01-21-2015 Basic Deaerator Science Revealed FINAL

Basic Deaerator Science Revealed
Presented by Steve Connor

January, 2015
What We Are Covering Today

Hydrological
Cycle
Benefits
Basic
Deaerator
Science
Revealed
Component
Selection &
Sizing
Types &
Operation
What is
Deaeration?
When to Apply
The Hydrologic Cycle
Water the Universal Solvent

Dissolved
Solids
Dissolved
Gasses
Suspended
Solids
CO2
O2
O2
O2
CO2
O2
Carbonates
Iron
Sulphates
Calcium
Magnesium
Sodium
Manganese
Na2SO4
CO2
Aluminum
Silica
Chlorides
Mg(HCO3)2
CaSO
4
5
MgSOFluorides
4
MgCl2
Tolerances are
Based on Pressure & Temperature
Water Constituent Tolerance: 0-300 operating psig

Feed Water
Boiler Water
Oxygen & CO2
Silica
Iron & copper
Total Alkalinity
Total Hardness
Free OH Alkalinity
pH
Specific Conductance
Non-Volatile TOC
(Total Organic Carbon)
Oily Matter
ASME Guidelines:
Broken down by feed water and boiler water, and then by firetube and watertube boilers.
Most Economical Long-Term Approach
Mechanical
Chemical
Water Quality: Dissolved Gases
Today were concentrating on
2
8
Oxygen Corrosion
Iron begins to dissolve when in contact with water.
Fe + 2H2O = Fe(OH)2 +
Iron +
Water
+
2H
= Ferrous Hydroxide + Hydrogen

Now add in dissolved O2
Process continues until 1 of 2
things occurs
1. No more dissolved O2
2. No more iron Fe
4Fe(OH)2 +O2 +H2O= 4Fe(OH)3

Ferrous Hydroxide + Oxygen
+ Water
10
Ferric Hydroxide (RUST)
Corroded Boiler Tubes

Watertube
Firetube
Holes
Blisters
11

2 times more
corrosive at
122oF than at
86oF
50 F
86 F
122 F
X
X
Courtesy:http://www.engineeringtoolbox.com/oxygen-steel-pipe-...
Carbon Dioxide Friend or Foe?
13
Creation of
CO2 from
Carbonates
Courtesy:http://www.spiraxsarco.com/resources/steam-engineering-tutorials/the-boiler-house/water-treatment-storageand-blowdown-for-steam-boilers.asp
CO2 + H2O = H2CO3

Combines with Water to Create Carbonic Acid
14
CO2 gas combines with condensate

forming carbonic acid; corroding pipes
and heat transfer units.
Carbonic Acid attack
15
Carbon Dioxide AND Oxygen:

Carbon Dioxide together with Dissolved
Oxygen is 40 percent more corrosive than if
the two were acting alone.
O2
CO2
16
Dissolved
Oxygen is
10 times
more
corrosive
than CO2
OK.what do we do?
17
Water Quality: Dissolved Gasses
Solution to Manage These Gasses
CO2
Raise the Temperature!

18

Free Gases Are Insoluble At Saturation Temperature
Oxygen Content, ppm
10
8
6
4
2
0
30 50 70
90 110 130 150 170 190 210

19
Temperature,
Degree F.
Manage pH @ approx. 11
CO2
20
Reducing Surface Tension
21
Mechanical Removal
Deaeration Removes
Oxygen
Free Carbon Dioxide
Heat
Agitate
22
Liberate
DA Methods: Operation
Spraying or filming Reduce surface tension

Heating Losing solubility
Mechanical Agitation & scrubbing - Liberating
Releasing O2 & CO2 to atmosphere in gaseous form
23
DA & Holding Hot Condensate
24
Saturated Steam Table

Pressure
(psig)
10
80
100
Saturation
Temp
227.3
239.5
323.9
337.9
Volume
(ft3/lb)
20.3
16.46
4.66
3.89
Sensible
Heat (btu/lb)
195.5
207.9
294.4
308.9
Latent Heat
(btu/lb)
960.5
952.5
891.9
880.7
Total Heat
(btu/lb)
1156
1160.4
1186.3
1189.4
25
Zero Condensate Returned

800 HP Process Boiler
Evaporates 27,600#/HR
Incoming feedwater temperature is 50 Deg. F
DA operating at 5# (227 Deg. F)
227 Deg. F 50 Deg. F = 177 Btu/#
27,600# X 177 = 4,885,200 Btus per hour
@ $0.50 per Therm (100,000)
4,885,200/100,000 = 49 Therms/HR X $0.50 = $25.00/HR
$25.00 X 4000 = $100,000/Year in FW heating cost
All Condensate
Dumped!
X
26
Return Some Condensate to Feed System

800 HP Process Boiler
Incoming FW Temperature is 125 Deg. F

227 Deg. F 125 Deg. F = 102 Deg. F
27,600 X 102 = 2,815,200/100,000 = 28 Therms/HR
28 X $0.50 = $14.00/HR X 4000 HRs/YR = $56,000/YR
Savings is $44,000 per year!
A Blend of Raw
Makeup & Condensate
125 Deg. F
DA
27
Deaerator Applications
Boiler plants @ at 75 PSIG

or higher
Plants with no standby
capacity
Plants with critical loads
Plants operating with 25%
makeup or more
28
Types of Deaerators
Spray Type
7,000 280,000 pph
Spray cone
29
Types of Deaerators
Spray Head Design
30
Types of Deaerators
Packed Column Type
1,500 135,000 pph
Deaerating Column
Storage Tank
31
Packed Column DA
O2 & CO2 Vent
Makeup Water In
Spray & Vent Condensing
Section
Deaerating Column
Corrosion Proof Rings

Steam In
Storage Tank
32
Types of Deaerators
Tray Type
30,000 1,200,000 PPH
1,000,000 PPH
40,000 PPH
33
Tray DA
Makeup/Condensate In
Vent Condenser
Steam
Inlet
Spray Valve
Assembly
Trays
Deaerated Water
Downcomer
34
High Temp. Returns
Advantages & Disadvantages

Type
Advantages
Spray
Head room
Weight
Price
Capacity
Column
DA consistency
Reliable
HP returns
Tray
DA consistency
Reliable
HP returns
Highest capacity
35
Disadvantages
Mechanical
components
Critical
adjustments to
steam nozzle
Limited HP returns
Head room
Weight
Limited capacity
Price
Head room
Weight
Price
Saturated Steam Table

Pressure
(psig)
10
80
100
Saturation
Temp
227.3
239.5
323.9
337.9
Volume
(ft3/lb)
20.3
16.46
4.66
3.89
Sensible
Heat (btu/lb)
195.5
207.9
294.4
308.9
Latent Heat
(btu/lb)
960.5
952.5
891.9
880.7
Total Heat
(btu/lb)
1156
1160.4
1186.3
1189.4
36
High Pressure Receiver Tank
Takes high pressure

condensate directly
from the user
No need to deaerate
Pump directly into
boiler
Feed the HPCR from
the DA
37
DA Component Selection & Sizing

Spray Type
38
Spray Cone & Tank Assembly

Formulas:
200 HP X 34.5 = 6900#/HR
6900/8.3 = 831 Gallons/HR
Tank storage: 10 minutes = 150 Gal.
39
Vent
Makeup Valve
H.P. Return
Steam
Exhaust Or
Flash Steam
Mechanical
Pneumatic
Electronic
Cold Make-Up
Water
Make-Up Valve
Check Valve
L.P. Condensate
Formula:
SQ Root of inlet press. tank press. nozzle press X

Cv = GPM
To
Boiler
Boiler Feed
Water Pump
Overflow
Drainer
Example: (50# - 5# - 7#) = 6.1 X 12 = 73.2 GPM

SQ Root
40
Vent
H.P. Return
PRV
Steam
Exhaust Or
Flash Steam
Cold Make-Up
Water
Make-Up Valve
Check Valve
L.P. Condensate
Selection Sequence:
To
Boiler
Boiler Feed
Water Pump
Overflow
Drainer
1.
2.
3.
4.
Maximum pumping rate of DA

Estimate Average mix temperature of FW
Determine amount of steam to heat FW to saturation
Determine PRV size based on boiler operating
pressure
41
Centrifugal Pumps
Flow:
BHP X Evaporation Rate = GPM

GPM X Safety Factor
- Continuous = 15%
- Intermittent = 50%
TDH
(In pounds or 2.31 feet of head )

Total Dynamic Head or
Discharge Pressure Requirement
for the pump to attain
Specific gravity
NPSHR
Vertical Multi-Stage
Net Positive Suction Head Required

2.31 Feet per pound
Close Coupled
Flexible Coupled
42
43
Centrifugal pumps
Formulation Example:
Flow
200 HP X 0.069 = 13.8 Gal
Continuous: X 15% = 16 GPM
Intermittent: X 50% = 21 GPM
TDH Duty
Vertical Multi-Stage
Boiler operating pressure + FW valve loss +

Line loss = Total pressure loss X 2.31 = Total loss in Feet of Head/SG
<100# + 25# + 5# = 135 X 2.31 = 301 Feet of Head/0.95 = 317>
NPSHR
Read from the pump curve at the respective duty points
44
Pump Curve
3' Centrifugal
4'
5'
6'
7'
8'
NPSHR
500
10 Dia.
400
Head in Feet
9 Dia.
300
280
8 Dia.
7Dia.
200
180
100
6 Dia.
5 Dia.
20
40
60
80
45
Capacity in GPM
100
120
140
160
Pump Curve
3' Centrifugal
4'
5'
6'
7'
8'
NPSHR
500
10 Dia.
400
Head in Feet
9 Dia.
300
8 Dia.
7Dia.
6 Dia.
100
200
5 Dia.
20
40
60
80
46
Capacity in GPM
100
120
140
160
Stand
Height depends on NPSHR for Pumps versus NPSHA
47
Safety Valve(s)
Sizing considerations:
1. Normally set at DA design pressure

2. Must handle full output from PRV @ boilers safety valve setting
48
Summary
DA Benefits:
-
Hotter boiler feedwater saves fuel energy (10 Deg. F rise = 1%)
Saves on chemical costs
Reduces blow down; saves water, chemicals and sewer charges
Better protects the boiler and piping system; reduces downtime &
capital expense
- Reduces thermal shock
MAJOR TAKE-A-WAYS
- DA removes O2 & CO2
- O2 corrosion increases with temperature
- CO2 is 40% more corrosive with O2 present
- DAs reduce water surface tension, heat, agitate & liberate gasses
- Three types; Spray, Tray & Column
- Return condensate as hot as possible
- Spray is limited in the amount of high temp condensate it can handle
- Changing duty points on a pump can cause cavitation.
- Safety valves are the last line of defense!
49
Contact Us
Thomas Leunig
Product Manager-Packaged
Water Systems
tleunig@cleaverbrooks.com
414-577-3197
cleaverbrooks.com
Jesse Steffen
Sales Engineer-Packaged
Water Systems
jsteffen@cleaverbrooks.com
414-577-2728
cleaverbrooks.com
50

01-21-2015 Basic Deaerator Science Revealed FINAL

Uploaded by

Copyright:

Available Formats

01-21-2015 Basic Deaerator Science Revealed FINAL

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

01-21-2015 Basic Deaerator Science Revealed FINAL

Uploaded by

Copyright:

Available Formats

Basic Deaerator Science Revealed

Presented by Steve Connor

What We Are Covering Today

The Hydrologic Cycle

Water the Universal Solvent

Water Constituent Tolerance: 0-300 operating psig

Oxygen & CO2

Iron & copper

(Total Organic Carbon)

Most Economical Long-Term Approach

Water Quality: Dissolved Gases

Today were concentrating on

Water Quality: Dissolved Gases

= Ferrous Hydroxide + Hydrogen

Water Quality: Dissolved Gases

4Fe(OH)2 +O2 +H2O= 4Fe(OH)3

Ferric Hydroxide (RUST)

Corroded Boiler Tubes

Water Quality: Dissolved Gases

Water Quality: Dissolved Gases

Carbon Dioxide Friend or Foe?

Water Quality: Dissolved Gases

CO2 + H2O = H2CO3

Water Quality: Dissolved Gases

CO2 gas combines with condensate

Carbonic Acid attack

Water Quality: Dissolved Gases

Carbon Dioxide AND Oxygen:

Water Quality: Dissolved Gasses

Solution to Manage These Gasses

Raise the Temperature!

Water Quality: Dissolved Gases

Oxygen Content, ppm

90 110 130 150 170 190 210

Water Quality: Dissolved Gases

Reducing Surface Tension

Spraying or filming Reduce surface tension

DA & Holding Hot Condensate

Saturated Steam Table

Zero Condensate Returned

Return Some Condensate to Feed System

Incoming FW Temperature is 125 Deg. F

Savings is $44,000 per year!

Boiler plants @ at 75 PSIG

7,000 280,000 pph

Corrosion Proof Rings

30,000 1,200,000 PPH

High Temp. Returns

Advantages & Disadvantages

Saturated Steam Table

High Pressure Receiver Tank

Takes high pressure

DA Component Selection & Sizing

Spray Cone & Tank Assembly

SQ Root of inlet press. tank press. nozzle press X

Example: (50# - 5# - 7#) = 6.1 X 12 = 73.2 GPM

Maximum pumping rate of DA

BHP X Evaporation Rate = GPM

(In pounds or 2.31 feet of head )

Net Positive Suction Head Required