LANCO KONDAPALLI POWER PLANT

ISO 9001 (2000) ISO 14001 (1996) OHSAS 18001 (1999) Certified

Boiler water Treatment by use of superior grade of tri sodium phosphate Content
! Why boiler water treatment
treatment treatment regime

! Boiler blow down

necessity criteria major problems and solutions

! Best practices in boiler water treatment

Fritz Miller General Manager, Genting Lanco Power (India) Pvt. Ltd. Sanjay Kumar Dubey Manager-Chem & Env, Genting Lanco Power (India) Pvt. Ltd. sources of ingress of impurities in drum & control saving of energy, water and chemicals

Introduction

Water Treatment

Boilers are an essential part of any industry, their efficient, economical operation significantly affect the reliability and profitability of the entire plant Best operation practices provide ! energy savings ! profitability improvement ! reduction in total cost of operations ! optimized treatment ! enhanced safety ! Feed water treatment ! Boiler water treatment ! Steam & Condensate treatment

Why boiler water treatment Boiler Scale and Deposits

untreated boiler water leads formation of scale and deposits results overheating and failure of boiler tubes

Why boiler water treatment Corrosion beneath deposits

Caustic imbritlement (Inter granular corrosion) is caused by concentration of caustic alkalinity in crevices under over stressed condition Caustic gouging is accumulation of caustic alkalinity under the deposit in the boiler

CORROSION DAMAGE IS IRREVERSIBLE

Why boiler water treatment Carryover

Carryover is described as contamination of the steam with boiler water It can be due to FOAMING when bubbles are formed on the surface and are carried out with the steam. High concentration of solids, excess free hydroxide & organic acids in the boiler water cause foaming The effects of carryover can be quite serious due to the contamination of steam which deposit in the steam and condensate system

Why boiler water treatment Thus

Untreated boiler water cause scale, Inter granular corrosion and steam contamination To protect a boiler from thermal damage and from the irreversible damage caused by corrosion, effective boiler water treatment is an absolute necessity

POOR WATER GIVES POOR STEAM

Boiler water treatment Coordinated Phosphate pH control

! Boiler operating up to 1200 psi ! Chemical used Tri sodium phosphate (TSP) ! pH 9.8 to 10.2 ! Phosphate 15 to 20 ppm ! Sodium/Phosphate ratio 3:1 Advantage ! Prevents caustic imbritlement - no free hydroxide ! Minimizes carry over - less hydroxide Disadvantage At high temp. leads conversion of TSP to DSP resulting hydroxide generation To overcome free hydroxide generation congruent Phosphate-pH control is adopted

Boiler water treatment Congruent Phosphate-pH control

! Boiler operating >1200 psi ! Chemical used Tri sodium phosphate (TSP) & Di sodium phosphate (DSP) in 60% & 40% ratio ! Use of DSP as pH control agent because it increases phosphate without affecting pH ! pH 8.5 to 9.3 ! Phosphate 2 to 6 ppm ! Sodium/Phosphate ratio 2.6:1

EFFECTIVE BOILER WATER TREATMENT IS A COST SAVER

Boiler water treatment regime

Suggested Phosphate in boiler water at different pressures Pressure (psi) 600 750 900 1000 1500 2000 Phosphate (ppm) 20-25 15-20 10-15 5-10 3-6 1-3

Boiler water Treatment by use of superior grade of tri sodium phosphate Content
! Why boiler water treatment
treatment treatment regime

! Boiler blow down

necessity criteria major problems and solutions

! Best practices in boiler water treatment

sources of ingress of impurities in drum & control saving of energy, water and chemicals

Boiler Blow down

Necessity The first priority for boiler blow down is for Silica control because boiler operating >600 psi pressure silica content in boiler water becomes significant due to silica stats volatilizing making max silica residual mandatory in boiler water
Volatility of silica as a function of pressure when boiler water contains 50 ppm silica

Boiler Blow down

Volatility of silica is proportional to its concentration in the boiler water and operating pressure and inversely proportional to pH of boiler water
Effect of pH on volatility of silica in boiler pressure at 1545 psi

pH 12 11 10 9 8 7

Pressure (psi) 500 1000 1500 2000 2500 3000 3200

Silica (ppm) 0.02 0.06 0.3 1.4 6.0 25.0 50.0

Silica in steam / silica in water (%) 0.55 0.77 1.02 1.25 1.48 1.73

Criteria

Boiler Blow down

Boiler Blow down

Problem in boiler blow down Improper Blow down is a major Cause for Scale Formation and Wasted Energy Scale and sludge can result even when chemicals are applied at the desired treatment levels when there is insufficient blow down In a number of cases, blow down has been treated as an unrelated procedure to the chemical treatment program The general attitude is that blow down will avoid trouble. Hence excessive blow down Excessive blow down leads to wastes energy, water, and chemical

Boiler blow down rate is monitored by phosphate mass balance The Blow down rate or Cycles of Concentration is the number of times the feed water is concentrated and calculated by dividing concentration of solids in boiler water by feed water
Permissible concentration of solids in boiler water

Pressure (psi) 600 750 900 1000 1500 2000

TDS (ppm) 2500 2000 1000 500 150 50

Silica (ppm) 35 30 20 10 3 1

Boiler Blow down

Suggested Actions It is better to control blow down continuously or in small frequent increments rather than infrequent long increments. This avoids wide swings in the silica / TDS and chemical levels in boiler drum water Proper blow down is achieved when adjustments are made to match boiler load changes, while maintaining the specific control ranges for TDS, alkalinity and silica

Boiler water Treatment by use of superior grade of tri sodium phosphate Content
! Why boiler water treatment
treatment treatment regime

! Boiler blow down

necessity criteria major problems and solutions

! Best practices in boiler water treatment

sources of ingress of impurities in drum & control saving of energy, water and chemicals

Best Practices in Boiler water treatment

Best Practices in Boiler water treatment

Sources of silica in the drum Ingress of impurities in the boiler water can be either from make up water or from TSP used for treatment Make up water

The best practices of boiler water treatment is energy savings & reduction in total cost of treatment to achieve this, some important points are: Selection of quality of boiler water treatment chemicals and Boiler blow down Most of the power plant uses TSP & DSP for boiler water treatment, however the quality of the chemicals are ignored. Poor quality of treatment chemicals leads to more blow down

Make up water silica either soluble or in soluble can be minimized on adopting suitable treatment methods Soluble silica can be minimized up to 10 ppb in Demin plant Insoluble silica can be removed by treatment of water with cationic flocculants (Di methyl Di allyl ammonium chloride) during pretreatment process

Best Practices in Boiler water treatment

Sources of silica in the drum Quality of TSP Parameters Purity (%) Tech. Grade 98.0 max LR grade >99 AR grade >99.5

Best Practices in Boiler water treatment

! Insoluble matter and turbidity of 5% solution is of greater importance while purchasing TSP / DSP ! Higher turbidity is due to presence of insoluble matter in the chemicals ! Insoluble matters are colloidal silica which increases the boiler water silica content ! Excess blow down is carried out to control silica in the drum

Free caustic (%) >2.5 Water insoluble Matter (%) >0.5 Turbidity of 5% solution (NTU)

2.5 (max)

2.5 (max)

0.01 (max)

0.001 (max)

37

0.3

Best Practices in Boiler water treatment

HRS G#2 D RUM S ILIC A V A LUE
SILICA (ppm)
2.000 1.500 1.000 0.500 0.000
04 -O 09 ct-O 01 14 ct-O 01 19 ct-O 01 25 ct-O 01 30 ct-O 01 05 ct -N -01 11 ov -N -01 16 ov-N 01 21 ov -N -01 26 ov-N 01 03 ov -D -01 08 ec -D -01 14 ec-D 01 21 ec -D -01 26 ec -D -01 01 ec-J 01 06 an-J 02 11 an-J 02 16 an-J 02 21 an-J 02 27 an-J 02 02 an-F 02 07 eb -F -02 12 eb -F -02 17 eb-F 02 22 eb -F -02 02 eb -M -02 ar -0 2

Best Practices in Boiler water treatment Inference

Impurity either from make up water or from treatment chemicals increase the silica content in the drum water Excess blow down is carried out to maintain the drum water chemistry Excessive blow down leads wastes energy, water and chemical

DA TE HP DRUM IP DRUM LP DRUM

H R S G # 2 D R U M S IL IC A V A L U E
SILICA (ppm)
2 .0 0 0 1 .5 0 0 1 .0 0 0 0 .5 0 0 0 .0 0 0
04 -O 09 ct-0 -O 1 c 14 t-0 -O 1 19 ct-0 -O 1 25 ct-0 -O 1 c 30 t-0 -O 1 05 ct-0 -N 1 o 11 v-0 -N 1 o 16 v-0 -N 1 o 21 v-0 -N 1 ov 26 -N 0 1 o 03 v-0 -D 1 e 08 c-0 -D 1 e 14 c-0 -D 1 e 21 c-0 -D 1 e 26 c-0 -D 1 e 01 c-0 -J 1 a 06 n-0 -J 2 an 11 -0 -J 2 a 16 n-0 -J 2 a 21 n-0 -J 2 a 27 n-0 -J 2 a 02 n-0 -F 2 e 07 b-0 -F 2 e 12 b-0 -F 2 e 17 b-0 -F 2 e 22 b-0 -F 2 e 02 b-0 -M 2 ar -0 2

D A TE HP DRUM IP D R U M LP DRUM

Best Practices in Boiler water treatment

Requirement of energy for generating superheated steam The amount of energy required when one kg of water is heated from 250C at one atom pressure to 3150C at 400 psi Step 1 2 3 4 Temp.(0C) 25 100 100 231 315 Incremental heat (kcal) 75 540 30 56 Enthalpy (kcal) 75 615 645 701 sate L L G G G Press psi 0 0 0 400 400

Best Practices in Boiler water treatment

Computation of cost of energy, water and chemical per Kl of blow down water
The cost of energy, water and chemical per Kl of blow down water Energy Energy DM Water Treatment (Kcal) cost (Rs) (Rs) cast (Rs)

Remarks

Step 1 Temp required to boil Step 2 Additional heat required to vaporize Step 3 Additional heat required to raise pressure & temp (saturation) Step 4 Additional heat required to raise temperature (super heating)

(1) energy required during stem 1&2 considered (2) steam cycle efficiency 33% (3) Heat rate 1900 615000 267 10 0.2 Kcal/kWH (4) per unit cost of electricity Rs. 2.5 (5) Chemical (TSP) cost Rs 40 per kg Total cost per KL of blow down is Rs. 277.2

Best Practices in Boiler water treatment Conclusion

Best Practices in Boiler water treatment

Recommendations

Boiler generating 425 tonnes steam per hour and operated at 1% blow down rate will discharge 102 KL hot chemically treated DM water per day which amounts to be Rs. 28275/On use of superior grade of TSP for boiler water treatment and makeup water with Soluble silica 10 ppb the blow down rate can be brought down to 0.4% leading 41 Kl per day blow down which amounts to be Rs 11365/- per day The net saving Rs. 17000/- per day (about 60%). Annual saving is Rs. 56 lakhs on use of superior grade of TSP for boiler water treatment

! Use LR grade of TSP/DSP for boiler water treatment to avoid less ingress of impurities ! Avoid excess boiler blow down

Thank You