BOILER Treatment

Contents
 Objectives of Boiler Water Treatment

 Problem in High Pressure Boiler
 Chemical Treatment Program
 Monitoring & Control
 Troubleshooting Guide
Objectives
Boiler Water Treatment
 Increase Unit Reliability
 Minimize contaminant ingress
 Decrease downtime
 Increase safety
 Decrease operational costs
HIGH PRESSURE BOILER
Definition of High Pressure Boiler
 A boiler which operates at a pressure

above 650-700 psi (USA standard)
High Pressure Boiler
Corrosion
Corrosion
the mechanism by which processed metals are
reverted back to their natural oxidized state.
Causes of Corrosion
 Oxygen Attack
 Caustic Attack (Alkalinity Concentration)
 Carbon Dioxide Attack
Oxygen Attack
Sources :
 Air in-leakage
 Inefficient daeration operation
 Raw water intrusion
OXYGEN CORROSION
• Pitting ( one type of oxygen corrosion ) - Leakage
• Three variables influences the corrosion :

1. pH
2. Temperature
3. Oxygen concentration
• Reaction :
Anodic : Fe ( metal )  Fe+2 + 2e- ( Oxidation )

Cathodic : ½ O2 + H2O + 2e-  2 OH- ( Reduction )
OXYGEN CORROSION
Anodic : Fe ( metal )  Fe+2 + 2e- ( Oxidation )

Cathodic : ½ O2 + H2O + 2e-  2 OH- ( Reduction )
PREVENTION :
1. Mechanical => Deaerator
2. Chemical => Oxygen scavengers & Metal passivators
Oxygen Attack
Characteristic
 Reaction :
 Fe -----> Fe2+ + 2e Anode
 2e + 1/2O2 + H2O ---> 2(OH-) Kathode
 O2 attack result in pitting type corrosion. Rapid

localized metal loss
 Combined corrosion rate of CO2 & O2 is 10% to
40% faster then the sum of either alone
Caustic Attack
 Characteristic
 Occur in high pressure boiler
 Localized corrosion
 Contributed by deposit accumulation
Caustic Attack
 Conditions required:
 A chemical substance in the boiler water that, if
sufficiently concentrated, would be corrosive to
boiler water
 A mechanism for concentrating the chemical
substance, locally, to corrosive levels
CAUSTIC CORROSION
LOCAL CORROSION - Due to deposit accumulation
Magnetite
Steam out
NaOH Boiler water

NaOH NaOH
Boiler water in
Fe3O4 porous
deposit
Caustic soda - Highly aggressive to boiler steel at high concentration

PREVENTION :
1. Make up water ( demin water ) pretreatment
2. Correct control of high pressure boiler water treatment - To avoid free caustic
Caustic Attack
 Reaction
 Fe2O3 + 2 NaOH ----> 2NaFeO2 + H2O
 FeO + 2 NaOH ----> Na2FeO2 + H2O
 Fe + 2 NaOH + 2 H2O ----> 2 NaFeO2 + 3 H2O
Caustic Attack
 Conditions Enhanced :
 Metal Oxide Deposits
 Operating at steam flows above rated capacity
 Excessive rates of boiler load increases
 Localized excessive heat input due to burner
alignment or other fireside condition
 Localized pressure differentials in a generating tube
Carbon Dioxide Attack
Sources :
 Breakdown of feed water alkalinity
 HCO3
 CO3
heat
CO2
 Air inleakage
 Organic breakdown
Carbon Dioxide Attack
Characteristic
 Dissolves in condensate forming carbonic acid
 CO2 + H2O <---> H2CO3 <--->H+ +
HCO3-
 Carbonic acid attack results in a thinning
and grooving of the metal surface
ALKALINITY / CO2 CORROSION
SOURCE : Thermal breakdown of bicarbonate &
carbonate alkalinity in BW
a. 2NaHCO3 ---> Na2CO3 + CO2 + H2O
b. Na2CO3 + H2O ---> 2NaOH + CO2
The produced CO2 is carried with steam &
dissolves in the condensate to form carbonic
acid, which will reduce condensate pH.
CO2 + H2O <---> H2CO3 <---> H+ + HCO3-
Corrosion : Uniform attack
leaving a rather smooth
surface, where the iron
has dissolved away
This quite high and it is
much aggressive to the
system metal
ALKALINITY / CO2 CORROSION
PREVENTION :
1. MECHANICAL
a. Eliminate air and process in-leakage
b. Demineralization => Alkalinity is still needed to maintain
proper BW Ph
2. CHEMICAL
Neutralizing amines, or ammonia will neutralize any acid
present in the condensate system and increase pH to a level
at which the condensate is much less aggressive to the
system metal
Deposition
 Source of Deposition  Condensate water

due to condensate
corrosion
 Boiler Feed Water
System
 Boiler Metal
Corrosion, especially
during idle period
Deposit
Boiler Treatment Training for CCPP 120MW KDL

DEPOSIT
SOURCE : METAL ( Fe & Cu ) OXIDES - Corrosion products of condensate & BFW systems
• Carbonic acid corrosion
Fe + 2H2CO3 ---> Fe+2 + 2HCO3-
• Oxygen corrosion
4Fe + 6H2O + 3O2 ----> 4Fe(OH)3
• Carbonic acid combined with oxygen corrosion

2Fe(HO3)2 + ½ O2 -----> Fe2O3 + 4CO2 + 2H2O
Metal ( Fe & Cu ) oxides will create deposits in the boiler system with high heat flux &
high metal temp.
DEPOSIT
SOLUTION :
1. MECHANICAL
Utilizing Consensate Polisher
2. CHEMICAL
Control corrosion in the condensate & BFW system by utilizing proper amines /
ammonia and O2 scavenger chemicals & metal passivator
CARRY OVER
Boiler CARRY OVER => DEPOSITS on steam-path parts ( e.g. : TURBINE ),

which has a significant effect on unit efficiency, capacity & reliability.
STRESS-CORROSION CRACKING
Due to small fraction of metal => Tensile strength
PREVENTION :
Good control of water chemistry to prevent
either SOLIDS DEPOSITION or CORROSION
of STEAM-GENERATOR and TURBINE
COMPONENTS
High Pressure Boiler
Chemical Treatment
Program
 Oxygen Scavenger & Metal Passivator -
Hydrazine
 Boiler Internal Treatment - Phosphate
 Condensate & FW Treatment – Ammonia
Oxygen Scavenger & Metal
Passivator
Reaction of Hydrazine with O2

N2H4 + O2 ---> N2 + 2H20
Passivator
Characteristic of Hydrazine
 Volatile  Excellent passivator
 Adds no solid to boiler  No pH limitation in feed
water water
 Reaction product are  No pressure limitation
water & nitrogen
Passivator
Advantages of Hydrazine
 Much superior metal passivation
 Quicker reaction rate with O2
 Lower corrosion rate when used for boiler wet
lay up
Internal Treatment
 Phospate Program :
 A Chemical treatment program for internal

drum boiler water where Phosphate injected
to maintain pH (pH buffer).
Condensate & Feed Water Treatment
 Contaminant in Condensate :
 Carbon Dioxide
 Oxygen
 Iron
 Hardness
 Silica
 Oil
Primary causes of corrosion
Carbon Dioxide
Oxygen
Condensate & Feed water Treatment
Chemical Program
Neutralizing Amines
Oxygen Corrosion
Inhibitor
Neutralizing Amines
Effective
against
Carbonic
Acid
Other Acid
Troubleshooting
 pH Possible Problem
:
Boiler carry over
high/low
 Conduct.
Boiler corrosion
high Condensate
contamination
Troubleshooting
 Total Iron Possible Problem
High Air leakage
Daerator
problem
 Sodium
high Boiler carry over
Thank you

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Contents

 Objectives of Boiler Water Treatment

Definition of High Pressure Boiler

 A boiler which operates at a pressure

• Three variables influences the corrosion :

Anodic : Fe ( metal )  Fe+2 + 2e- ( Oxidation )

Anodic : Fe ( metal )  Fe+2 + 2e- ( Oxidation )

 O2 attack result in pitting type corrosion. Rapid

NaOH Boiler water

Caustic soda - Highly aggressive to boiler steel at high concentration

 Source of Deposition  Condensate water

Boiler Treatment Training for CCPP 120MW KDL

• Carbonic acid combined with oxygen corrosion

Boiler CARRY OVER => DEPOSITS on steam-path parts ( e.g. : TURBINE ),

Reaction of Hydrazine with O2

 A Chemical treatment program for internal

Primary causes of corrosion

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