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Email: sandipkale.shrikrishna@wilp.bits-pilani.ac.in
• Bibliography
• Liquids and vapours used to transport and transfer heat require special properties.
• High boiling temperatures and low vapour pressures reduce the possibility of hazards and
limit the capital cost of the plant.
• Fluids should have high specific heat capacity or specific latent heat, a high thermal
conductivity, be non-toxic and, if possible, non-corrosive, commercially available and
economical to use.
• Water treatment is, collectively, the industrial-scale processes that makes water more acceptable for an
end-use, which may be drinking, industry, or medicine.
• Water treatment should remove existing water contaminants or so reduce their concentration that their
water becomes fit for its desired end-use, which may be safely returning used water to the environment.
• Water purification is the removal of contaminants from untreated water to produce drinking water that
is pure enough for the most critical of its intended uses, usually for human consumption.
• Substances that are removed during the process of drinking water treatment include suspended solids,
bacteria, algae, viruses, fungi, minerals such as iron, manganese and sulphur, and other
chemical pollutants such as fertilisers.
• Two of the main processes of industrial water treatment are boiler water treatment and cooling water
treatment.
• A lack of proper water treatment can lead to the reaction of solids and bacteria within pipe work and boiler
housing.
• Steam boilers can suffer from scale or corrosion when left untreated. Scale deposits can lead to weak and
dangerous machinery, while additional fuel is required to heat the same level of water because of the rise in
thermal resistance.
• Poor quality dirty water can become a breeding ground for bacteria such as Legionella causing a risk to
public health.
• The most appropriate boiler feed water treatment system will help the facility avoid
– costly plant downtime,
– expensive maintenance fees, and
– boiler failure as a result of scaling, corrosion, and fouling of the boiler and downstream equipment.
• Treating boiler feed water is essential for both high- and low-pressure boilers. Ensuring the
correct treatment is implemented before problems such as fouling, scaling, and corrosion
occur, will go a long way in avoiding costly replacements/upgrades down the line.
• An efficient and well-designed boiler feed water treatment system should be able to:
– Efficiently treat boiler feed water and remove harmful impurities prior to entering the
boiler.
– Promote internal boiler chemistry control.
– Maximize use of steam condensate
– Control return-line corrosion
– Avoid plant downtime and boiler failure
– Prolong equipment service life
• Depending on the impurities present in your water, any combination of these treatments
might best suit your facility and make up your treatment system, and depending on the needs
of your plant and process, these standard components are usually adequate.
• However, if your plant requires a system that provides a bit more customization, there might
be some features or technologies you will need to add on.
Instructor: Sandip S. Kale PEABZC353 /POWAB ZC333Energy Management 26 Feb 2019 8
What does a boiler feed water treatment system
typically remove?
• A boiler feed water treatment system might be made up of the technologies necessary to
remove problematic dissolved solids, suspended solids, and organic material, including any
number of the following:
– Iron
– Copper
– Silica
– Calcium
– Magnesium
– Hardness
– Dissolved gases
• The following are three reasons for using very pure water in reactor facility systems.
– To minimize radiation levels in a reactor facility. Some of the natural impurities and most of
the corrosion products become highly radioactive after exposure to the neutron flux in the core region. If
not removed, these soluble and insoluble substances may be carried to all parts of the system.
– To minimize fouling of heat transfer surfaces. Corrosion products and other impurities may deposit on core
surfaces and other heat transfer regions, which result in decreased heat transfer capabilities by fouling
surfaces or blockage of critical flow channels.
– Areas of high concentrations of these impurities and corrosion products may also lead to extreme
conditions of the various corrosion processes with resultant failure of components or systems.
• Volatile amines (ex. Octadecylamine) are used in boilers to minimize the effects of acid. In some cases, the
amines form a protective film on the steel surface and, at the same time, act as an anodic inhibitor.
• An inhibitor that acts both in a cathodic and anodic manner is termed a mixed inhibitor.
• Total dissolved solids (TDS) is a measure of the combined content of all inorganic(principally calcium,
magnesium, potassium, sodium, bicarbonates, chlorides, and sulfates) and organic substances
contained in a liquid in molecular, ionized or micro-granular suspended form.
• Generally the operational definition is that the solids must be small enough to survive filtration through a
filter with two-micrometer (nominal size, or smaller) pores. Total dissolved solids are normally discussed
only for freshwater systems, as salinity includes some of the ions constituting the definition of TDS.
• Cooling systems that use a water's cooling capacity a single time are called once-through cooling systems.
• These systems use large volumes of water and typically discharge the once-through water directly to waste.
• Large volumes of water are necessary for even the smallest once-through systems; therefore, a plentiful water
supply at a suitably low temperature is needed.
• Problems encountered in once-through cooling systems can be grouped into three general categories:
– Corrosion
– Scale or other deposition
– Biological fouling
• Cooling towers, spray ponds, and evaporative condensers are used for this purpose.
• Open recirculating cooling systems save a tremendous amount of fresh water compared to the alternative
method, once-through cooling.
• The closed recirculating cooling water system evolved from methods used for the cooling of early
engine designs.
• In a closed system, water circulates in a closed cycle and is subjected to alternate cooling and heating
without air contact.
• Heat, absorbed by the water in the closed system, is normally transferred by a water-to-water
exchanger to the recirculating water of an open recirculating system, from which the heat is lost to
atmosphere.
• Makeup water is needed only when leakage has occurred at pump packings or when water has been
drained to allow system repair.
• Little, if any, evaporation occurs. Therefore, high-quality water can usually be used for makeup, and
as a result, scale deposits are not a problem.
• Closed systems also reduce corrosion problems drastically, because the recirculating water is not
continuously saturated with oxygen, as in an open system.
Steam can be
Wet,
Dry or
Superheated
Wet Steam: When steam contains water in the form of fine
particles known as wet steam.
Wet steam is two phase mixture.
It consist liquid & vapour phases.
Instructor: Sandip S. Kale PEABZC353 /POWAB ZC333Energy Management 26 Feb 2019 25
Q ua lit y o f S te am
• It means that the evaporation of water is not complete, and the whole of the latent
heat has not been absorbed.
• Dry saturated steam: when the wet steam is further heated , and it does not contain
any suspended particles of water, it is known as dry saturated steam.
• The dry saturated steam has absorbed its full latent heat and behaves practically, in
the same way as a perfect gas
• Since the pressure is constant, therefore the volume of superheated steam increases.
• The steam dryness fraction is used to quantify the amount of water within steam.
• If steam contains 10% water by mass, it's said to be 90% dry, or have a dryness fraction of 0.9.
• Steam dryness is important because it has a direct effect on the total amount of transferable energy contained
within the steam (usually just latent heat), which affects heating efficiency and quality.
• For example, saturated steam (100% dry) contains 100% of the latent heat available at that pressure.
• Saturated water, which has no latent heat and therefore 0% dryness, will only contain sensible heat.
• Wet Steam:
• Dry Steam:
• Enthalpy : hdry= hf + hfg =hg ----KJ/kg
• Steam for power generation is typically in a superheated condition, whereas steam used in process
applications is typically saturated steam.
• In the case where the steam is being used for both applications, power is likely to win out and hence the
steam is more likely to be created in a superheated condition, and then desuperheated to its saturated
condition for use as process steam.
• Desuperheating steam is the resultant of water coming into contact with steam in a controlled manner,
causing the water to evaporate.
• In essence to reduce the temperature of the steam to a desired set-point as quickly as possible while avoiding
damage to process equipment and piping in an efficient manner to minimise use of process water.
• The term consists of two words: "thermal", meaning heat, and "fluids", which refers
to liquids, gases and vapours.
• Thermal fluids can operate at temperatures in the range -30 to 650 ⁰C.
• In relatively simple plant and at moderate pressures compared with those of water at similar temperatures.
• The selection of thermal fluid for a specific application depends on the process requirements and the
environment in which the fluid will operate. The factors that may need to be considered include:
– Operating temperatures range and corresponding vapour pressure range.
– Latent heat of vaporisation at the operating pressure
– Magnitude of film and overall heat transfer coefficients
– Pumpability over temperature range
– Coefficient of thermal expansion
– Potential corrosiveness
– Thermal stability, life under operating conditions, possibility of regeneration and problems of eventual
disposal.
– Toxicity of the liquid and vapour phases
– Limits of explosive mixtures with the air.
– Degree of fire resistance necessary in operating environment.
– Price
• Synthetic heat transfer fluids generally are more expensive than mineral oils and in some case have
shorter life when used at the upper limit of their operating temperature range.
• In properly designed systems, these heat transfer fluids will perform within their respective temperature
ranges for extended periods without breakdown or thermal degradation.
• DOWTHERM : A heat transfer fluid is a eutectic mixture of two very stable compounds, biphenyl
(C12H10) and diphenyl oxide (C12H10O). The fluid is dyed clear to light yellow to aid in leak detection.
– Freeze point - 12⁰C
– Boiling point (atmospheric) - 257 ⁰C
– Flash point (SETA) - 113 ⁰C
– Fire point (C.O.C) - 118 ⁰C
– Auto-ignition temperature - 599 ⁰C
– Density (25 ⁰C, 75 ⁰F) - 1056 kg/m3
• Molten salts and liquid metals can be used up to temperatures of about 600 ⁰C. But their use involves
problems in design, handling, safety and expense.
• A commonly used molten salt is eutectic mixture of sodium nitrite (40% w/w), sodium nitrate (7%
w/w) and potassium nitrate (53% w/w).
• It is non-toxic and chemically stable upto 450 ⁰C and its maximum operating temperature of 600 ⁰C the
sodium nitrite undergoes a slow thermal breakdown.
• Mercury is suitable for use at temperatures in the range 300-540 ⁰C. Its freezing point is -39 ⁰C and its
boiling point is 357 ⁰C at atmospheric pressure.
• The properties and quantities of air-water mixtures pertinent to their use as a heat transfer
media are important to understand and these properties are given in the form of
psychrometric chart.
• Absolute Humidity: Represents amount of water vapor actually present in the air (Gram per
cubic meter of air ).
• The above relation shows that if the total pressure remains constant specific humidity is a
function of partial pressure of water vapor only.
• The Humid heat is the constant-pressure specific heat of moist air, per unit mass of the dry air.
• It is the heat required to raise temperature of 1kg of bone dry air plus its associated water vapor by one
degree C.
• Total Heat: The total heat or total specific enthalpy, h, is the sum of the enthalpies of the bone dry air and
its associated water vapour, both being relative to a reference temperature of 0 ⁰C.
hA = CpA t (J/Kg)
• If the water vapour is superheated then specific enthalpy is given as:
• The Humid volume or specific humid volume is the volume of 1 Kg of bone dry air plus its
associated water vapour
vG = vA + w. vWV
where, vA and vWV are specific volumes of bone dry air and water at N.T.P., (cu.meter/Kg).
• Dew point temperature: From the state point follow the horizontal line of constant humidity ratio to the
intercept of 100% RH, also known as the saturation curve. The dew point temperature is equal to the fully
saturated dry bulb or wet bulb temperatures.
• Wet bulb temperature: These lines are oblique lines that differ slightly from the enthalpy lines. They are
identically straight but are not exactly parallel to each other. These intersect the saturation curve at DBT
point.
• Humidity ratio: These are the horizontal lines on the chart. Humidity ratio is usually expressed as mass of
moisture per mass of dry air (kilograms of moisture per kilogram of dry air). The range is from 0 for dry air
up to 0.03 on the right hand ω-axis, the ordinate or vertical axis of the chart.
• Specific enthalpy: These are oblique lines drawn diagonally downward from left to right across the chart
that are parallel to each other. These are not parallel to wet bulb temperature lines.
• Specific volume: These are a family of equally spaced straight lines that are nearly parallel.
• Yunus A. Cengel, “Heat Transfer – A Practical Approach”, Mcgraw-Hill (Tx); 2nd edition
(November 1, 2002).
• Dr. D.S. Kumar, “ Referigeration and Air Conditioning ”, Kaston Publication, First Edition, Jan
2107.
• https://en.wikipedia.org/