all of these purposes,
utilizing reverse osmosis is an ideal
The salt concentration of the water Due to smaller boiler types with treatment process.
is reduced using this type of treat- high steam chamber loads the
water quality requirements for boiler
ment by the amount of carbonate The operation method of reverse
feed water are becoming increas-
hardness present in the feed water. osmosis is shown on the following
This is called partial demineraliza- ingly stringent. drawing.
tion.

Fig. 4:

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DOSHION - Boiler Feed Water Treatment

Feed Water

Permeate

Concentra

Rinse Water Tank

Dosing Systems
Fig. 5

Raw water which is free from un- Usually a reverse osmosis plant is system may be required. Since a
dissolved solids and which should operated with at a recovery rate of reverse osmosis system does not
be softened, first flows via a fine 75%, i.e. 75 l/h permeate and 25 l/h require regeneration, it can be op-
filter to the booster pump. saline concentrate from 100 I/h feed erated on a continuous basis. Main-
water. The salt concentration in the tenance requirement are very low
The water is passed, under pres- concentrate line is approximately 4 and rinsing or cleaning are only
sure, through a semi-permeable times higher than in the feed water. required on a periodic basis. But
membrane and the treated water long shutdown periods should be
flows into the permeate line. The permeate quality is monitored avoided, if possible.
by a conductivity meter. If quality is
Modern plants usually operate at a not acceptable the permeate may Reverse osmosis systems are well
feed pressure of approximately 12- be sent to drain until quality im- suited for expansion of available
16 bar. The residual salt in the pure proves. If quality does not improve boiler feed water treatment plants.
water, or the permeate, is between after a predetermined period, rins- Available softeners can also be
2 and 5 % of the original value. ing or cleaning of the membrane utilized.

Softeners Reverse Osmosis

Raw Water Softened Water Permeate
Membrane

Filter

Concentrate
Fig. 6

04/99 Boiler Feed Water Treatment 10

DOSHION – Boiler Feed Water Treatment

Residual hardness in the RO feed also be removed by the reverse 2.6 Demineralization Plants
water is acceptable, the softener osmosis system.
installed preceding the reverse Normally, the feed water for steam
osmosis plant can be regenerated Utilizing custom engineered sys- boilers is treated by partial demin-
with brine, as opposed to hydro- tems, residual hardness of less eralization.
chloric acid for the weak acid than 1.0 µS/cm is possible. The
cations. The softened boiler feed oxygen still present in the water is At a boiler pressure above 30 bar,
water is hardness free, has a lower bound chemically when using a or for steam turbine operation,
salt concentration and is not as treatment system that does not demineralization of the feed water
aggressive as the product water involve degasification, e.g. by dos- becomes necessary.
from a weak acid cation unit. ing of sodium sulfite.
Of primary concern is the residual
The steam boiler blowdowns will be silicic acid. This acid is a very
less frequent and corrosion in the slightly dissociated acid. In order to
condensate and boiler systems is avoid silicic acid scaling, the maxi-
greatly reduced. mum allowable SiO2 concentration
in the boiler feed water is 0.02 mg/l.
One can work without additional This results in a maximum SiO2
thermal degassing at smaller boiler concentration of 0.02 mg/l in the
capacities (up to max. 1 t/h). With boiler steam.
the alkaline operation method used
by DOSHION, the free carbonic
acid contained in the raw water can

Fig. 7

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DOSHION - Boiler Feed Water Treatment

The demineralization system serves bonding sites on the anion resin.

to demineralize the raw water and Now the decarbonized water flows This CO2 will load up the resin
provide boiler feed water. The sys- into the resin chamber of the strong bonding sites and will lead to
tem consists of a cation ex- acid cation exchanger. The cations quicker exhaustion of the anion
changer(s), a CO2 degasifier(s), an still contained in the decarbonized resin bed.
+ + +
anion exchanger(s) and a mixed water like Ca , Mg , and Na are
+
bed exchanger(s) as the final pol- exchanged against H ions from the For removal of carbonic acid the
ishing step. resin media. The corresponding feed water enters the CO2 degasi-
acids are created from the cation fier from the top via a distribution
Cation and anion exchangers are parts of the salts in the raw water. nozzle, is then atomized and flows
designed for an operation period of then downwards through the tower
approximately 8-12 hours at full After a calculated throughput the packing layers.
load. Regeneration is carried out resin material is exhausted and has
automatically and is quality de- to be regenerated with a dilute acid In the counterflow to the water, air
pendent. Use of duplex plants guar- solution. is force up through the tower via a
antee that demineralized boiler feed fan. The air enriches with carbonic
water is continuously available. Regeneration is carried out in the acid and escapes the degasifier
counterflow according to the packed through the top of the degasifier
For chemical saving a CO2 degasi- bed process in flow direction from vessel.
fier is installed between the cation top to bottom.
and anion exchangers. The degasi- The water free from carbonic acid
fier physically removes most of the As with all packed bed systems, collects in the degasifier clearwell
free carbonic acid. the regeneration has to be carried and is supplied from there to the
out with a mininum velocity of 10 anion exchangers via booster
A mixed bed exchanger is installed m/h in order to maintain a packed pumps..
for final polishing of the demineral- bed and to avoid rearrangement of
ized water. the resin. The level in the degasifier clearwell
is controlled via an level control
This water is then collected in a The hydrochloric acid demand for valve. The degasifier pumps are
demineralized water storage tank, regeneration is between 50 and 65 protected by a separate level con-
from which the thermal degasifier is g HCl 100% per liter of resin. tact in the degasifier clearwell.
supplied with feed water.
The cation exchanger is continu-
The wastewater generated during ously circulated via the degasifier
one regeneration is collected in the pumps, so that the product water
2.6.3 Anion Exchanger:
neutralization tank and is neutral- outlet can be stopped at any time,
ized there before being discharged without causing the resin bed to fall, The anion exchanger serves to
to drain. resulting in high sodium leakage. deacidify the decationized water. It
is the second part of the deminer-
2.6.1 Cation Exchanger: alization process.
2.6.2 CO2 - Degasifier:
The cation exchanger serves to Regeneration of the anion ex-
remove positive ions from the iron changer is carried out with a down-
The degasifier serves to remove flow dilute caustic solution.
and manganese-free raw water. free carbonic acid from the deca-
tionized water. For deacidification the water enters
It is the first part of the deminerali-
zation process and is supplemented the anion exchanger from the bot-
By decationizing the raw water, free tom and is equally distributed by
by a downstream degasifier and an carbonic acid is created from the
anion exchanger. the distributor plate. the water then
bound carbonic acid. flows up through the resin material.
For decationization the water enters Per mval CO2 (m-value) of the raw
the cation exchanger from the bot- At a linear water velocity of ap-
water, 44 mg/ltr free carbonic acid proximately 10 m/h the resin bed is
tom and is equally distributed over is created by decarbonization. The
the complete tank cross-section. lifted up against the upper distribu-
CO2 present in the water reacts tor plate, forming a packed bed.
First, the water flows through the aggressive at a pH of approximately
resin chamber of the weak acid 4 to 5.
cation exchanger from bottom to In order to avoid resin mixing at
top. Here, the cations associated lower flow rates, the demineraliza-
Furthermore, in the following strong tion system is re-circulated via the
with the carbonate hardness are base anion exchanger, CO2 com-
removed (decarbonized). degasified water forwarding pumps.
petes with other negative ions for

04/99 Boiler Feed Water Treatment 12

DOSHION – Boiler Feed Water Treatment

So, a product flow rate of 0-100%

of the designed capacity is possible. The water flows into the mixed bed
exchangerer from the top and is
As water flows through the strongly equally distributed through a distri-
alkaline resin bed, the strong anions bution header. It then flows down-
contained in the water like Cl, SO4, ward through the resin bed. The
NO3, HCO3 and SiO2 are ex- resin bed consists of a mixture of
- strong acid cation and strong base
changed with OH ions from the
anion resins.
resin.
A lot of very small demineralization
After a calculated water throughput,
units arise from the resin mixing
the resin becomes loaded with
which demineralizes the water. The
anions and has to be regenerated
resins are separated from the lower
with a dilute caustic solution
pure water chamber by a nozzle
(NaOH).
distribution plate at the bottom. The
demineralized water leaves the
Usually regenerations are carried
exchanger vessel via the lower
out in a downflow direction, accord-
collector outlet.
ing to the suspended bed process.
After a calculated water through-
The effluent conductivity down- put, the resin material becomes
stream of a strong base anion ex- loaded with cations and anions and
changer is normally below 5 µS/cm. has to be regenerated with dilute
The caustic soda demand per liter caustic (NaOH) and dilute acid
of resin for regeneration is between solutions (H2SO4 or HCl).
35 and 50 g NaOH 100%.

External backwashing is carried out

in a separate backwashing tank
approximately once per year.

The complete regeneration is car-

ried out with demineralized water.

2.6.4 Mixed-Bed Exchanger:

The mixed-bed exchanger acts as a

final polishing step for the deminer-
alized water stream. It is installed
downstream of the cation and anion
exchangers.

By installing a mixed-bed exchanger

downstream of the cation/anion
exchangers, an effluent conductivity
of less than 0.2 µS/cm and an ef-
fluent silicic acid concentration of
less than 0.02 mg/l can be
achieved. In case of salt break-
through the preceding exchangers,
the downstream mixed-bed ex-
changer can provide a margin of
safety.

Regeneration of the mixed-bed

exchanger is carried out in a co-
current manner for the anion resin
and in a counter-current manner for
the cation resin.

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DOSHION - Boiler Feed Water Treatment

3 Degasifier creased in order to promote the fier is installed approximately 3.5 m

transfer of the gas from the feed above the boiler feed pumps.
3.1 Basics water to the air.
By dosing dissolved oxygen binding
Natural water contains oxygen and DOSHION has developed degasifi- media like sodium sulfite, hydrazine
carbonic acid. Although these ers and spray nozzles that create and alkalization media like ammo-
gases are required in drinking wa- water droplets of optimal size for nia or trisodiumphosphate atrium-
ter, for process applications these effective degasifying. The gases phosphate, boiler feedwater is
constituents are major contributors removed from the feedwater are treated to meet all requirements.
to boiler corrosion. To avoid corro- transported from the degasifier with
sion, the maximum allowable dis- the air vapour forced up through the 3.2 Thermal Degasifiers
solved oxygen (DO) concentration tower.
for a boiler feed water application is DOSHION has standard designs for
0.02 mg/l. In the case of smaller towers (<20 flowrates in the range of 3 - 300 t/h,
t/h), the forced air vapour is dis- as low or high pressure degasifiers.
Gases found in water, like oxygen, charged directly to the outside. With custom designed degasifier
nitrogen and carbonic acid, are Larger plants are equipped with columns and internals designed for
physically removed by degasifiers. vapour condensators for energy and optimal water droplet formation,
The water is brought to the tem- water recovery. dissolved oxygen values of less
perature of ebullition and the sur- than 0.01 ppm can be expected.
face area of the feedwater is in- In order to avoid cavitation of the
boiler feedwater pumps, the degasi-

Thermal Degasification
Vent

Condensate

Steam/Hot Water
Feedwater

LIS

Treated Water

Phos. Sulfite

Fig. 8:
Classical thermal degasifier, separate inlets for fresh water and condensate. Reboiling device as well as dosing systems for
sulphite and phosphate.

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DOSHION – Boiler Feed Water Treatment

Fig. 9:
Degasifier with heat recovery and condensate return.

3.3 Spray Degasser t/h, as a low pressure degasifier support construction is required for
(0.2 bar). With a circulation pump installation of this design.
As a small, economical plant for and internals with special spray
sites with limited square footage. nozzles for optimal degasifying. No Dissolved oxygen concentration
Design flowrates range from 0 - 10 less than 0.02 ppm.

Fig. 10:
Spray Circulation Degasifier
with circulation pump, steam fittings,
inflow device for feedwater.

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DOSHION - Boiler Feed Water Treatment

3.4 Vacuum Degasifiers height is reduced to approx. 1000 The reaction of the oxygen with the
mm. hydrogen to form water is carried
These units are used where there is out in the ion exchanger vessel. The
no heating medium (steam/heating 3.5 Removal of Oxygen by water flowrate, oxygen concentra-
water). Designed with a degasifier Ion Exchanger tion and hydrogen concentration
column of stainless steel and tower downstream of the vessel are con-
packing of PPL or PVC. Operating This design is more suited to large tinuously measured and evaluated.
pressures ranging from 0.05 to 0.99 flowrates (>30 t/h) and where the The dissolved oxygen concentration
bar absolute and operating tem- water shall be free from oxygen, can be less than 0.005 ppm (5 ppb)
peratures of 30 to 99° C. e.g. after a demineralization.
Note:
This design is especially suitable for By injecting hydrogen gas, the oxy-
degasifying of warm water in large gen contained in the water reacts The removal of oxygen by injecting
systems. The operating pressure is with hydrogen to form H2O. By hydrogen and ion exchange is not
adjusted to the required value by using DOSHION dosing system current economically viable.
liquid ring vacuum pumps. technology the hydrogen gas is
stoichiometrically added to the New methods of degasification by
Depending on the required effluent water and mixed, bubble-free, with utilitzing membrane technology
dissolved oxygen concentration, the a specially designed water/gas have been tested for smaller sys-
degasifier sump is equipped with mixer. tems and remains to be seen,
reboiling devices. By using side- whether the membrane technology
channel pumps the required inflow will be more economical in this
application.

Fig. 11:
Vacuum Degasifier with horizontal
feed water tank, vacuum pump,
heating pipe bundle for reboiling and
dosing system.

04/99 Boiler Feed Water Treatment 16

DOSHION – Boiler Feed Water Treatment

4.0 Dosing Systems the residual iron concentration in

the condensate water. A number of alternatives for oxygen
4.1 Basics for Dosing binding are also available.
4.3 Dosing in Food Industries
In addition to the water treatment
5.0 Condensate Treatment
and degasification, treatment Usually trisodium phosphate for
chemicals, like trisodiumphosphate alkalization and sodium sulphite for
and sodium sulfite or film formers, oxygen binding are used in this Normally it is not necessary to treat
are added to the feedwater. application. As mentioned previ- the condensate chemically. A de-
ously, small quantities of bound gassing of the condensate is always
Dosing to the feedwater tank is carbonic acid can lead to corrosion useful. Only in the case of contami-
carried out at a mixture intensive in the condensate system. There- nation of the condensate (e.g. un-
point. Often the dosing pumps are fore, the boiler feed water is often tight heat exchanger) or in the case
operated in conjuction with the inlet pretreated by reverse osmosis. The of high demands to the feed water
solenoid valve or the boiler feedwa- pH for boiler feedwater, as required (turbine operation) is a condensate
ter pump. This results in quantity- by the boiler manufacturer, may not treatment necessary.
proportionate dosing of chemicals. be maintained simply by dosing
phosphate. It is possible to add 5.1 Condensate Filtration
If possible, residual hardness stabi- caustic soda for alkalization of the
lizers and oxygen binding media boiler water, in addition to, or as an Condensate filtration removes par-
should be added via two separate alternative to phosphate and sulfite. ticles from the condensate. Com-
dosing pumps. Adapting exact monly, anthracite is utilized as a
chemical dosing rates for various 4.4 Oxygen Binding Media filter material. One should abstain
operating conditions is made possi- from filtration via quartz sand, as
ble with this design. Primarily, dissolved oxygen in the quartz sand can add silicic acid to
feedwater has to be reduced by the condensate. For space reasons
At separate dosing points the alkali- physical processes (thermal degasi- candle filters, bag filters and mem-
zation media, like trisodium phos- fication) in order to reach the levels brane filters are also used as alter-
phate, and the oxygen binding me- described in chapter 2.1. If, in prac- natives for condensate filteration.
dia, like sodium sulfite, are added tical operation, this is not possible The filter fineness should be <5.0
to the feedwater tank at the boiler because of frequent shutdowns, an µm.
feed pump suction. oxygen binding media has to be
added. 5.2 Removal of Iron/Residual
4.2 Dosing for Salt-free
Hardness
Operation 4.4.1 Sodium Sulfite
Dissolved substances (hardness,
By using the above described dos- Na2SO3 is a non-steam volatile iron, copper) cannot be removed by
ing of phosphate and sulfite, the oxygen binding media. It does not filtration. In the case of low re-
salt concentration in the boiler wa- enter the steam condensate circuit. quirements for condensate quality,
ter is increased. This, however, is Sulfite is the suitable medium, es- softeners are used here. Any hard-
not permitted for high pressure pecially for food industries or any ness present in the condensate is
steam boilers. Pretreatment nor- other industry where steam may exchanged with sodium ions. Re-
mally consists of a demineralization have direct contact with food, drink- sidual hardness is continuously
plant. ing water or the air. monitored.
Residual hardness leakage is not Regeneration should be carried out
to be expected here. Slightly higher 4.4.2 Hydrazine
when effluent quality exceeds a
dissolved oxygen concentrations specified setpoint. In the case of
are permitted in the feedwater with N2H4 is a steam volatile oxygen
binding media that has an alkalizing iron concentration in the conden-
less salt, often an alkalization me- sate, a level above 0.1 mg/l re-
dia like ammonia is added. Ammo- effect. Hydrazine enters the steam
circuit and the condensate. quires that the softener be regener-
nia does not concentrate in the ated with hydrochloric acid every
boiler water. Ammonia can bind three months.
free carbonic acid in the steam Unfortunately though, hydrazine is
condensate system as ammonium carcinogenic. During handling and
carbonate, alkaline condensate is dosing, the corresponding health
achieved. The quantity of ammonia and safety regulations have to be
to be dosed can be determined via maintained.

4.4.3 Other Dosing Chemicals 5.3 Removal of Silicic Acid

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DOSHION - Boiler Feed Water Treatment

The removal of undissolved, emul-

In turbine power plants a cation sified oil by activated carbon is
exchanger is used as condensate difficult. The oil should be present in
treatment for removal of ammo- dissolved form, the oil concentra-
nium, iron, lime, etc. and a mixed tion can amount to a maximum of 5
bed exchanger for demineralization ppm. For short intervals, 10 ppm
of condensate. The mixed bed ex- can be tolerated. The activated
changer is only loaded with the carbon should be exchanged after a
sodium leakage from the cation and service life of approximately 1 year.
with silicic acid and possibly car-
bonic acid. Typical service runs of 1 Usually carbon loaded with oil is not
- 3 months are achieved, before a thermally reactivated again, but
regeneration is required. only disposed of. Whether thermally
reactivated carbon is useful can be
The cation exchanger can be con- decided only after a test with the oil-
trolled by an online sodium ana- loaded carbon. Reactivation seems
lyzer. Often the cation exchanger is to be useful, if the reactivation costs
regenerated either on a thoughput do not exceed approximately 80%
or service time basis. of the replacement cost for the new
carbon.
Regeneration is carried out with a
dilute hydrochloric acid solution. If a
high concentration of NH3 is present
in the condensate, ammonium
chloride (NH4Cl) can form in the
cation exchanger effluent. The
maximum allowable concentration
of ammonium chloride in the efflu-
ent is 10 mg/l .

The mixed bed exchanger is regen-

erated with dilute hydrochloric acid
and dilute caustic soda. No
ammonium chloride is formed.

5.4 Condensate Deoiling

Condensate deoiling is carried out

by simple filtration with an activated
carbon filter. The oil contained in
the condensate is adsorbed by the
activated carbon media by simple
flow through the activated carbon
layer.

Filter material is an activated car-

bon washed with acid and conden-
sate. The hardness and silicic acid
are still present in trace amounts in
the condensate feedwater. With
continuous operation the carbon
gives no hardness or silicic acid to
the condensate. The operation time
of the carbon depends on many
factors (condensate temperature,
flow velocity, type and quantity of
the dissolved oil etc). There-
fore, the operation time cannot be
determined exactly.

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