Oxygenated treatment (OT) is a technique used to reduce corrosion in a boiler and its associated feedwater system in flow-through boilers.
With oxygenated treatment, oxygen is injected into the feedwater to keep the oxygen level between 30 and 50 ppb. OT programs are most commonly used in supercritical (i.e. >3250psi) power boilers. The ability to change an existing sub-critical boiler over to an OT program is very limited. "Common injection points are just after the condensate polisher and again at the deaerator outlet." [1] This forms a thicker protective layer of hematite (Fe2O3) on top of the magnetite. This is a denser, flatter film (vs. the undulation scale with OT) so that there is less resistance to water flow compared to AVT. [2] Also, OT reduces the risk of flow-accelerated corrosion. [3]
When OT is used, conductivity after cation exchange (CACE) at the economiser inlet must be maintained below 0.15μS/cm [4] this can be achieved by the use of a full-flow condensate polisher. [5]
Characteristic | All-Volatile Treatment (Reducing) | All-Volatile Treatment (Oxidizing) | Oxygenated Treatment (Neutral Water Treatment) | Oxygenated Treatment (Combined Water Treatment) |
---|---|---|---|---|
Feedwater system piping | ferrus or mixed metallurgy (e.g. copper feedwater train) | all-ferrous metallurgy | all-ferrous metallurgy | all-ferrous metallurgy |
Dissolved oxygen level | < 10 ppb | 1 to 10 ppb | 30-50 ppb (drum), 30-150 (supercritical) | 30-50 ppb (drum), 30-150 (supercritical) |
Chemicals added | a reducing agent (such as hydrazine), ammonia to raise pH | ammonia to raise pH | an oxidizing agent (such as hydrogen peroxide or oxygen) | an oxidizing agent, ammonia to raise pH |
pH [6] | 9.0-9.3 | 9.2-9.6 | 9.2-9.6 | 8.0-8.5 (once-through), 9.0-9.4 (drum) |
Top layer composition | magnetite (Fe3O4) on steel piping, cuprous oxide (Cu2O) on copper piping | hematite (Fe2O3) forms on top of the porous magnetite (Fe3O4) [7] | ferric oxide hydrate (FeOOH) or hematite (Fe2O3) forms over the porous magnetite | ferric oxide hydrate (FeOOH) or hematite (Fe2O3) forms over the porous magnetite |
Advantages | Can be used with mixed metallurgy piping | More protection against FAC than AVT(R), minimizes orifice fouling [8] | Less flow resistance, lower dissolved feedwater iron concentrations, FeOOH film is more stable, reduced boiler cleaning frequency | - |
Disadvantages | Increased risk of FAC, a deaerator is required, more frequent chemical cleaning is required, hazardous chemicals (hydrazine) are used. | A deaerator is required. | Air leakage is more serious. Two-phase FAC can be a concern. | Condensate polishers are required. |
A boiler is a closed vessel in which fluid is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including water heating, central heating, boiler-based power generation, cooking, and sanitation.
The Rankine cycle is an idealized thermodynamic cycle describing the process by which certain heat engines, such as steam turbines or reciprocating steam engines, allow mechanical work to be extracted from a fluid as it moves between a heat source and heat sink. The Rankine cycle is named after William John Macquorn Rankine, a Scottish polymath professor at Glasgow University.
A supercritical fluid (SCF) is a substance at a temperature and pressure above its critical point, where distinct liquid and gas phases do not exist, but below the pressure required to compress it into a solid. It can effuse through porous solids like a gas, overcoming the mass transfer limitations that slow liquid transport through such materials. SCFs are superior to gases in their ability to dissolve materials like liquids or solids. Near the critical point, small changes in pressure or temperature result in large changes in density, allowing many properties of a supercritical fluid to be "fine-tuned".
A heat recovery steam generator (HRSG) is an energy recovery heat exchanger that recovers heat from a hot gas stream, such as a combustion turbine or other waste gas stream. It produces steam that can be used in a process (cogeneration) or used to drive a steam turbine.
A corrosion inhibitor or anti-corrosive is a chemical compound added to a liquid or gas to decrease the corrosion rate of a metal that comes into contact with the fluid. The effectiveness of a corrosion inhibitor depends on fluid composition and dynamics. Corrosion inhibitors are common in industry, and also found in over-the-counter products, typically in spray form in combination with a lubricant and sometimes a penetrating oil. They may be added to water to prevent leaching of lead or copper from pipes.
A thermal power station, also known as a thermal power plant, is a type of power station in which the heat energy generated from various fuel sources is converted to electrical energy. The heat from the source is converted into mechanical energy using a thermodynamic power cycle. The most common cycle involves a working fluid heated and boiled under high pressure in a pressure vessel to produce high-pressure steam. This high pressure-steam is then directed to a turbine, where it rotates the turbine's blades. The rotating turbine is mechanically connected to an electric generator which converts rotary motion into electricity. Fuels such as natural gas or oil can also be burnt directly in gas turbines, skipping the steam generation step. These plants can be of the open cycle or the more efficient combined cycle type.
A deaerator is a device that is used for the removal of dissolved gases like oxygen from a liquid.
The supercritical water reactor (SCWR) is a concept Generation IV reactor, designed as a light water reactor (LWR) that operates at supercritical pressure. The term critical in this context refers to the critical point of water, and should not be confused with the concept of criticality of the nuclear reactor.
A surface condenser is a water-cooled shell and tube heat exchanger installed to condense exhaust steam from a steam turbine in thermal power stations. These condensers are heat exchangers which convert steam from its gaseous to its liquid state at a pressure below atmospheric pressure. Where cooling water is in short supply, an air-cooled condenser is often used. An air-cooled condenser is however, significantly more expensive and cannot achieve as low a steam turbine exhaust pressure as a water-cooled surface condenser.
A steam–electric power station is a power station in which the electric generator is steam-driven: water is heated, evaporates, and spins a steam turbine which drives an electric generator. After it passes through the turbine, the steam is condensed in a condenser. The greatest variation in the design of steam–electric power plants is due to the different fuel sources.
Chemical fouling inhibitors are products that are mixtures of fouling and corrosion inhibitors use in boiler feedwater treatment. Several of these products use aliphatic polyamines to coat the surface of pipes.
A condensate pump is a specific type of pump used to pump the condensate (water) produced in an HVAC, refrigeration, condensing boiler furnace, or steam system.
A boiler feedwater pump is a specific type of pump used to pump feedwater into a steam boiler. The water may be freshly supplied or returning condensate produced as a result of the condensation of the steam produced by the boiler. These pumps are normally high pressure units that take suction from a condensate return system and can be of the centrifugal pump type or positive displacement type.
Boiler water is liquid water within a boiler, or in associated piping, pumps and other equipment, that is intended for evaporation into steam. The term may also be applied to raw water intended for use in boilers, treated boiler feedwater, steam condensate being returned to a boiler, or boiler blowdown being removed from a boiler.
Economizers, or economisers (UK), are mechanical devices intended to reduce energy consumption, or to perform useful function such as preheating a fluid. The term economizer is used for other purposes as well. Boiler, power plant, heating, refrigeration, ventilating, and air conditioning (HVAC) may all use economizers. In simple terms, an economizer is a heat exchanger.
A condensate polisher is a device used to filter water condensed from steam as part of the steam cycle, for example in a conventional or nuclear power plant. It is frequently filled with tiny polymer resin beads which are used to remove or exchange ions so that the purity of the condensate is maintained at or near that of distilled water.
Boiler feedwater is the water which is supplied to a boiler. The feed water is put into the steam drum from a feed pump. In the steam drum the feed water is then turned into steam from the heat. After the steam is used, it is then dumped to the main condenser. From the condenser, it is then pumped to the deaerated feed tank. From this tank it then goes back to the steam drum to complete its cycle. The feedwater is never open to the atmosphere. This cycle is known as a closed system or Rankine cycle.
Flow-accelerated corrosion (FAC), also known as flow-assisted corrosion, is a corrosion mechanism in which a normally protective oxide layer on a metal surface dissolves in a fast flowing water. The underlying metal corrodes to re-create the oxide, and thus the metal loss continues.
A deaerating feed tank (DFT), often found in steam plants that propel ships, is located after the main condensate pump and before the main feed booster pump. It has these three purposes:
Steam and water analysis system (SWAS) is a system dedicated to the analysis of steam or water. In power stations, it is usually used to analyze boiler steam and water to ensure the water used to generate electricity is clean from impurities which can cause corrosion to any metallic surface, such as in boiler and turbine.