Presented by Steve Connor January,...
Transcript of Presented by Steve Connor January,...
Basic Deaerator Science Revealed
Presented by Steve ConnorJanuary, 2015
Component Selection &
Sizing
What is Deaeration?
Types & Operation When to Apply
Benefits Hydrological Cycle
What We Are Covering Today
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Basic DeaeratorScience Revealed
The Hydrologic Cycle
3
Water the Universal Solvent
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Dissolved Solids
Dissolved Gasses
Suspended Solids
CO2
CO2
Aluminum Chlorides
FluoridesNa2SO4
Mg(HCO3)2CaSO4MgSO4 MgCl2
O2
O2
O2O2
CarbonatesIronCO2
Calcium
SilicaSodium Magnesium
Manganese
Sulphates
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Tolerances are Based on Pressure & Temperature
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Feed Water Boiler WaterOxygen & CO2 SilicaIron & copper Total AlkalinityTotal Hardness Free OH AlkalinitypH Specific ConductanceNon-Volatile TOC(Total Organic Carbon)
Oily MatterASME Guidelines:
Broken down by feed water and boiler water, and then by firetube and watertube boilers.
Water Constituent Tolerance: 0-300 operating psig
Mechanical Chemical
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Most Economical Long-Term Approach
Water Quality: Dissolved Gases
2 2
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Today we’re concentrating on…
Oxygen CorrosionIron begins to dissolve when in contact with water.
Fe + 2H2O = Fe(OH)2 + 2H+
Iron + Water = Ferrous Hydroxide + Hydrogen
Water Quality: Dissolved Gases
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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)3Ferrous Hydroxide + Oxygen + Water = Ferric Hydroxide (RUST)
Water Quality: Dissolved Gases
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Corroded Boiler Tubes
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Firetube Watertube
Blisters
Holes
Courtesy:http://www.engineeringtoolbox.com/oxygen-steel-pipe-...
50 F
86 F
122 F
2 times more corrosive at 122oF than at 86oF
Water Quality: Dissolved Gases
X
X
Carbon Dioxide – Friend or Foe?
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Water Quality: Dissolved Gases
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Combines with Water to Create Carbonic Acid
CO2 + H2O = H2CO3
Creation of CO2 from Carbonates
Courtesy:http://www.spiraxsarco.com/resources/steam-engineering-tutorials/the-boiler-house/water-treatment-storage-and-blowdown-for-steam-boilers.asp
Water Quality: Dissolved Gases
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CO2 gas combines with condensate forming carbonic acid; corroding pipes and heat transfer units.
Water Quality: Dissolved Gases
Carbonic Acid attack
Carbon Dioxide AND Oxygen:
CO2
Carbon Dioxide together with Dissolved Oxygen is 40 percent more corrosive than if the two were acting alone.
O2
Water Quality: Dissolved Gases
Dissolved Oxygen is 10 times more corrosive than CO2
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OK….what do we do?
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Solution to Manage These Gasses
Raise the Temperature!
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Water Quality: Dissolved Gasses
CO2
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10
0
2
4
6
8
21019017015013011090705030
Oxy
ge
n C
on
ten
t, p
pm
Temperature, Degree F.
Free Gases Are Insoluble At Saturation TemperatureWater Quality: Dissolved Gases
Manage pH @ approx. 11
CO2
Water Quality: Dissolved Gases
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Reducing Surface Tension
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Mechanical Removal
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Deaeration Removes• Oxygen• Free Carbon Dioxide
Heat Agitate Liberate
• Spraying or filming – Reduce surface tension• Heating – Losing solubility• Mechanical – Agitation & scrubbing - Liberating• Releasing O2 & CO2 to atmosphere in gaseous form
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DA Methods: Operation
DA & Holding Hot Condensate
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Saturated Steam Table
Pressure (psig) 5 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
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Zero Condensate Returned800 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 Btu’s 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
XAll Condensate
Dumped!
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Return Some Condensate to Feed System
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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 RawMakeup & Condensate125 Deg. F DA
Deaerator Applications
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• Boiler plants @ at 75 PSIG or higher
• Plants with no standby capacity
• Plants with critical loads
• Plants operating with 25% makeup or more
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7,000 – 280,000 pph
Types of DeaeratorsSpray Type
Spray cone
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Types of DeaeratorsSpray Head Design
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1,500 – 135,000 pph
Deaerating Column
Storage Tank
Packed Column TypeTypes of Deaerators
Packed Column DA
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Deaerating Column
Makeup Water In
Storage Tank
O2 & CO2 Vent
Corrosion Proof Rings
Steam In
Spray & Vent Condensing Section
Types of DeaeratorsTray Type
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30,000 – 1,200,000 PPH
40,000 PPH1,000,000 PPH
Tray DA
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Makeup/Condensate In
Spray Valve Assembly
Vent Condenser
Trays
Deaerated Water Downcomer
SteamInlet
High Temp. Returns
Advantages & Disadvantages
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Type Advantages DisadvantagesSpray • Head room
• Weight• Price• Capacity
• Mechanical components
• Critical adjustments to steam nozzle
• Limited HP returnsColumn • DA consistency
• Reliable• HP returns
• Head room• Weight• Limited capacity• Price
Tray • DA consistency• Reliable• HP returns• Highest capacity
• Head room• Weight• Price
Saturated Steam Table
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Pressure (psig) 5 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) 195.5 207.9 294.4 308.9Latent Heat
(btu/lb) 960.5 952.5 891.9 880.7
Total Heat (btu/lb) 1156 1160.4 1186.3 1189.4
High Pressure Receiver Tank
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• Takes high pressure condensate directly from the user
• No need to deaerate• Pump directly into
boiler• Feed the HPCR from
the DA
DA Component Selection & Sizing
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Spray Type
Spray Cone & Tank Assembly
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Formulas:• 200 HP X 34.5 = 6900#/HR• 6900/8.3 = 831 Gallons/HR• Tank storage: 10 minutes = 150 Gal.
Makeup Valve• Mechanical• Pneumatic• ElectronicSteam
H.P. Return
Vent
Exhaust OrFlash Steam
ToBoiler
Boiler FeedWater Pump
OverflowDrainer
Cold Make-UpWater
L.P. Condensate
Make-Up Valve
Check Valve
Formula:SQ Root of inlet press. – tank press. – nozzle press XCv = GPM
Example: (50# - 5# - 7#) = 6.1 X 12 = 73.2 GPMSQ Root
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Steam
H.P. Return
Vent
Exhaust OrFlash Steam
ToBoiler
Boiler FeedWater Pump
OverflowDrainer
Cold Make-UpWater
L.P. Condensate
Make-Up Valve
Check Valve
PRV
Selection Sequence:1. Maximum pumping rate of DA2. Estimate Average mix temperature of FW3. Determine amount of steam to heat FW to saturation4. Determine PRV size based on boiler operating
pressure
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Centrifugal Pumps
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Flexible Coupled Close Coupled
Vertical Multi-Stage
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• Net Positive Suction Head Required• 2.31 Feet per pound
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Formulation Example:Flow200 HP X 0.069 = 13.8 GalContinuous: X 15% = 16 GPMIntermittent: X 50% = 21 GPM
TDH DutyBoiler 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’>
NPSHRRead from the pump curve at the respective duty points
Centrifugal pumps
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Vertical Multi-Stage
Centrifugal Pump Curve
100
200
300
400
500
20 40 60 80 100 120 140 160
10” Dia.
9” Dia.
8” Dia.
7”Dia.
6” Dia.
5” Dia.
3' 4' 5' 6' 7'8'
NPSHR
Hea
d in
Fee
t
Capacity in GPM
280
180
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Centrifugal Pump Curve
100
200
300
400
500
20 40 60 80 100 120 140 160
10” Dia.
9” Dia.
8” Dia.
7”Dia.
6” Dia.
5” Dia.
3' 4' 5' 6' 7'8'
NPSHR
Hea
d in
Fee
t
Capacity in GPM
X X
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Stand
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Height depends on NPSHR for Pumps versus NPSHA
Safety Valve(s)
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Sizing considerations:1. Normally set at DA design pressure2. Must handle full output from PRV @ boiler’s safety valve setting
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- DA’s 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!
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Contact Us
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Thomas LeunigProduct Manager-Packaged
Water [email protected]
Jesse SteffenSales Engineer-Packaged
Water [email protected]