Basic Deaerator Science Revealed

Presented by Steve Connor

January, 2015
 What We Are Covering Today

Hydrological
Benefits
Cycle

Basic
Component Deaerator What is
Selection &
Sizing Science Deaeration?

Revealed

Types &
Operation When to Apply

2
 The Hydrologic Cycle

3
 Water the Universal Solvent
Dissolved Dissolved Suspended
Solids Gasses Solids

4
 CO2
O2
O2
O2
O2 CO2

CO2 Iron
Carbonates
Sulphates
Calcium
Magnesium Silica
Sodium
Aluminum Chlorides
Manganese

Mg(HCO3)2 MgSOFluorides
4
CaSO MgCl2
Na2SO4 4

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 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.

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 Most Economical Long-Term Approach

Mechanical Chemical

7
 Water Quality: Dissolved Gases

Today we’re concentrating on…

2 2

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 Water Quality: Dissolved Gases

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

Fe + 2H2O = Fe(OH)2 + 2H +
Iron + Water = Ferrous Hydroxide + Hydrogen

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 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 = Ferric Hydroxide (RUST)

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 Corroded Boiler Tubes

Firetube Watertube

Holes

Blisters

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 Water Quality: Dissolved Gases

2 times more 50 F
corrosive at 86 F
122oF than at 122 F

86oF

Courtesy:http://www.engineeringtoolbox.com/oxygen-steel-pipe-...
 Water Quality: Dissolved Gases

Carbon Dioxide – Friend or Foe?

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 Water Quality: Dissolved Gases

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

CO2 + H2O = H2CO3

Combines with Water to Create Carbonic Acid

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 Water Quality: Dissolved Gases

CO2 gas combines with condensate

forming carbonic acid; corroding pipes
and heat transfer units.

Carbonic Acid attack

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 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.

CO2 O2
Dissolved
Oxygen is
10 times
more
corrosive
than CO2

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 OK….what do we do?

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 Water Quality: Dissolved Gasses

Solution to Manage These Gasses

2 CO2

Raise the Temperature!

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 Water Quality: Dissolved Gases
Free Gases Are Insoluble At Saturation Temperature

10
Oxygen Content, ppm

2
0
30 50 70 90 110 130 150 170 190 210
Temperature,
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Degree F.
 Water Quality: Dissolved Gases

Manage pH @ approx. 11

CO2

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Reducing Surface Tension

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 Mechanical Removal

Deaeration Removes
• Oxygen
• Free Carbon Dioxide

Heat Agitate Liberate

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 DA Methods: Operation

• 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 & Holding Hot Condensate

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 Saturated Steam Table

Pressure
5 10 80 100
(psig)
Saturation
227.3 239.5 323.9 337.9
Temp
Volume
20.3 16.46 4.66 3.89
(ft3/lb)
Sensible
Heat (btu/lb) 195.5 207.9 294.4 308.9

Latent Heat
960.5 952.5 891.9 880.7
(btu/lb)
Total Heat
1156 1160.4 1186.3 1189.4
(btu/lb)

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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 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

All Condensate
Dumped!
X
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 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

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 Types of Deaerators
Spray Type
7,000 – 280,000 pph
Spray cone

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 Types of Deaerators
Spray Head Design

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 Types of Deaerators
Packed Column Type
1,500 – 135,000 pph

Deaerating Column

Storage Tank

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 Packed Column DA

O2 & CO2 Vent Makeup Water In

Spray & Vent Condensing

Section
Deaerating Column
Corrosion Proof Rings
Steam In

Storage Tank

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 Types of Deaerators
Tray Type
30,000 – 1,200,000 PPH

1,000,000 PPH 40,000 PPH

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 Tray DA
Makeup/Condensate In
Steam
Inlet
Vent Condenser

Spray Valve
Assembly

Trays

Deaerated Water
Downcomer
High Temp. Returns

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 Advantages & Disadvantages

Type Advantages Disadvantages

Spray • Head room • Mechanical
• Weight components
• Price • Critical
• Capacity adjustments to
steam nozzle
• Limited HP returns
Column • DA consistency • Head room
• Reliable • Weight
• HP returns • Limited capacity
• Price
Tray • DA consistency • Head room
• Reliable • Weight
• HP returns • Price
• Highest capacity

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 Saturated Steam Table

Pressure
(psig)
5 10 80 100
Saturation
227.3 239.5 323.9 337.9
Temp
Volume
20.3 16.46 4.66 3.89
(ft3/lb)
Sensible
Heat (btu/lb)
195.5 207.9 294.4 308.9
Latent Heat
960.5 952.5 891.9 880.7
(btu/lb)
Total Heat
1156 1160.4 1186.3 1189.4
(btu/lb)

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 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

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DA Component Selection & Sizing

Spray Type

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 Spray Cone & Tank Assembly

Formulas:
• 200 HP X 34.5 = 6900#/HR
• 6900/8.3 = 831 Gallons/HR
• Tank storage: 10 minutes = 150 Gal.

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 Vent
Makeup Valve
• Mechanical
H.P. Return • Pneumatic
• Electronic
Steam

Exhaust Or
Flash Steam
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 Overflow Example: (50# - 5# - 7#) = 6.1 X 12 = 73.2 GPM

Boiler Feed Drainer SQ Root

Water Pump
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 Vent

H.P. Return
PRV
Steam

Exhaust Or
Flash Steam
Cold Make-Up
Water

Make-Up Valve

Check Valve L.P. Condensate

Selection Sequence:
1. Maximum pumping rate of DA
To 2. Estimate Average mix temperature of FW
3. Determine amount of steam to heat FW to saturation
Boiler Overflow 4. Determine PRV size based on boiler operating

Boiler Feed Drainer pressure

Water Pump
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 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

Flexible Coupled Close 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

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 NPSHR 3' Centrifugal
4' Pump Curve
5'
500 6'
10” Dia. 7'
8'

400
9” Dia.
Head in Feet

300 8” Dia.
280
7”Dia.
200
180 6” Dia.

5” Dia.
100

20 40 60 80 100 120 140 160

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Capacity in GPM
 NPSHR 3' Centrifugal
4' Pump Curve
5'
500 6'
10” Dia. 7'
8'

400
9” Dia.
Head in Feet

300 8” Dia.

7”Dia.
200 X X
6” Dia.

5” Dia.
100

20 40 60 80 100 120 140 160

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Capacity in GPM
 Stand

Height depends on NPSHR for Pumps versus NPSHA

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 Safety Valve(s)

Sizing considerations:
1. Normally set at DA design pressure
2. Must handle full output from PRV @ boiler’s safety valve setting

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 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

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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