Condensate and Feedwater Treatment.

The 3 Main elements associated with Feedwater treatment are components of Water
H2O O2 H+ OHGood Bad Bad Good (Most of the time)

Types of Corrosion
General Corrosion - Hematite
Localised Corrosion

General Corrosion
Hematite Layer

Localised Corrosion
Pitting O2 plus Cl Often associated with scale deposit Crevice Corrosion starts in pre-existing crack or crevice, flanges with porous gaskets Selective Leaching one element of a multielement metal Galvanic Corrosion different metal, different zones Stress Corrosion/Stress Cracking

The principal Contributors to corrosion in boiler condensate and feedwater systems are:

Oxygen Carbon Dioxide Low pH Deposits

Oxygen Corrosion
Oxygen, dissolved in boiler water having traces of chlorides or solids can cause pitting corrosion of metal surfaces.
The resulting condition may be severe, even at low pressure.

Oxygen and other gases must be removed from the feedwater before they can enter the boiler

Oxygen Removal
can be accomplished both mechanically and chemically

A Mechanical means of removing oxygen is called a deaerator.

Deaeration can be either vacuum or pressure enhanced.

The Turbine Condenser

Deaerating Feedwater Heater

Boiler Steam/Water Drum has a role in the deaeration of the feedwater at startup.

Chemical Deaeration is carried out by the addition of an

oxygen scavenger

Hydrazine, Carbohydrazide
Theoretical 1mole of Hydrazine will scavenge 1 mole of Oxygen Usually injected at 3:1 ratio to maintain a residual at entry to the boiler Hydrazine promotes the formation of a magnetite layer Decomposes to form ammonia Combines with condensate in the condenser to form NaoH Assists in pH control. Ammonia is highly corrosive to copper

CO 2

Corrosion in steam and condensate return lines may be caused by a low pH induced by carbonic acid resulting from the association of CO 2 with water.

A buildup of acid reduces condensate pH leading to loss of metal and grooving of the condensate piping. ( General Corrosion)

The affect is accelerated in the presence of O2

Volatile, alkaline, neutralising chemicals are traditionally used to control low pH.

Chemicals used to control pH in the condensate system include:

ammonia morphaline

They function only to neutralise

are effective only against corrosion initiated by a low pH

Neutralising Amines.

 High CO2 levels will demand a greater quantity of Neutralising Amines Neutralising Amines are ineffective against O2 The use of a film forming Amine can be more effective.

Filming Amine

A long Chain Molecule having both a hydrophilic and a hydrophobic end.

 The hydrophilic end bonds to the metal forming an adherent, nonwettable, monomolecular layer ( film on the metal surface. Prevents contact between the low pH condensate and the metal beneath as well as inhibiting O2 attack. Not really effective where pitting has occurred can undercut iron oxide deposits causing rapid removal and possible problem associated with steam trap blockage etc.

Combined use of the two amines provides a more effective corrosion control

By the addition of an oxygen scavenger the regime is further enhanced.

Condensate and Feedwater Polishers

Resin must be suitable for Higher water temperatures Pick up metals scale crude etc. Can be detrimental if they are allowed to exhaust. NA and Cl slip.

Low pH in Local Areas is the second most common cause of corrosion

Magnetite
Above 200 Deg C mild steel corrosion results in the formation of magnetite forms a strongly adherent barrier between the boiler water and the metal. Corrosion stops when a uniform layer is formed. If the layer is disrupted rapid general corrosion can occur. Water chemistry must be controlled to maintain this layer. pH is maintained > 9.0 , =< 10.5

Phosphate Control

Na Hydroxide and Tri Na Phosphate are common chemicals used to control pH. To prevent caustic attack such as Caustic Gouging the amount of Na has to be carefully monitored

Caustic Gouging
Scale is formed by deposit of solid material from boiler water This scale is porous Boiler Water enters the scale and forms a cavity between the scale and the metal (Wick Boiling) continuous operation concentrates the corrosion product 100ppm TDS - 220,000 ppm Caustic Corrosion accelerated locally

Phosphate dosing using either a coordinated or congruent method is used to control free Hydrate alkalinity (Caustic)

Coordinated Method
Boiler Water pH is monitored and kept below a value responding to a curve relating the pH and Tri Na Phosphate ( Na3Po4 ) Na and PO4 maintained in a ratio of <3:1.

Congruent method
Used more commonly in higher pressure boilers
Dosing maintains pH and a ratio of Na : PO4 of 2.6 to 2.8

Silica

Silica
High levels of silica form an adherent scale Above 4Mpa silica begins to volatilise and is carried over to the after boiler and turbine sections of the plant Silica can hideout in a boiler at high pressure not showing up in boiler water analysis and then redissolving into the boiler water at lower pressures.

Maximum silica recommended

2 Mpa 4Mpa 8Mpa 150ppb 40 2

Hydrogen Embrittlement

Hydrogen can evolve in a low pH environment

If damage to the magnetite layer occurs, It can diffuse into the boiler metal React with ferrous carbide in the metal Produce methane Gas pressure at grain barriers can cause separation Lowers the carbon content and strength of the metal

Stress Cracking
can occur in areas of high tensile stress in the presence of an excess of free alkalinity ( NaOH ) Crack may initiate at an existing flaw or high stress point and then begin to propagate as a very fine segregation line between grain boundaries Not uncommon above 4Mpa

Build up of Deposits.
Failure of Heating surfaces. Deposit Control through Blowdown.

Equipment Associated with Condensate and Feedwater water Quality Control.

Continuous and Intermittent Blowdown Hydrazine Dosing System Amine Dosing System Phosphate Dosing System Sampling and Analysis Equipment