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

Water Quality: Dissolved Gases

Oxygen Corrosion
Iron begins to dissolve when in contact with water.

Fe + 2H2O = Fe(OH)2 +
Iron +

Water

+
2H

= Ferrous Hydroxide + Hydrogen

Water Quality: Dissolved Gases

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

Water Quality: Dissolved Gases

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-...

Water Quality: Dissolved Gases

Carbon Dioxide Friend or Foe?

13

Water Quality: Dissolved Gases

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

Water Quality: Dissolved Gases

CO2 gas combines with condensate

forming carbonic acid; corroding pipes
and heat transfer units.

Carbonic Acid attack

15

Water Quality: Dissolved Gases

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

Water Quality: Dissolved Gases

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.

Water Quality: Dissolved Gases

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

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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
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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!
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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
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