Boiler Water Quality Research Articles

Maintenance of Steam Bottle Water to Keep Operational Auxiliary Steam Bottles on The Mv. Ile De Re

Various types of marine vessels require fuel to drive the main engine and auxiliary engines. The fuel requires hot steam as a heater so that the fuel reaches the appropriate temperature, not only fuel but hot steam is also needed for the accommodation space on the ship. The steam boiler is a closed vessel that can produce hot steam with a pressure greater than one atmosphere, to be able to produce hot steam, a heated medium is needed, namely fresh water. The water used in the steam generation process greatly affects the condition of the boiler. Therefore, the quality of water in the boiler must always be considered and maintained so that it is always in good condition, so that the boiler will always be in prime condition. In reality, steam boilers often experience disturbances, such as on the MV. ILE DE RE there is a decrease in the quality of boiler water and the occurrence of scale in the boiler. In this case, the research used an observation research method on boiler water by testing boiler water and it was found that the quality of boiler water was not up to standard with low pH levels up to 6.8, high alkalinity and high chloride up to 200 ppm. there is also a scale formation on the boiler water pipe which can be seen from the dirty condition of the boiler water when taken.

Design of Online Detection System of Boiler Water Quality Based on STM32

Industrial boilers have strict requirements for water quality. It is necessary to adjust water treatment measures and regular blowdown according to the monitoring of phosphate and soluble silica content in boiler water to avoid boiler scaling, corrosion, and deterioration of steam quality, and prevent major accidents. The traditional boiler water quality detection technology has a strong lag and long detection time, which cannot meet real-time online detection. Aiming at the requirement of detection of phosphate radical and soluble silica content in boiler water quality, a portable and low-cost online detection system of boiler water quality based on STM32 was studied. The pump valve flow path is constructed with a syringe pump equipped with a syringe and a distribution valve, LED and silicon photocell are used for the light source and detector of the system respectively, and the photoelectric detection part is composed of a designed Z-shaped flow cell, which reduces the experimental cost; Design a data acquisition circuit based on STM32 microcontroller and a 16-bit high-precision analogy-to-digital converter, as well as a constant-current drive circuit for driving LED light sources, to improve the stability and high precision of the automatic measuring instrument. The system test results show that the boiler water quality online detection system based on STM32 can accurately detect the phosphate and soluble silica concentrations in boiler water quality.

Data Driven Technique for Palm Oil Mills Boiler Water Quality Monitoring in State of Perak Malaysia

Steam boilers are widely used in oil palm mills industries which physically converting the water into steam. Heating water in the boiler allows solid waste such as potassium, calcium, magnesium, silica and ions to stay in the boiler and creates a solid waste layer that coats the tubes and boilers. This strong coating would increase the heating surface of the boiler and decrease the efficiency of heat transfer. This situation will also increase the consumption of fuel, causing the boiler to overheat, which in turn leads to tube failure. The impact of this issue will cause losses to the oil palm plantation due to the shutdown of unplanned plants. Therefore, for this study, Statistical Process Control (SPC) has been utilized to monitor the quality of the 6 parameters of the boiler and boiler feedwater for palm oil mill in Perak State Malaysia to overcome the problem stated above. Boxplot has been utilized to monitor continuously the parameter based on the probability distribution of the data according to ASME guidelines. The findings from this analysis show that some of the palm oil mills is able to maintain their boiler quality accordingly, however, on controlling the silica, hardness and total iron, its need further improvement.

Failure analysis of SA210-C steel pipe in power plant

The reason and mechanism of the failure of SA210-C steel liquid wall were analyzed by means of macro morphology analysis, chemical composition analysis, microstructure analysis and XRD phase analysis. The test results show that the main reason for the failure of SA210-C steel water wall tube is the corrosion under the inner wall scale, and the long-term unqualified boiler water quality is the main factor causing the corrosion of water wall.

Treatment of organized industrial zone wastewater by microfiltration/reverse osmosis membrane process for water recovery: From lab to pilot scale

The global increase in industrialization has resulted into water scarcity. Research on water use efficiency and water reclamation is paramount in addressing this scarcity. In this study, laboratory and on-site pilot scale tests were conducted for water recovery from an industrial wastewater treatment plant. Different RO membranes (BW30, HP, and LE) were investigated with chemical treatment and ceramic microfiltration (MF) as pretreatment steps. Laboratory studies were conducted in dead-end filtration mode, whereas pilot scale studies were performed in cross flow mode with two spiral wound membranes. The removal efficiencies ranged from 40.0-86.3% for COD, 97.6- 99% for SO42-, 69.2-94.9% for Cr ion, 89.3-100% for Pb ion, 66.3-98.2 for Fe ion, 97.5- 99.7% for Zn ion, 95.1-99.5% for Si ion, and 79.1-100% for total phosphorus (TP). For the laboratory studies with 80% water recovery, the permeate flux reduced from 27.2 to 7.1 L/m2h, 35.7 to 1.3 L/m2h and 25.6 to 0.8 L/m2h for BW30, LE, and HP, respectively. On the other hand, four different operation modes were investigated to determine the effect of each mode on membrane performance and fouling properties. Average permeate flux of 18.7 and 21.3 L/m2h, 12.7 and 12.8 L/m2h, 13.4 and 14.6 L/m2h, 12.5 and 14.1 L/m2h were recorded for LE and BW30 membranes in the first, second, third, and fourth modes, respectively. Membrane autopsies were performed by atomic force microscopy (AFM), scanning electron microscopy (SEM), and energy dispersive X-rays (EDX). The system was effective in recovering the permeate to required industrial cooling and boiler water quality.

Correction of the Water and Chemical Mode of Boilers Utilizers at Sharp Changes of a Boiler Water Quality, Including for Power Complexes on Recycling

The results of a research of the water and chemical mode of boiler utilizers including determination of quality of saturated steam, nutritious and boiler water are given in article. Researches were conducted at the actual loadings and pressure and the average level of boiler water in a drum. The dependence of change of controlled indicators of quality of boiler water and saturated steam of a boiler utilizer on fluctuations of a purge size a copper and the set range of change level is established, and also dynamics of salinity of saturated steam depending on salinity of nutritious and boiler waters. We developed recommendations about control of additional indicators when carrying out chemical control at threat of various violations of the water and chemical mode. We gave an assessment of extent change a quality of boiler water when using on water treatment installations of membrane methods of desalting of initial waters. Also studied water and chemical modes can be used in units for recycling.

Analysis of the causes of leakages and preventive strategies of boiler water-wall tubes in a thermal power plant

The reasons for the failures of a boiler water-wall tube used in the thermal power plant were investigated in this paper. The material of water-wall tube was made of medium-carbon steel, SA-210 Grade C, which is pearlitic heat-resistant steel with a working temperature lower than 500 °C and is widely used in boilers tubes. To investigate the causes of failure, various techniques including macroscopic inspection, chemical composition analysis, mechanical performance testing, optical microscopy observation and Energy Dispersive Spectroscopy (EDS) were carried out. Corrosive products were found on the inner wall of the tube’s bulge positions. The thickness of the tube wall covered by the corrosive products reduced due to the corrosion. The boiler water quality was analyzed and it was found that there was excessive Sodium Hydroxide (NaOH), which was the main corrosion-induced substance. Metallographic examination results showed that the microstructure in the corroded area has aged. Based on the analysis results, failure causes can be drawn: excessive NaOH in the boiler water was the main reason for the corrosion. The characters of alkaline corrosion products provided the condition that corrosion can proceed continuously which caused the thinning of the water-wall tube. As the process proceeds, it reduces performance of the tube and creates bulge which finally causes leakage.

Treatment Method Assessment of the Impact on the Corrosivity and Aggressiveness for the Boiler Feed Water

The aim of the study was the assessment of corrosivity and aggressiveness for boiler feed water. The negative effects of water corrosivity and aggressiveness may include silting up of the steel water supply system and the destruction of boiler equipment touched or washed by such water. They may cause the whole industrial production system to fail or be destroyed. That is why it was important to reach a high water purification level, including the calculation of water aggressiveness and corrosivity indicators. The carried out test showed that the simple system used before the modernization of the industrial water treatment plant is not sufficient to reach clean and stable water. The authors proposed modernization, including additional processes to improve boiler water quality, and designed new devices for water treatment. As a result of the new idea, groundwater taken as raw water was treated in individual and complex processes, such as pre-aeration, filtration, ion exchange (cation and anion exchange resigns), extra aeration, and extra degassing. The conducted research included chemical analyses of raw and treated water. In the conducted studies, the indirect method of water aggressiveness and corrosivity assessment was applied using mathematical calculation of the Langelier Saturation Index (LSI), the Ryznar Stability Index (RI), the Larson–Skold Index (LI), and the Singley Index (SI). The results proved that the new proposed processes for the boiler feed water treatment station allow reaching a high water quality and low level of water aggressiveness and corrosion.

Establishment of Method for Identification of Water Quality in Fire-Tube Boiler - A Case Study for UTHM Biodiesel Plant's Boiler

Water treatment process for a boiler is essential to ensure the boiler operates at an optimum condition. Accordingly, the present study aimed to introduce a water quality assurance method for a boiler at UTHM biodiesel plant. The water quality is investigated by experimental study, which includes the monitoring of total dissolved solids, potential of Hydrogen (pH), sulphate, iron and chloride content, total hardness, and alkalinity. The water sampling was conducted at three different points. Subsequently, for the purpose of water quality assurance, the amount and type of chemical needed for a boiler to maintain a substantial value of water treatment were also been determined. The results obtained in this study has revealed that most of the parameters investigated are within the allowable limits. Further work needs to be done to establish whether the steam produced by the boiler can be influenced by the boiler water quality.

A hybrid regression model for water quality prediction

In this work, we propose a hybrid regression model to solve a specific problem faced by a modern paper manufacturing company. Boiler inlet water quality is a major concern for the paper machine. If water treatment plant can not produce water of desired quality, then it results in poor health of the boiler water tube and consequently affects the quality of the paper. This variation is due to several crucial process parameters. We build a hybrid regression model based on regression tree and support vector regression for boiler water quality prediction and show its excellent performance as compared to other state-of-the-art.

ANALISA KEGAGALAN MATERIAL SA-210C PADA APLIKASI BOILER STEAM PIPE

The purpose of this study was to determine the cause of pipe failure in super saturated area boilers. The research method begins with the collection of chronological data on material failure, operating data collection and material sampling. After material sampling is carried out, photos of failed material are subsequently carried out, thickness measurements, hardness testing, metallographic testing and internal pipe pressure calculations. The results showed that the outside of the pipe had erosion corrosion due to a reduction in thickness of the pipe, especially location 1. Thickening was caused by high pressure auxiliary steam bursts from the sootblower equipment which lasted for a long time at the pipe surface, resulting in Fe + O FeO reaction. FeO formed at the beginning will be released due to high-pressure auxiliary steam bursts and at the same time the auxiliary steam burst reacts chemically again to form FeO. Because of the repeated processes, the pipe thickness slowly decreases. As a result of the depletion, the pipe reaches a critical value so it is unable to withstand the pressure from the pipe and eventually fails. The failure factor, supported by some data on boiler water quality and continuous operating pressure from sootblower that affect erosion corrosion. Changes in microstructure also affect the decrease in hardness in the material which can be seen from the size and shape of the grain.

Analysis of results obtained using the automatic chemical control of the quality of the water heat carrier in the drum boiler of the Ivanovo CHP-3 power plant

Results of industrial tests of the new method used for the automatic chemical control of the quality of boiler water of the drum-type power boiler (P d = 13.8 MPa) are described. The possibility of using an H-cationite column for measuring the electric conductivity of an H-cationized sample of boiler water over a long period of time is shown.

Exploitation results of seven RO plants for recovery and reuse of treated effluents in textile industries

The paper comprises a case study on the implementation of the advance treatment process (ATP) in seven small-scale textile industries. The ATPs installed and commissioned are in compliance with the Statutory Board directions for recovery and reuse of treated effluent leading to zero effluent discharge. The textile effluents are treated in effluent treatment plants comprising a physicochemical option followed by biological activated sludge process, pressure sand filtration and activated carbon adsorption. The tertiary treated effluents (25–65 m 3/d) are high in total dissolved solids, chlorides and hardness, and partly reused for washing screens, cloth and ash quenching. The tertiary treated effluent contained suspended solids and total dissolved solids in the range, 4–30 mg/L and 1980–2682 mg/L, respectively, with COD concentrations in the range, 125–410 mg/L and did not meet the stipulated standards for discharge into inland surface waters. A part of the tertiary treated effluent (4.0–9.5 m 3/d) is routed to ATP for recovery of boiler feed quality water. The ATP comprises a multi-grade filter, ultrafiltration (UF) unit and a reverse osmosis (RO) unit. The multi-grade filter ensured complete removal of suspended solids with a marginal decrease in COD. The fouling index (b) for the feed to the ultrafiltration was estimated to be varying in the range 0.6–2.1× 10 −3 s −1.The UF operated at 200–300 kcals with 88–95% permeate recovery. This unit achieved 80–90% removal of BOD and COD and 65–90% removal of phosphates. The RO unit at a pressure range of 1270–1670 kPascals produced 68–84% permeate. The permeate characteristics conforms the boiler water quality as prescribed by the Indian Standards Institution for low-pressure drum type boilers. The pH of the recovered water was adjusted with alkali to pH 10–11 and mechanically deaerated for use in boilers. Recycle/reuse of tertiary treated effluents for various purposes and reuse of the recovered water from advance treatment process as boiler water make-up has resulted in a reduction in water requirements by 30–35% in each industry.

船用タービンプラント水質管理とその自動化に関する研究（Ｉ）｀＊´―不純物の混入と水処理による主ボイラ水質の変化―

For steam turbine ships, it is very important to control accurately water quality of the main boiler and its plant. The recovery rate of condensed water in recent marine turbine plants has been increasing and approaching a perfect closed cycle, and the techniques of pH monitoring and Fresh Water Generators have been improved too. However, as for the automation of boiler water treatment, its development seems to be very late compared to other ship techniques.This paper investigates, therefore, the current situation of the water quality control of marine turbine plant in order to develop an automatic water treatment system. As the fundamental research on the boiler water quality control and its automatic water treatment, this first report analyzes theoretically the water treatment data of actual ship for making clear the impacts of (1) impurity mixing from make-up water (2) boiler compounds (3) blow-down of boiler water on boiler water quality, especially pH and PO4. The analysis shows some characteristics of boiler water quality and its treatment system which are to be helpful to marine engineers.

船用タービンプラントの水質管理とその自動化に関する研究（ＩＩ）―ボイラ水の濃縮管理基準と脱酸剤のプラントに及ぼす影響について―

It is very important for realizing the automatic water quality treatment to analyze the behavior of water quality of marine turbine plant. Following the first report, which investigated the change of pH and phosphate ion concentration in boiler water, this second report studies the influence of hydrazine on the water quality of marine steam turbine plant.In this study, the authors analyze theoretically the concentrations of chloride ion, silica and electric conductivity of boiler water, and also pH and electric conductivity of feed water. The analysis can reveal the maximum allowable concentration of residues in boiler water so that it makes possible to control the blowing-down appropriately. And the analysis shows some characteristics of boiler water quality and its treatment system which are to be helpful to marine engineers.

MULTIPLE-EFFECT EVAPORATION REGIME IN HIGH-PRESSURE BOILERS

In the 1930’s, a multiple-effect evaporation technique was proposed for generating clean steam that was based on the use of boiler drums partitioned into sections for processing boiler water with different salt concentration [1]. In a sectioned drum, the “clean” section served for generating steam with a salt concentration lower than that in the steam generated in the “salt collection” section; the steam flowing from the two sections was mixed together to produce a steam with rated characteristics required for normal operation of superheaters and turbines. The method in question is quite satisfactory for low-pressure boilers in which requirements placed on the quality of steam are too stringent and can be provided by use of simple water treatment techniques. Numerous data have been reported in the literature that were mainly focused on the advantages of drum boilers with multiple-effect evaporation for generating standard-quality steam. It was shown in [2] that in steam generators using steam washing techniques that gained wide acceptance in the 1950’s, the continued application of multiple-effect evaporation added little (if any) to the quality of steam. Therefore in view of the ever-increasing requirements placed on the quality of feed water supplied at higher pressures (which caused the increase in impurities, especially silicic acid, in steam), the advisability of using multiple-effect evaporation in high-pressure boilers was questioned in a number of works [3–7]. At present, even in the use of incompletely desalinized water for feeding high-pressure (HP) boilers at thermal power plants (TPPs), no problem arises with the quality of steam produced either by multiple- or single-effect evaporation (domestic TP-100-, VPG-250-, and TPE-214-type boilers, as well as boilers available from foreign manufacturers, or medium-pressure boilers currently in service in Russia). As is known, the performance of an evaporating heating surface is to a significant extent determined by the rate at which inside fouling deposits build up. With this in mind, it is important to consider the water-and-salt regime (WSR) for the boiler water fed to drum boilers with multiple-effect evaporation. The annual rate of faults in the water-wall tubes of drum boilers (bulging, corrosion) is rather high, whereas these faults seldom (if ever) occur in high-pressure and supercritical-pressure (SCP) direct-flow boilers. The reason for this is that, with the feed water of the same quality, the boiler water for the cooling water wall of drum boilers contains soluble impurities in concentrations higher than that for direct-flow boilers (by a factor of 100 against the feed water at a 1% blow-down), which creates favorable conditions for the buildup of deposits and corrosion. Water-soluble impurities (Ca, Mg, Na, SiO2 salts, etc.) are removed from the drum boiler via continuous blow-down. Therefore requirements placed on the quality of boiler water and, consequently, feed water for drum boilers in terms of soluble impurities can be less stringent than for direct-flow boilers: in the latter, all the impurities are confined within the water-steam circuit. As to iron oxides, the situation is somewhat different; most iron oxides deposit inside the water-wall tubes and are not removed readily by blow-down. With the increase in operating pressure, requirements placed on the quality of boiler water and, consequently, feed water become more stringent — with a view to preventing corrosion and fouling of the wa

混入海水によるボイラ水質の変化 (2)

For the water quality control of marine boiler, it is very important to investigate the effects of sea water mixing on the conditions of boiler water quality such as pH, concentrations of phosphoric ion PO43-, chloric ion Cl-, and electric conductivity EC. At first, the paper investigates theoretically the change of pH, that is molarity of hydroxyl [OH-], PO43- concentration and EC due to mixing of sea water into boiler water by the consideration of the chemical reactions between scale components and phosphate/alkali type of water treatment chemicals. According to this investigation, the paper proposes a method of automatic water quality control. Secondly the paper carries out an experimental study by the use of an actual boiler in order to confirm the validity of the above theoretical investigation. The experiment reveals the followings; (1) There is some difference between the theoretical estimation and the measurement result regarding the change of pH, PO43- concentration and EC due to sea water mixing. It is found, however, the difference has a certain regular trend being related with the mixing rate of sea water. (2) The PO43- concentration can be arranged corresponding to the addition rate of some blended type of phosphate/alkali treatment chemicals even when Cl- concentration is high, provided that hardness components do not exist. (3) When the pH is kept around 11.0, there are good correlations between concentration of [OH-] and concentrations of P-Alkalinity, M-Alkalinity and PO43-, and also between EC and Cl-. Using adequately these correlations, therefore, there would be a possibility of automatic control of boiler water quality.

海水混入によるボイラ水質の変化

There seems to be a very delay in the automation of boiler water treatment compared to other domains of ship techniques. The difficulties of monitering the boiler water quality is considered to be one of main reasons of such delayed situation. As for marine boiler, most of impulities of boiler water are due to mixing of sea water. A basic experimental study was carried out in order to investigate effects of sea water mixing on boiler water qualities, especially on pH, concentrations of phosphoric ion PO3-4and of chloric ion Cl-, and electric conductivity EC. The obtained results are (1) theoretical estimation of Cl- change almost agreed with experimental results, (2) theoretical estimation of pH was valid when pH was in the range larger than 10, (3) as for PO3-4, some discrepancies between theory and experiment were observed, and decrease of PO3-4, obtained by the latter was larger than that predicted by the former, (4) the flow-through type sensors were confirmed to be useful for monitoring pH and EC when flow velocity was regulated carefully so as to avoid the influence of streaming potential. According to those obtained results, there would be the possibility to advance the automatic control of water quality of marine boiler by monitoring pH and EC.

Boiler Water Quality and Treatment

Boiler Water Quality and Treatment