BOILER EXTERNAL INTERNAL TREATMENT Of Palm oil Mill
HeruPramudya2
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Mar 11, 2025
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About This Presentation
Boiler
Size: 1.12 MB
Language: en
Added: Mar 11, 2025
Slides: 62 pages
Slide Content
MOHD IKHSAN YAACOB
BOILER BOILER
EXTERNALEXTERNAL
&&
INTERNAL INTERNAL
TREATMENTTREATMENT
MOHD IKHSAN YAACOB
INTRODUCTION AND PURPOSE ToINTRODUCTION AND PURPOSE To
understand fundamentals of water understand fundamentals of water
treatment, as well as the system in POMtreatment, as well as the system in POM
To be aware of treatment requirement and To be aware of treatment requirement and
prevent problems to boilerprevent problems to boiler
BOILER EXTERNAL & INTERNAL TREATMENTBOILER EXTERNAL & INTERNAL TREATMENT
MOHD IKHSAN YAACOB
Water treatment in POM Water treatment in POM
1.1.External treatmentExternal treatment
ClarifierClarifier
FilterFilter
SoftenerSoftener
DeaeratorDeaerator
2.2.Internal treatmentInternal treatment
Chemical treatment in boiler and Chemical treatment in boiler and
condensate systemcondensate system
BOILER EXTERNAL & INTERNAL TREATMENTBOILER EXTERNAL & INTERNAL TREATMENT
MOHD IKHSAN YAACOB
Water treatment in POMWater treatment in POM
River
Water pump
Clarifier
Filter
Softener
De-aerator
Feed
Water
Tank
MOHD IKHSAN YAACOB
Water treatment in POMWater treatment in POM
External treatment is so crucial as…External treatment is so crucial as…
It is most critical part of the total boiler It is most critical part of the total boiler
system with respect to maintaining boiler system with respect to maintaining boiler
cleanliness.cleanliness.
It is to produce water of acceptable quality It is to produce water of acceptable quality
for use in the boilerfor use in the boiler
MOHD IKHSAN YAACOB
ClarifierClarifier
MOHD IKHSAN YAACOB
ClarifierClarifier
To remove the settable To remove the settable
and suspended solidsand suspended solids
To provide liquid-solids To provide liquid-solids
separation with addition separation with addition
of coagulant and of coagulant and
flocculantsflocculants
To achieve TSS 10ppm To achieve TSS 10ppm
or lessor less
Typical type in POM-up Typical type in POM-up
flow and sludge flow and sludge
recirculation, water recirculation, water
retention time at 2 retention time at 2
hours and rise rate at hours and rise rate at
2m2m
33
/hr/hr
MOHD IKHSAN YAACOB
Step 1: pH adjustmentStep 1: pH adjustment
If pH less than 6, use soda ash(Na2CO3)/ If pH less than 6, use soda ash(Na2CO3)/
caustic soda(NaOH)/ lime (Ca(OH)2/ caustic soda(NaOH)/ lime (Ca(OH)2/
pottasium hydroxide(KOH)pottasium hydroxide(KOH)
If pH more than 8, use acid (HCI, H2SO4)If pH more than 8, use acid (HCI, H2SO4)
Important to get correct pH before addition Important to get correct pH before addition
of coagulant (especially alum)of coagulant (especially alum)
How liquid solids separation takes How liquid solids separation takes
place in clarifierplace in clarifier
MOHD IKHSAN YAACOB
Step 2: CoagulationStep 2: Coagulation
Charge neutralization processCharge neutralization process
Addition of chemical coagulant to destabilize Addition of chemical coagulant to destabilize
colloidal particles in water by neutralizing the colloidal particles in water by neutralizing the
forces that keep them apart. The process forces that keep them apart. The process
requires mixing energy to make destabilized requires mixing energy to make destabilized
particles to collide for floc formationparticles to collide for floc formation
Chemical coagulants commonly used areChemical coagulants commonly used are
Aluminium salts: Alum, Polyaluminium Chloride Aluminium salts: Alum, Polyaluminium Chloride
(PAC)(PAC)
PolyelectrolytePolyelectrolyte
Organic coagulantOrganic coagulant
How liquid solids separation takes How liquid solids separation takes
place in clarifierplace in clarifier
MOHD IKHSAN YAACOB
Step 3: FlocculationStep 3: Flocculation
Floc building process Polymers are added Floc building process Polymers are added
to agglomerate small coagulated flocs to to agglomerate small coagulated flocs to
form big & dense ones so that it can settle form big & dense ones so that it can settle
fastfast
Step 4: SettlingStep 4: Settling
After coagulation and flocculation process, After coagulation and flocculation process,
dense flocs will settle at the bottom of dense flocs will settle at the bottom of
clarifier and form sludge blanket.clarifier and form sludge blanket.
How liquid solids separation takes How liquid solids separation takes
places place in clarifierplaces place in clarifier
MOHD IKHSAN YAACOB
Sludge blanketSludge blanket
Depth of sludge blanket is the working depth of Depth of sludge blanket is the working depth of
sludge over the bottom of the sludge sludge over the bottom of the sludge
recirculation draft tube in an upflow-solids recirculation draft tube in an upflow-solids
contact clarifier. Typically 60 to 80 inches below contact clarifier. Typically 60 to 80 inches below
the water surfacethe water surface
Too high or too low a blanket will results into Too high or too low a blanket will results into
carryovercarryover
How liquid solids separation takes How liquid solids separation takes
places place in clarifierplaces place in clarifier
MOHD IKHSAN YAACOB
Clear Water
Clear Water
Typical Flow Diagram
Of a Up flow Sludge Blanket
Water Clarifier
MOHD IKHSAN YAACOB
Sludge blowdownSludge blowdown
Sludge must be removed in proportion to the Sludge must be removed in proportion to the
amount formed and frequent intervalsamount formed and frequent intervals
Too less sludge blowdownToo less sludge blowdown
Sludge solidified and become hard to removeSludge solidified and become hard to remove
Raised sludge blanket too high>excessive carryoverRaised sludge blanket too high>excessive carryover
Scum floating and odor – anaerobic decompositionScum floating and odor – anaerobic decomposition
Too much sludge blowdownToo much sludge blowdown
Deplete sludge blanket>excessive suspended solids Deplete sludge blanket>excessive suspended solids
carry over.carry over.
How liquid solids separation takes How liquid solids separation takes
places place in clarifierplaces place in clarifier
MOHD IKHSAN YAACOB
How to determine How to determine
chemical dosage?chemical dosage?
MOHD IKHSAN YAACOB
How to determine chemical How to determine chemical
dosage?dosage?
Jar TestJar Test
And And
Plant Plant
TrialTrial
MOHD IKHSAN YAACOB
Where are typical injection points?Where are typical injection points?
Flocculants
Coagulant
Soda Ash
10 ~15 ft 5 ft
W
a
t
e
r
r
i
s
e
r
a
t
e
2
m
3
/
h
r
Coagulant Soda Ash Raw Water
MOHD IKHSAN YAACOB
FilterFilter
MOHD IKHSAN YAACOB
FilterFilter
To filter the solids To filter the solids
escaped from the escaped from the
clarifierclarifier
To remove fine particles To remove fine particles
up to 10 micron sizeup to 10 micron size
Optimally operated Optimally operated
filter will not burden filter will not burden
softenersoftener
To achieve water To achieve water
turbidity <5NTUturbidity <5NTU
MOHD IKHSAN YAACOB
When to backwash the filter?When to backwash the filter?
High pressure dropped across the filter and High pressure dropped across the filter and
resulting low water throughput, orresulting low water throughput, or
Filtered water turbidity has reached the Filtered water turbidity has reached the
preset value, i.e. turbidity >5NTUpreset value, i.e. turbidity >5NTU
FilterFilter
MOHD IKHSAN YAACOB
Functions to remove Total Hardness, namely Functions to remove Total Hardness, namely
calcium and magnesium ions by ion exchange calcium and magnesium ions by ion exchange
process in sodium zeolite resinprocess in sodium zeolite resin
Subject to mud and iron fouling – hence Subject to mud and iron fouling – hence
important to receive acceptable influentimportant to receive acceptable influent
Backwash and brine regeneratiom is requiredBackwash and brine regeneratiom is required
Reversible process – based on ion selectivity Reversible process – based on ion selectivity
and concentration dominantand concentration dominant
SoftenerSoftener
MOHD IKHSAN YAACOB
Ion Exchange ProcessIon Exchange Process
C
a
l
c
i
u
m
M
a
g
n
e
s
i
u
m
Sodium
MOHD IKHSAN YAACOB
Ion Exchange ProcessIon Exchange Process
S
o
d
i
u
m
Calcium
MOHD IKHSAN YAACOB
How Can You Tell If Your Softener How Can You Tell If Your Softener
Is Not Working Correctly?Is Not Working Correctly?
Check hardness of water leaving Check hardness of water leaving
softener. Good if below 2 ppmsoftener. Good if below 2 ppm
Check amount of treated water Check amount of treated water
between regeneration – to determine between regeneration – to determine
regeneration cycles (in days)regeneration cycles (in days)
MOHD IKHSAN YAACOB
Brining
45~60 min
Slow Rinse
20~25 mins
Fast Rinse
45~60 mins
Backwash
Until clear water
What if softener is exhausted What if softener is exhausted
and high hardness breakthrough?and high hardness breakthrough?
MOHD IKHSAN YAACOB
Purpose Of BackwashPurpose Of Backwash
Remove mud, sand, dirt and broken resin Remove mud, sand, dirt and broken resin
beadsbeads
Dirt and broken resin beads must reach Dirt and broken resin beads must reach
top of water distribution headertop of water distribution header
A successful backwashA successful backwash
50% expansion of resin bead50% expansion of resin bead
10~20 minutes10~20 minutes
Clear waterClear water
MOHD IKHSAN YAACOB
Purpose Of BackwashPurpose Of Backwash
SOFTENER-BriningSOFTENER-Brining
Remove hardness ions from resin beadsRemove hardness ions from resin beads
Replenish sodium ions on resinReplenish sodium ions on resin
Must be enough salt to force calcium & magnesium off Must be enough salt to force calcium & magnesium off
the resin SOFTENER-Regenerationthe resin SOFTENER-Regeneration
A successful regenerationA successful regeneration
Use 1kg of salts/ 5liters of resinUse 1kg of salts/ 5liters of resin
Prepare brine solution concentration of 25~27% by Prepare brine solution concentration of 25~27% by
weight in brine tank stirrerweight in brine tank stirrer
Has at least brine solution concentration 8% by weight Has at least brine solution concentration 8% by weight
after softener eductorafter softener eductor
Maintain a brine concentration at 8% by weight >30 Maintain a brine concentration at 8% by weight >30
minutes to fluidized resin bedminutes to fluidized resin bed
MOHD IKHSAN YAACOB
Purpose Of BackwashPurpose Of Backwash
SOFTENER-Slow rinseSOFTENER-Slow rinse
Push salt all the way through the softenerPush salt all the way through the softener
Is at the same rate as generation for 20~25 minutesIs at the same rate as generation for 20~25 minutes
SOFTENER- Fast RinseSOFTENER- Fast Rinse
Remove excess salt from the softener before it goes Remove excess salt from the softener before it goes
back on serviceback on service
Uses the same flow rate at which the softener Uses the same flow rate at which the softener
operatesoperates
MOHD IKHSAN YAACOB
ELUTION STUDYELUTION STUDY
REGENERATION PROFILEREGENERATION PROFILE
0
10
20
30
Salometer
Degree
10203040506070
Regeneration
Time
Regeneration
MOHD IKHSAN YAACOB
How do you determine the How do you determine the
condition of the resincondition of the resin
MOHD IKHSAN YAACOB
Poor control and Poor control and
monitoring of softenermonitoring of softener
MOHD IKHSAN YAACOB
Poor control and monitoring of Poor control and monitoring of
softener: SCALEsoftener: SCALE
MOHD IKHSAN YAACOB
DEAERATORDEAERATOR
MOHD IKHSAN YAACOB
DEAERATORDEAERATOR
REMOVING GAS FROM WATERREMOVING GAS FROM WATER
Dissolved gases present in boiler waterDissolved gases present in boiler water
OxygenOxygen
Carbon dioxideCarbon dioxide
They are corrosive and must be They are corrosive and must be
removed before boiler useremoved before boiler use
DEAERATOR is used to removed this DEAERATOR is used to removed this
dissolved gases by achieving water dissolved gases by achieving water
boiling pointboiling point
MOHD IKHSAN YAACOB
DEAERATORDEAERATOR
Solubility of Oxygen in Pure Solubility of Oxygen in Pure
WaterWater
0
4
8
12
16
20
24
28
Temperature C
O
x
y
g
e
n
,
MOHD IKHSAN YAACOB
DEAERATORDEAERATOR
TWO TYPES OF DEAERATORTWO TYPES OF DEAERATOR
1.1.PRESSURE DEAERATORPRESSURE DEAERATOR
2.2.VACUUM DEAERATORVACUUM DEAERATOR
MOHD IKHSAN YAACOB
PRESSURE DEAERATORPRESSURE DEAERATOR
Water
InletVent
To
atmosphere
Water Outlet
Steam
Inlet
MOHD IKHSAN YAACOB
MOHD IKHSAN YAACOB
PRESSURE DEAERATORPRESSURE DEAERATOR
Usually used in power plant to remove Usually used in power plant to remove
OO
22 in feed water in feed water
Water is atomized, steam scrubbing and Water is atomized, steam scrubbing and
venting of gasesventing of gases
Operate at 5psig, 100~105OCOperate at 5psig, 100~105OC
OO
22 can be reduced to 0.07~0.04ppm can be reduced to 0.07~0.04ppm
MOHD IKHSAN YAACOB
VACUUM DEAERATORVACUUM DEAERATOR
Extraction pump
From
Feed Water
Tank
Steam
Deaerated
Water
-550mmHg Vacuum
Boiling Point 70
O
C
MOHD IKHSAN YAACOB
VACUUM DEAERATORVACUUM DEAERATOR
OO
2 2 and COand CO
22 is removed by creating is removed by creating
vacuum pressurevacuum pressure
In this case water boiling point is In this case water boiling point is
loweredlowered
Pressure -550mmHg, coupled with water Pressure -550mmHg, coupled with water
temperature between 60temperature between 60
OO
~70~70
OO
CC
Decrease solubility of dissolved gases at Decrease solubility of dissolved gases at
boiling pointboiling point
MOHD IKHSAN YAACOB
VACUUM DEAERATORVACUUM DEAERATOR
Vacuum is created using steam ejector Vacuum is created using steam ejector
(Venturi effect with high kinetic head(Venturi effect with high kinetic head
OO
22 can be reduced to 0.2~0.5 ppm can be reduced to 0.2~0.5 ppm
Have to prevent air in leakage into the Have to prevent air in leakage into the
system through pump, seals, valve, system through pump, seals, valve,
fittings, flanges etc.fittings, flanges etc.
Water level must be below the water Water level must be below the water
sprayer nozzles for atomizationsprayer nozzles for atomization
MOHD IKHSAN YAACOB
Poor Control & Monitoring of De-Poor Control & Monitoring of De-
aerator will results into OXYGEN aerator will results into OXYGEN
PITTINGPITTING
MOHD IKHSAN YAACOB
BOILER INTERNAL BOILER INTERNAL
TREATMENTTREATMENT
MOHD IKHSAN YAACOB
Circulation in A Water Tube Circulation in A Water Tube
BoilerBoiler
Steam
Drum
Mud
Drum
D
o
w
n
c
o
m
e
r
s
R
i
s
e
r
s
Hot
Gase
s
Fire
Box
Mud
Drum
Super
Heater
Header
MOHD IKHSAN YAACOB
Steam
Drum
Down
comers
Risers
Bottom Side Wall Tube Header
Main Steam
Range
Saturated Steam
Superheated
Steam
Top
Side Wall
Tube Header
Typical Water/Steam
Flow Diagram of a Fraser
Water Tube Boiler
Super Heater
Header
MOHD IKHSAN YAACOB
BOILER WATER BOILER WATER
TREATMENTTREATMENT
THREE MAJOR PROBLEMS IN BOILERTHREE MAJOR PROBLEMS IN BOILER
CorrosionCorrosion
Scale and depositionScale and deposition
CarryoverCarryover
THE PURPOSE OF BOILER WATER THE PURPOSE OF BOILER WATER
TREATMENTTREATMENT
To prevent corrosionTo prevent corrosion
To prevent scale and depositionTo prevent scale and deposition
To prevent carryoverTo prevent carryover
MOHD IKHSAN YAACOB
ROOT CAUSE OF BOILER ROOT CAUSE OF BOILER
WATER PROBLEMSWATER PROBLEMS
Poor water qualityPoor water quality
Hardness, TDS, pH, Silica, Iron, etcHardness, TDS, pH, Silica, Iron, etc
Poor external treatmentPoor external treatment
Pre-treatment i.e. Clarification, Filter, Pre-treatment i.e. Clarification, Filter,
Softener and De-aerationSoftener and De-aeration
Poor internal treatmentPoor internal treatment
Scale and deposit Control, Corrosion Scale and deposit Control, Corrosion
prevention, anti foamingprevention, anti foaming
MOHD IKHSAN YAACOB
CORROSIONCORROSION
Corrosion causeCorrosion cause
Oxygen and low pH is the main culpritOxygen and low pH is the main culprit
Deposition that cause underneath corrosionDeposition that cause underneath corrosion
MOHD IKHSAN YAACOB
CORROSIONCORROSION
IMPACTIMPACT
Deterioration of boiler metal/tube punctureDeterioration of boiler metal/tube puncture
High repair costHigh repair cost
Unscheduled shutdownUnscheduled shutdown
PREVENTIONPREVENTION
Remove dissolved gases (ORemove dissolved gases (O
22 and CO and CO
22) by deaerator before ) by deaerator before
entering boilerentering boiler
Maintain alkaline pH in boiler waterMaintain alkaline pH in boiler water
Use oxygen scavenger to remove residual OUse oxygen scavenger to remove residual O
22 and maintain and maintain
sufficient reserve in boiler watersufficient reserve in boiler water
Keep TDS within operating limitsKeep TDS within operating limits
Proper wet storage procedure when boiler will be idle for Proper wet storage procedure when boiler will be idle for
long periodlong period
MOHD IKHSAN YAACOB
MOHD IKHSAN YAACOB
SCALESCALE
SCALE CAUSESCALE CAUSE
Calcium, magnesium, sulfate, silica, soluble iron, aluminium form Calcium, magnesium, sulfate, silica, soluble iron, aluminium form
precipitates (Over saturation)precipitates (Over saturation)
IMPACTIMPACT
Scale form insulator film affecting heat transfer efficiency.Scale form insulator film affecting heat transfer efficiency.
Tube failure from overheatingTube failure from overheating
Underneath deposits corrosionUnderneath deposits corrosion
Deposits plug tubes causing starvation and subsequently Deposits plug tubes causing starvation and subsequently
overheatoverheat
Take long time for cleaningTake long time for cleaning
Might need acid cleaning, depends on scaleMight need acid cleaning, depends on scale
Productivity downedProductivity downed
Mill profitability downedMill profitability downed
MOHD IKHSAN YAACOB
SCALESCALE
PREVENT SCALINGPREVENT SCALING
Minimize hardness in softener water(0~2 ppm)Minimize hardness in softener water(0~2 ppm)
Maintain recommended Silica levelMaintain recommended Silica level
Maintain suspended solids/ turbidity in feed Maintain suspended solids/ turbidity in feed
water <3 NTUwater <3 NTU
Keep minimum Aluminum in feed water<0.3ppmKeep minimum Aluminum in feed water<0.3ppm
Minimized the amount of iron in feed water < Minimized the amount of iron in feed water <
0.3ppm0.3ppm
Maintain good blow down frequency over TDS Maintain good blow down frequency over TDS
level <2000ppmlevel <2000ppm
MOHD IKHSAN YAACOB
SCALESCALE
MOHD IKHSAN YAACOB
CARRYOVERCARRYOVER
WHAT IS CARRY WHAT IS CARRY
OVEROVER
Boiler water carried Boiler water carried
into steaminto steam
CAUSE BYCAUSE BY
Foaming (Chemical)Foaming (Chemical)
Misting (Operational)Misting (Operational)
Priming (Operational)Priming (Operational)
MOHD IKHSAN YAACOB
CARRYOVERCARRYOVER
WHAT ARE THE CONSEQUENCESWHAT ARE THE CONSEQUENCES
Deposits in superheated tubes-tube burstDeposits in superheated tubes-tube burst
Deposits in turbine blades-Efficiency droppedDeposits in turbine blades-Efficiency dropped
Turbine erosionTurbine erosion
PREVENTIONPREVENTION
Use anti foam if cause by foamingUse anti foam if cause by foaming
Do not run boiler at high water levelDo not run boiler at high water level
Do not overload boilerDo not overload boiler
Control dissolved solids levelControl dissolved solids level
Avoid oil contaminationAvoid oil contamination
MOHD IKHSAN YAACOB
BOILER INTERNAL BOILER INTERNAL
TREATMENTTREATMENT
Sulfite Oxygen ScavengerSulfite Oxygen Scavenger
Prevent pitting corrosionPrevent pitting corrosion
Catalyzed: React with O2 500 times faster Catalyzed: React with O2 500 times faster
than ordinary sulfitethan ordinary sulfite
Maintained reserve at 30~50 ppmMaintained reserve at 30~50 ppm
Low sulfiteLow sulfite
High DO in feedwaterHigh DO in feedwater
Boile may have corrosion problemBoile may have corrosion problem
High SulfiteHigh Sulfite
High treatment costHigh treatment cost
MOHD IKHSAN YAACOB
BOILER INTERNAL BOILER INTERNAL
TREATMENTTREATMENT
OrthophosphateOrthophosphate
Hardness inhibitorHardness inhibitor
Form Calcium HydroPatixe (less Adhesive Sludge) Form Calcium HydroPatixe (less Adhesive Sludge)
before it is removed through blow downbefore it is removed through blow down
Below range ~ No protection on hardness in leakageBelow range ~ No protection on hardness in leakage
Maintain 30~80 as reserveMaintain 30~80 as reserve
Low PO4Low PO4
High hardness in feed waterHigh hardness in feed water
Boiler may have scale problemBoiler may have scale problem
High PO4High PO4
High treatment costHigh treatment cost
MOHD IKHSAN YAACOB
BOILER INTERNAL BOILER INTERNAL
TREATMENTTREATMENT
Alkalinity BoosterAlkalinity Booster
pH Maintained at 10.5 ~ 11.5
P-Alkalinity maintained at 350~800 ppm
for boiler pressure <350psi
Dose depend on feed water M-Alkalinity
& Silica level
Maintain Silica to Alkalinity ratio 1:5
Important in preventing corrosion and
scale especially silicate deposit.
MOHD IKHSAN YAACOB
BOILER INTERNAL BOILER INTERNAL
TREATMENTTREATMENT
Scale inhibitor or dispersantScale inhibitor or dispersant
Synthetic polymerSynthetic polymer
Keep the hardness solubilization in bulk Keep the hardness solubilization in bulk
waterwater
Disperse precipitates and keep the Disperse precipitates and keep the
sludge suspension form in bulksludge suspension form in bulk
Low dose ~Deposits or Scale formationLow dose ~Deposits or Scale formation
MOHD IKHSAN YAACOB
Control specificationsControl specifications
Total Total
hardnesshardness
(ppm)(ppm)
Total ironTotal iron
(ppm)(ppm)
pHpH
M-M-
alkalinityalkalinity
(ppm)(ppm)
Softened Softened
waterwater
0~2 0~2 <0.3<0.3
Boiler Boiler
feed feed
waterwater
0~20~2 <0.3<0.3 7.0~7.57.0~7.5 25~3525~35