internal boiler water treatment (product & chemistry)

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INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

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INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY). Boiler Water Treatment. Untuk mencegah: Kerak/deposit Korosi Carry over Agar: Menjamin kontinutas tersedianya steam untuk operasi pabrik-meminimalkan downtime Safety Memproteksi biaya capital. Boiler. Pre-Treatment. Process. - PowerPoint PPT Presentation

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Page 1: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

INTERNAL BOILER WATER TREATMENT (PRODUCT &

CHEMISTRY)

INTERNAL BOILER WATER TREATMENT (PRODUCT &

CHEMISTRY)

Page 2: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Boiler Water TreatmentBoiler Water Treatment

Untuk mencegah:– Kerak/deposit– Korosi– Carry over

Agar:• Menjamin kontinutas tersedianya steam

untuk operasi pabrik-meminimalkan downtime

• Safety • Memproteksi biaya capital

Page 3: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

CondensateReceiver

Blowdown flash tank

Process

Process

Process

Flash tank

Low pressure steam

Pre-TreatmentBoiler

Page 4: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Kerak/DepositKerak/Deposit

Page 5: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Mekanisasi Pembentukan KerakMekanisasi Pembentukan Kerak

Presiptitasi dari hardness yang tidak larut/ insoluble

Ca(HCO3 )2 + Panas ---> CaCO3 + H2O + CO2

Mg+2 + OH- ---> MgOH+

H2SiO3 ---> H+ + HSiO3-

MgOH+ + HSiO3- ---> MgSiO3 + H2O

Melebihi batas kejenuhan/kelarutan melalui evaporasi mengakibatkan terjadinya kristalisasi; contoh: CaSO4, SiO2

Page 6: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Boiler DepositBoiler DepositName FormulaAcmite Na2OFe2O34SiO2

Analcite Na2OAl2O34SiO22H2OAnhydrite CaSO4

Aragonite CaCO3 (gamma form)Basic magnesium phosphate Mg3(PO4)2Mg(OH)2

Brucite Mg(OH)2

Calcium hydroxide Ca(OH)2

Calcite CaCO3 (beta form)Copper CuCuprite Cu2OFerrous oxide FeOGoetnite Fe2O3 H2O (alpha form)Gypsum CaSO42 H2OHematite Fe2O3

Hydroxyapatite Ca10(PO4)6(OH)2

Magnetite Fe3O4

Serpentine (magnesium silicate) 3MgOSiO22 H2OSodium ferrous phosphate NaFePO4

Tenorite CuOThenardite Na2SO4

Xonotlite 5 CaO5 SiO2 H2O

Page 7: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

SilicaSilica

Membentuk deposit pada boiler/waterside

Terbentuk sebagai magnesium silicate atau silicic acid

Selective silica carryover

Tidak dapat dikontrol secara mekanikal dengan steam separator

Page 8: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Selective Silica CarryoverSelective Silica Carryover

• Silica terlarut pada steam

• Dikontrol dengan pembatasan kandungan silica pada air boiler

• Dikontrol dengan pembatasan tekanan operasi boiler

• Dikontrol dengan mempertahankan kontrol pH yang tinggi

Page 9: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Bentuk Kerak Besi/Iron Bentuk Kerak Besi/Iron

Kerak besi biasanya ditemukan dalam boiler sebagai salah satu atau lebih bentuk berikut:

Bentuk kompleks dengan calcium

Bentuk kompleks dengan phosphate

Hematite Fe2O3

Magnetite Fe3O4

Page 10: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Efek Kerak Pada Heat TransferEfek Kerak Pada Heat Transfer

Page 11: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Efek Kerak pada Temperatur PipaEfek Kerak pada Temperatur Pipa

Page 12: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Contoh Efek Kerak

Contoh Efek Kerak

Page 13: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Problem KerakProblem Kerak

Boiler tube failure

Disebabkan karena pengurangan heat transfer dan tube overheating

Under-deposit corrosion

Disebabkan karena konsentrasi tinggi dari bahan bersifat korosif concentration of corrosive agents (dapat berupa NaOH)

Page 14: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Apa yang dapat dilakukan untuk mencegah kerak/deposit

Apa yang dapat dilakukan untuk mencegah kerak/deposit

• Kontrol secara ketat terhadap kualitas air umpan (sesuai dengan batas kontrol)

• Mengaplikasikan internal treatment

• Kontrol secara ketat terhadap kualitas air umpan (sesuai dengan batas kontrol)

• Mengaplikasikan internal treatment

Page 15: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Internal Treatment OptionsInternal Treatment Options

• Presipitasi kontaminan• Pelarutan (solubilize) kontaminan • Pendispersian (disperse) kontaminan

Page 16: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program Internal Treatment Secara Umum/Konvensional

Program Internal Treatment Secara Umum/Konvensional

• Coagulation programs• Organic sludge conditioners• Phosphate residual programs• Phosphate-Polymer Programs• Chelates & Chelate / Polymer programs• All-Polymer program

Page 17: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Historical Overview of Nalco’s Internal Treatment ProgramsHistorical Overview of Nalco’s Internal Treatment Programs

• Soda ash, Sodium Aluminate, and Phosphates

• Chelation• Synthetic organic polymers• Transport-Plus

Page 18: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

ONDEO Nalco’s Internal Treatment Programs

ONDEO Nalco’s Internal Treatment Programs

• Phosphate Residual Programs• Phosphate Polymer Program• All Polymer (Transport-Plus) Programs• Supplemental Programs (dispersants

and antifoam)

Page 19: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program Pengendapan/KoagulasiProgram Pengendapan/Koagulasi

Page 20: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Perlakuan secara Koagulasi (Coagulation Treatments)Perlakuan secara Koagulasi (Coagulation Treatments)

• Calcium hardness dipresipitasikan sebagai Calcium Carbonate.

• Magnesium hardness dipresipitasikan sebagai Magnesium Hidroksida atau Magnesium Silicate

Page 21: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Aplikasi Program Koagulasi:Aplikasi Program Koagulasi:

Program Koagulasi dapat diaplikasikan bila;

Tekanan operasi boiler < 350 psig

Hardness feedwater/air umpan > 60 ppm

Alkalinity air boiler < 500 ppm

Page 22: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program KoagulasiProgram Koagulasi Kebaikan: Dapat diaplikasikan untuk air umpan

dengan kandungan hardness yang tinggi.

Kekurangan: Cycle operasi boiler rendah

TDS air boiler tinggi

Jumlah blowdown banyak – pembuangan panas (wastes heat)

Pembentukan kerak

Page 23: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program Phosphate Program Phosphate

• Calcium dipresitasikan sebagai calcium phosphate

• Magnesium dipresitasikan sebagai magnesium hydrosida

Page 24: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Phosphate TechnologyPhosphate Technology

Ortho phosphates Mono-, di-, tri- sodium phosphates

Poly Phosphates Sodium hexa meta phosphate

Sodium hepta meta phosphate

Sodium tripoly phosphate

Tetra sodium pyro-phosphate

Page 25: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Phosphate TechnologyPhosphate Technology

Titik Injeksi

Ortho phosphate

Diinjeksikan lansung ke drum boiler

Poly phosphate

Diinjeksikan ke line air umpan

Page 26: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Phosphate TechnologyPhosphate Technology

Kelebihan Mudah dimonitor dan dikontrol

Tidak memerlukan air umpan dengan kemurnian tinggi

Dapat diaplikasikan pada boiler tekanan tinggi

Dikenal luas

Memiliki perizinan FDA dan USDA

Fluktuasi hardness air umpan dapat ditangani

Residual PO4 tidak bersifat korosif

PO4 residual yang tinggi - buffer untuk ekskursi

Biaya relatif murah

Page 27: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Phosphate TechnologyPhosphate Technology

Kekurangan

Menghasilkan presipitasi/endapan pada sistem

Kelebihan alkalinity dapat menyebabkan korosi

Memerlukan lebih banyak blowdown

Jika demikian, lebih banyak panas hilang dan lebih

banyak pemakaian bahan kimia

Kemungkinan dapat menyebabkan terjadi kerak

Umumnya diaplikasikan bersama sludge dispersant

Page 28: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Phosphate TechnologyPhosphate Technology

Detailed Chemistry

(poly) Na5P3O10 + 4NaOH -> 3Na3PO4 + 2H2O

(ortho) Na2HPO4 + NaOH -> Na3PO4 + H2O

3CaCO3 + 2Na3PO4 -> Ca3(PO4)2 + 3Na2CO3

3CaSO4 + 2Na3PO4 -> Ca3(PO4)2 +3Na2SO4

Mg(HCO3)2 + 4NaOH -> Mg(OH)2 + 2Na2CO3 + 2H2O

MgCl2 + 2NaOH -> Mg(OH)2 + 2NaCl

Page 29: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Sludge ConditioningSludge Conditioning

Padatan Calcium Phosphate dan Magnesium Hydroxide yang tidak terlarut terbentuk (Sludge)

Particulate Iron Oxide kembali ke kondensat

Padatan mengendap pada permukaan panas boiler

Transfer panas tidak seimbang, dapat beresiko pipa pecah

Page 30: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Tipe Sludge ConditionersTipe Sludge Conditioners

Synthetic polymers

Tannins

Lignins

Starches

Page 31: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Pengaplikasian Sludge Conditioners Pengaplikasian Sludge Conditioners

Produk Starch Organic

Jika Mg:SiO2 ratio < 2

Jika minyak mengkontaminasi air boiler

Dalam pabrik pengolahan makanan

Produk Lignin Organic

Untuk mengkondisi Calcium Phosphate & Iron Oxide

Page 32: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Titik Injeksi Sludge ConditionersTitik Injeksi Sludge Conditioners

Tangki Deaerator

Jalur air umpan boiler

Lansung ke steam drum

Page 33: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Solubilizing ProgramSolubilizing Program

Page 34: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

ChelantsChelants

Melarutkan ion logam

Membentuk senyawa kompleks yang sangat larut

Ion-ion bersaing (PO4, SiO2, OH) mengurangi efetivitas

Page 35: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Chelant yang UmumChelant yang Umum

EDTA(Ethylene diamine tetracetic acid)

Memiliki 6 sisi logam kompleks termasuk atom nitrogen dan oksigen

NTA(Nitrilo triacetic acid)

Memiliki 4 sisi logam kompleks

Page 36: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Perbandingan Kedua Jenis ChelantPerbandingan Kedua Jenis Chelant

NTA lebih stabil secara thermal– 900 psig max. untuk NTA,– 600 psig max. untuk EDTA

Biaya NTA lebih murah dari pada EDTA

EDTA memkompleks Magnesium lebih baik dari pada NTA

EDTA memkompleks besi lebih baik dari pada NTA

EDTA memiliki perizinan FDA

Page 37: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Aplikasi ChelantsAplikasi Chelants

Harus diinjeksikan secara kontinu pada jalur air umpan memakai injection quill & piping stainless steel

Tidak boleh ada oksigen

Konsentrasi residual pada air boiler harus dijaga di bawah 10 ppm sebagai CaCO3 untuk meminimalkan korosi

Akurasi kontrol pemakaian diperlukan

Page 38: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Chelant Control RangesChelant Control Ranges

Boiler Pressure Chelant Residual psig (Bar) ppm as CaCO3

400 (30) 4 - 8

401 - 600 (30 - 40) 3 - 6

601 - 1000 (40 - 70) 3 - 5

Page 39: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Kelebihan ChelantKelebihan Chelant

Tidak terbentuk endapan

Permukaan perpindahan panas lebih bersih

Frekwensi acid cleaning lebih sedikit

Terkadang dapat mengurangi jumlah blowdown

Page 40: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Kekurangan ChelantKekurangan Chelant

Biaya lebih mahal

Memerlukan kontrol yang sangat ketat

terhadap mutu air umpan

Lebih sulit untuk test kontrol

Residual berlebih bersifat korosif

Ion-ion yang bersaing dapat bersifat korosif

Page 41: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program Phosphate-PolymerProgram Phosphate-Polymer

• Mempresipitasikan hardness dan besi

• Polymer mendispersikan sludge hasil reaksi, untuk menghindari pengendapan pada pipa

• Boiler lebih bersih daripada program phosphate konvensional

Page 42: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Aplikasi Program Phosphate-PolymerAplikasi Program Phosphate-Polymer

Hardness air umpan lebih rendah dari 3 ppm

Softener atau air baku dengan hardness rendah

Page 43: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program Phosphate-Polymer Program Phosphate-Polymer

Kelebihan

• Perizinan FDA/USDA

• Dapat diaplikasikan pada air umpan dengan T.hardness tinggi.

• Boiler lebih bersih

• Lebih mudah ditest/dikontrol.

• Tidak mahal.

• Tidak bersifat korosif

Disadvantage

Requires much stricter control of feedwater hardness and chemical program

Page 44: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program Phosphate-Polymer Program Phosphate-Polymer

Kekurangan

• Memerlukan kontrol yang ketat terhadap hardness air umpan dan residual bahan kimia

Page 45: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program All-Organic Polymer Program All-Organic Polymer

All-polymer program, polymeric blend

Tidak mengandung chelant atau phophate, tidak memerlukan tambahan dispersan

Berfungsi dengan melarutkan Calcium & Magnesium dan mendispersi besi dan partikulat lainnya

Tidak bersifat agresif terhadap metal boiler

Page 46: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program All-Organic PolymerProgram All-Organic Polymer

Diinjeksikan ke tangki deaerator untuk boiler bertekanan < 600 psig dan menggunakan air softener

Program/dosis injeksi berdasarkan batas atas kontrol untuk hardness dan besi, bukan nilai rata-rata

Kekurangan dosis (<20% dari yang diperlukan) dapat membentuk deposit Calcium Acrylate pada boiler

Page 47: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program All-Organic PolymerProgram All-Organic Polymer

Tidak bersifat korosif untuk internal boiler

Memberikan hasil boiler yang lebih bersih - clean boilers – meningkatkan heat transfer

Transport 100% of hardness

Tidak bersifat volatil – aman untuk turbin

Hardness air boiler dapat ditest

Test produk sederhana/mudah

Program passivasi yang baik

Page 48: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Program All-Organic PolymerProgram All-Organic Polymer

Pengaplikasian terbatas untuk tekanan boiler <1000 psig

Memerlukan air umpan dengan hardness rendah

Beberapa formulasi mengkontribusikan ammonia ke

steam

Page 49: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Definisi KorosiDefinisi Korosi

• Korosi adalah proses elektrokimia, dimana metal (teroksidasi) kembali ke bentuk alamiahnya (natural state).

• Sell Korosi (corrosion cell) : anoda, katoda dan elektrolit harus ada

2 e- + 1/2 O2 + H2O <---> 2OH-

2OH- + Fe <---> Fe(OH)2 + 2 e-

Cathodic (reduction) half cell reaction

Anodic (oxidation) half cell reaction

Page 50: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Korosi pada BoilerKorosi pada Boiler

Tipe korosi

Korosi akibat oksigen/oxygen corrosion

Konsentrasi alkalinity/alkalinity concentration

Korosi akibat caustic/caustic corrosion

Korosi akibat asam/Acid corrosion

Korosi akibat chelant/Chelant corrosion

Erosi/korosi

Page 51: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Korosi Akibat OksigenKorosi Akibat Oksigen

• Oksigen yang terlarut di air merupakan materi dasar terjadinya reaksi di katoda

Page 52: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Korosi Akibat OksigenKorosi Akibat Oksigen

ANODE: Natural Metal Electrically Charged Metal ElectronsFe0 Fe+2 + 2e-

CATHODE: Electrons Oxygen Water Charged Ion2e- + 1/2 O2 + H2O 2(OH-)

Metal Ions Dissolve

Hydroxide or Oxide Corrosion Products

Active Anodic Area

Electron flow

O2OH-

Less Active Cathodic Area

Hydroxyl Ions Form

Page 53: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Korosi akibat Oksigen/Oxygen CorrosionKorosi akibat Oksigen/Oxygen Corrosion

Dapat terjadi pada sepanjang sistem

Mekanisme sama seperti sel korosi akibat oksigen

Mekanisme korosi dipengaruhi oleh:

– Konsentrasi oksigen

– Temperatur

– pH

Page 54: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Korosi Akibat OksigenKorosi Akibat Oksigen

Page 55: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Korosi Akibat OksigenKorosi Akibat Oksigen

Bahan kimia : Oxygen ScavengerBahan kimia : Oxygen Scavenger

Page 56: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Oxygen Scavenger yang Umum DipakaiOxygen Scavenger yang Umum Dipakai

• Sulfite• Hydrazine• Hydroquinone• DEHA (Diethyhydroxylamine)• MEKO (Methylethylketoxime)• Carbohydrazide• Erythorbic acid

Page 57: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

ONDEO Nalco’s Oxygen ScavengersONDEO Nalco’s Oxygen Scavengers

• Sulfite/Catalyzed Sulfite

• Carbohydrazide (Elimin-Ox)

• Erythorbic acid (SUR-GARD)

ONDEO Nalco Patents

Page 58: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Sodium Sulfite - Inorganic Oxygen ScavengerSodium Sulfite - Inorganic Oxygen Scavenger

2Na2SO3 + O2 -------> 2Na2SO4

• 8,6 ppm per 1 ppm oxygen terlarut• Pada temperatur kamar sodium sulfite

mengurangi oxygen sebesar 30 % dalam 10 menit

• Pada temp.> 120 oC, masih dibutuhkan waktu reaksi lebih dari 30 detik

Di atas 150 °C ,oxygen mengkorosi permukaan metal/besi lebih cepat dari pada waktu reaksi sulfite dengan oksigenCatalyzed Sulfite ( dengan

katalis Cobalt Salt ) lebih baik

Page 59: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Kelebihan SulfiteKelebihan Sulfite

• Reaksi cepat• Lebih murah• Lebih mudah dianalisa• Perizinan FDA/USDA

Page 60: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Kekurangan SulfiteKekurangan Sulfite

• Menambah solid/padatan ke air boiler

Kemungkinan dapat menambah jumlah blowdown

• Tidak ada efek passivasi pada metal boiler• Tidak sesuai untuk boiler dengan tekanan operasi

> 600 psi (40 bar)

Terurai menjadi H2S & SO2

Page 61: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Elimin-OxElimin-Ox

• Oxygen Scavenger

• Bersifat volatil/tidak menambah solid

• Mempasivasi permukaan metal

Page 62: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Reaksi Elimin-Ox Reaksi Elimin-Ox

Elimin-Ox * + 2O2 2N2 + 3H2O + CO2**<150 C

+ H2O< 150 C + 2N2H4 + CO2**

>205 C

+ 2O2 2N2 + 4H2O

2NH3 + N2 + H2

** Maximum 29 ppb/ppm Elimin-Ox Fed* As Carbohydrazide

Page 63: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Sur-GardSur-Gard

• Non-volatile Oxygen Scavenger

• Menghilangkan Dissolved Oxygen

• Mengurangi potensi korosi

• Bereaksi dengan oksigen secara kimiawi

• Mempasivasi permukaan metal

• Food Grade Approval

Page 64: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Surgard, Eliminox - Organic Oxygen Scavengers

Surgard, Eliminox - Organic Oxygen Scavengers

Kelebihan

•Tidak menambah solid/padatan ke air boiler, sehingga tidak menaikkan jumlah blowdown.

•Mempasivasi permukaan metal, sehingga dapat melindungi dari korosi. •Surgard sudah diizinkan FDA/USDA

Kelebihan

•Tidak menambah solid/padatan ke air boiler, sehingga tidak menaikkan jumlah blowdown.

•Mempasivasi permukaan metal, sehingga dapat melindungi dari korosi. •Surgard sudah diizinkan FDA/USDA

Kekurangan

• Reaksi lebih lambat

• Lebih mahal

Kekurangan

• Reaksi lebih lambat

• Lebih mahal

Page 65: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

HydrazineHydrazine

• toxic material - safe storage and handling issues become paramount

N2H4 + O2 ---> 2 N2 + 2H2ON2H4 + O2 ---> 2 N2 + 2H2O

3 N2H4 ---> 4 NH3 + N23 N2H4 ---> 4 NH3 + N2 at temp. > 390°F (200°C)at temp. > 390°F (200°C)

Page 66: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

HydroquinoneHydroquinone

• reacts quickly with oxygen at room temperature

• decomposition -> acetates, CO2, and H2O

• some toxicity issues

C6H4(OH)2 + 1/2O2 ---> C6H4O2 + H2OC6H4(OH)2 + 1/2O2 ---> C6H4O2 + H2O

Page 67: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

DiethylhydroxylamineDiethylhydroxylamine

• volatile neutralizing amine• hydroquinone may be added to increase low

temp. scavenging rate• decomposition > 148°C (300°F) is rapid

(seconds) acetic acid, CO2, acetaldehyde, ethylamine, low

mwt organics, and NH3 at temperatures above 275°C

4 (CH3CH2)2NOH + 9 O2 ---> 8 CH3COO- + 8 H+ + 2N2 + 6 H2O

4 (CH3CH2)2NOH + 9 O2 ---> 8 CH3COO- + 8 H+ + 2N2 + 6 H2O

Page 68: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

CondensateReceiver

Condensate System

Blowdown flash tank

Process

Process

Process

Flash tank

Low pressure steam

Pre-Treatment

DEAERATOR

Page 69: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Condensate CorrosionCondensate Corrosion

• Destroys capital equipment– repair, maintenance, loss of efficiency

• Can affect end products– if condensate contacts final products

• Will lead to increased boiler deposits of corrosion products (metal oxides)

Page 70: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Primary Causes of Condensate CorrosionPrimary Causes of Condensate Corrosion

• Carbon dioxide• Oxygen• Ammonia

Page 71: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Condensate CorrosionCondensate Corrosion

• Carbonic acid corrosion– dissolved carbon dioxide and the resulting

carbonic acid, is the most common source of condensate corrosion

CO2 + H2O <---> H2CO3 <---> H+ + HCO3-

Fe + 2 H+ + 2 HCO3-2 ---> Fe(HCO3)2 + H2

CO2 + H2O <---> H2CO3 <---> H+ + HCO3-

Fe + 2 H+ + 2 HCO3-2 ---> Fe(HCO3)2 + H2

Page 72: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Condensate CO2 CorrosionCondensate CO2 Corrosion

• Sources of CO2

– thermal decomposition of carbonate alkalinity in the boiler

– in-leakage of air into the condensate system

2 NaHCO3 ---> Na2CO3 + CO2 + H2O

Na2CO3 + H2O <---> 2 NaOH + CO2

2 NaHCO3 ---> Na2CO3 + CO2 + H2O

Na2CO3 + H2O <---> 2 NaOH + CO2

Page 73: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Condensate CO2 & O2Condensate CO2 & O2

• Carbonic acid and oxygen– in the presence of oxygen 2 cathodic

reactions are possible

– oxygen may react with other corrosion products

2 Fe + O2 + 4H+ ---> 2 Fe+2 + 2 H2O

4 Fe+2 + O2 + 4H+ ---> 4 Fe+3 + 2 H2O

4 Fe(HCO3)2 + O2 ---> 2 Fe2O3 + 4H2O + 8 CO2

2 Fe + O2 + 4H+ ---> 2 Fe+2 + 2 H2O

4 Fe+2 + O2 + 4H+ ---> 4 Fe+3 + 2 H2O

4 Fe(HCO3)2 + O2 ---> 2 Fe2O3 + 4H2O + 8 CO2

Page 74: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Chemical Condensate Treatment Chemical Condensate Treatment

• Neutralizing amines

• Filming amines

• ACT Program

Page 75: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

• Neutralizes carbonic acid and increases pH

• Effective against other acids

Neutralizing AminesNeutralizing Amines

Page 76: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Neutralizing AminesNeutralizing Amines

• Neutralization of carbonic or other acids

• Basicity or pKa• cyclohexylamine 10.6• diethylaminoethanol 9.6• morpholine 8.4

RNH2 + H2CO3 ---> (RNH3)+ + (HCO3)-

pKa is a function of solution temperature

keep pH above 8.8

Page 77: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Simple Acid/Base NeutralizationSimple Acid/Base Neutralization

• Amine hydrolysis in water:

R-NH2 + H2O « R-NH3+ + OH-

Neut. amine water Neut. amine hydroxide• CO2 hydrolysis in water:

CO2 + H2O « H2CO3 « H+ + HCO3-

carbon dioxide water carbonic acid bicarbonate• Net reaction:

R-NH2 + H2CO3 « R-NH3+ + HCO3

-

Neut. Amin carbonic acid Neut. amine bicarbonate

Page 78: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Optimum pH ControlOptimum pH Control

8.5 9. 2

Increases coppercorrosion

8.0

Increases mildsteel corrosion

Optimum pH

Page 79: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Prefer Water Prefer Vapour

Amine A Amine B

a blend of amines is typically required

Neutralizing Amines

Page 80: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

• Not effective against oxygen corrosion• Expensive in high alkalinity systems• Distribution can cause problems

– a blend of amines is typically required

• Difficult to test

DisadvantagesDisadvantages

Page 81: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Filming AminesFilming Amines

Metallic wall Protective filming

amine layer

O2 CO2

CO2

O2

O2

O2

O2

O2

O2

CO2

CO2

CO2

CONDENSATE

O2

O2

O2

O2CO2

CO2

CO2

CO2

O2

• Long chain amines that absorb onto the metal surface

• Function at the lower pH range of 6.5 to 9.0

Page 82: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

• A filmed metal surface promotes dropwise condensation

Page 83: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Filming AminesFilming Amines

• Protect against acids, O2, and ammonia

• Dosage dependent on surface area and not contaminant concentration

• Cost effective in high CO2

systems

Page 84: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Filming AminesLimitations/ConsiderationsFilming AminesLimitations/Considerations

• Film formation takes time• pH control still necessary• Overfeed may cause sticky

deposits and “gunk” ball formation

• Should be fed after turbines and condensate polishers

• Will clean up old deposits

Page 85: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Advanced Condensate Treatment (ACT)Advanced Condensate Treatment (ACT)

• ACT is an innovative condensate corrosion program that uses new technology to prevent operational problems.

Page 86: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Innovative ApproachInnovative Approach

Instead of neutralizing carbonic acid or using a filming amine,

Nalco researchers discovered safe emulsifiers which provide a barrier to corrosion in the condensate system.

Brand New Approach!

Page 87: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

So Safe, it is in the stuff you eat ...So Safe, it is in the stuff you eat ...

• Nalco’ ACT program is made from food grade materials used in many food products.

• The ACT program has received U.S. FDA clearance under 21 CFR Part 173 for Secondary Direct Food Additives Permitted in Food for Human Consumption; Boiler Water Additives.

Page 88: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

Provides Safe Corrosion Barrier to Metal Surfaces

Provides Safe Corrosion Barrier to Metal Surfaces

• no filmer

Page 89: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

ACT Program ACT Program

• It serves the regulatory needs• It serves the safety needs• It serves the technical needs• It serves the economic needs

Page 90: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

BenefitsBenefits

• Effective against carbonic acid• Effective against oxygen corrosion• Effective against erosion corrosion• Easy to test for• Dosage dependent on surface area and

not contaminant concentration• Cost effective in high CO2 systems• Operate at lower pH and not alter pH

Page 91: INTERNAL BOILER WATER TREATMENT (PRODUCT & CHEMISTRY)

DisadvantagesDisadvantages

• Must be fed to the steam header• Not volatile