Deaerator

A deaerator is a device that removes oxygen and other dissolved gases from liquids and
pumpable compounds.

History

Before 1881, feed water heaters were used for marine applications. [1] Two sister ships
Olympic and Titanic (1912) had contact feed heaters on board. [2] In 1934 the US Navy
purchased an atomizing deaerator. [3]

Before 1867, deaerators were used as part of the ice manufacturing purification process. [4]
In 1899, George M Kleucker received a patent for an improved method of deaerating water. [5]
During the 1920 the feedwater headers and deaerators designs improved. [6] [7] Stickle,[8]
Cochrane, and Permutit are three of the oldest Deaerator manufacturers in the USA.[9][10][11] In
1929, a court case between Elliott Company (no longer in business) and H.S.B.W. Cochrane
Corporation allowed both business to continue manufacturing deaerators.[12]

Deaerators continue to be used today for many applications.

Types

The thermal deaerators [13][14][15]

The spray & tray-type (also called the cascade-type) includes a vertical or horizontal
domed deaeration section mounted on top of a horizontal cylindrical vessel which
serves as the deaerated boiler feedwater storage tank.
 The spray-type consists only of a horizontal (or vertical) cylindrical vessel which serves
as both the deaeration section, and a storage tank for boiler feedwater.

The vacuum deaerators

Dynamic deaerator for medium to high viscous products

Static deaerator for low viscous products

The ultrasound deaerator for very viscous products

Thermal deaerators

Deaerator plant

Thermal deaerators are commonly used to remove dissolved gases in feedwater for steam-
generating boilers. Dissolved oxygen in feedwater will cause serious corrosion damage in a
boiler by attaching to the walls of metal piping and other equipment and forming oxides (like
rust). Dissolved carbon dioxide combines with water to form carbonic acid that may cause
further corrosion. Most deaerators are designed to remove oxygen down to levels of 7 ppb by
weight or less, as well as essentially eliminating carbon dioxide.[16][17] The deaerators in the
steam generating systems of most thermal power plants use low pressure steam obtained
from an extraction point in their steam turbine system. However, the steam generators in
many large industrial facilities such as petroleum refineries may use whatever low-pressure
steam is available.

There are many different deaerators available from a number of manufacturers, and the
actual construction details will vary from one manufacturer to another.

Figures 1 and 2 are representative schematic diagrams that depict each of the two major
types of deaerators.
Spray and tray-type deaerator

Figure 1: A schematic diagram of a typical tray-type deaerator.

The typical spray & tray-type deaerator in Figure 1 has a vertical domed deaeration section
mounted above a horizontal boiler feedwater storage vessel. Boiler feedwater enters the
vertical deaeration section through spray valves above the perforated trays and then flows
downward through the perforations. Low-pressure deaeration steam enters below the
perforated trays and flows upward through the perforations. Combined action of spray valves
& trays guarantees very high performance because of longer contact time between steam
and water.[18] Some designs use various types of packed beds, rather than perforated trays,
to provide good contact and mixing between the steam and the boiler feed water.

The steam strips the dissolved gas from the boiler feedwater and exits via the vent valve at
the top of the domed section. This vent valve should not be opened sufficiently the deaerator
will not work properly, causing high oxygen content in the feed water going to the boilers.
Should the boiler not have an oxygen-content analyser, a high level in the boiler chlorides may
indicate the vent valve not being far enough open. Some designs may include a vent
condenser to trap and recover any water entrained in the vented gas. The vent line usually
includes a valve and just enough steam is allowed to escape with the vented gases to provide
a small visible telltale plume of steam.
The deaerated water flows down into the horizontal storage vessel from where it is pumped
to the steam generating boiler system. Low-pressure heating steam, which enters the
horizontal vessel through a Sparge Pipe in the bottom of the vessel, is provided to keep the
stored boiler feedwater warm. Stainless steel material is recommended for the sparger
pipe.[19] External insulation of the vessel is typically provided to minimize heat loss.

Spray-type deaerator

Figure 2: A schematic diagram of a typical spray-type deaerator.

As shown in Figure 2, the typical spray-type deaerator is a horizontal vessel which has a
preheating section (E) and a deaeration section (F). The two sections are separated by a
baffle (C). Low-pressure steam enters the vessel through a sparger in the bottom of the
vessel.

The boiler feedwater is sprayed into section (E) where it is preheated by the rising steam
from the sparger. The purpose of the feedwater spray nozzle (A) and the preheat section is to
heat the boiler feedwater to its saturation temperature to facilitate stripping out the dissolved
gases in the following deaeration section.

The preheated feedwater then flows into the deaeration section (F), where it is deaerated by
the steam rising from the sparger system. The gases stripped out of the water exit via the
vent at the top of the vessel. Again, some designs may include a vent condenser to trap and
recover any water entrained in the vented gas. Also again, the vent line usually includes a
valve and just enough steam is allowed to escape with the vented gases to provide a small
and visible telltale plume of steam.
The deaerated boiler feedwater is pumped from the bottom of the vessel to the steam
generating boiler system.

Silencers (optional) have been used for reducing venting noise levels in the Deaerator
equipment industry.

Vacuum deaerator

Deaerators are also used to remove dissolved gases from products such as food, personal
care products, cosmetic products, chemicals, and pharmaceuticals to increase the dosing
accuracy in the filling process, to increase product shelf stability, to prevent oxidative effects
(e.g. discolouration, changes of smell or taste, rancidity), to alter pH, and to reduce packaging
volume. Vacuum deaerators are also used in the petrochemical field. [20]

In 1921 a tank with vacuum pump for removing gases was used in Pittsburgh.[21] In 1934 and
1940 a tank with vacuum pump for removing gases were used in Indiana.[22] [23]

Dynamic deaerator

As shown in Figure 3, the product is distributed as a thin layer on a high speed spinning disc
[3] via special feed system [1]. The centrifugal force slings it through a perforated screen
onto the inner wall of the vessel, which is under vacuum . Air (gas) pockets are released in
the process and are drawn off by the vacuum [4]. A discharge pump [2] carries the deaerated
product to the next process in the production line. For high viscous products the rotating disc
is replaced with static one.
Figure 3: A schematic diagram of rotating disc deaerator

Principles of operation

Thermal deaeration relies on the principle that the solubility of a gas in water decreases as
the water temperature increases and approaches its boiling point. In the deaerator, water is
heated up to close to its boiling point with a minimum pressure drop and minimum vent.
Deaeration is done by spraying feedwater into a chamber to increase its surface area, and
may involve flow over multiple layers of trays. This scrubbing (or stripping) steam is fed to
the bottom of the deaeration section of the deaerator. When steam contacts the feedwater, it
heats it up to its boiling point and dissolved gases are released from the feedwater and
vented from the deaerator through the vent. The treated water falls into a storage tank below
the deaerator.[24][16]

Oxygen scavenging

Oxygen scavenging chemicals are very often added to the deaerated boiler feedwater to
remove any last traces of oxygen that were not removed by the deaerator. The type of
chemical added depends on whether the location uses a volatile or non-volatile water
treatment program.

Most lower pressure systems (lower than 650 psi (4,500 kPa)) use non-volatile treatment
programs. The most commonly used oxygen scavenger for lower pressure systems is
sodium sulfite (Na2SO3). It is very effective and rapidly reacts with traces of oxygen to form
sodium sulfate (Na2SO4) which is non-scaling.

Most higher pressure systems (higher than 650 psi (4,500 kPa)) and all systems where
certain highly alloyed materials are present are now using volatile programs, as many
phosphate-based treatment programs are being phased out. Volatile programs are further
broken down into oxidizing or reducing programs [(AVT(O) or AVT(R)] depending whether the
environment requires an oxidizing or reducing environment to reduce the incidence of flow-
accelerated corrosion. Flow-accelerated corrosion related failures have caused numerous
accidents in which significant loss of property and life has occurred. Hydrazine (N2H4) is an
oxygen scavenger commonly used in volatile treatment programs.

Other scavengers include carbohydrazide, diethylhydroxylamine, nitrilotriacetic acid,

ethylenediaminetetraacetic acid, and hydroquinone.

Inspection and maintenance

NACE International (now known as Association for Materials Protection and Performance
(AMPP)) and CIBO (Council of Industrial Boiler Owners) have several recommendations to
increase the life of the deaerator unit. First, regular inspections (and testing) of the pressure
vessel for cracking of welds, and repairing of any weld defects. Second, maintaining a proper
water chemistry to reduce deaerator deterioration. Third, minimize temperature and pressure
fluctuation. Fourth, internals and accessories should be inspected for proper operation. [25]
[26][27] NACE had created a Corrosion Task Group in 1984 that studied causes of corrosion
and provided recommendations;[28] NACE still provides recommendations to improve
operations of the equipment.

Fabrication of deaerator

Welding of the steel pressure vessels during the manufacturing process sometimes require
Post weld heat treatment, XRAY, Dye Penetration, Ultrasonic, and other type non-destructive
testing. ASME Boiler and Pressure Vessel Code, NACE International, and HEI (Heat Exchange
Institute) have recommendations on the type of testing required. [29]

Thermal insulation is sometimes required after fabrication or after installation at the project
site.

See also
References

Additional reading

External links

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