Eco-Friendly Boiler Water Treatment: Eloguard Conditioning

ECO FRIENDLY TECHNOLOGY
WELCOME TO THE
DISCUSSION ON
ELOGUARD TREATMENT
FOR BOILER FEED
WATER
MONNET ISPAT 21 10 11

ELOF HANSSON AB
A multinational
organization
engaged in
global trading
CARINGFOROURFUTUREGENERATIONS

ELOGUARD
An Eco Friendly
multicomponent polyamine
formulation
for
Boiler Feed Water
Conditioning
OCT 2011

A brief Recap
A brief note water treatment/chemistry
A brief note on failures
A brief note on metals used in the boiler
A brief note on Feed water/
conventional treatment
Certain drawbacks faced with
conventional treatment

ELOGUARD
What is Eloguard?
Fundamentals of the Eloguard treatment
Uniqueness of the treatment
How does it differ from PO4 treatment?
Why should we go for Eloguard
treatment – Benefits
Dosing techniques
Regulation of Eloguard treatment
Water Parameters with EL treatment
Eloguard users – notable references
Savings to the user – Eloguard treatment

What causes tube failues?
Corrosion
Erosion
Over pressure & heating
Creep (Deforamtion resulted by continuaos long term
stress at an elevated temperature)
Creep – longitude
Fatigue (Stress rupture)
Stress corrosion (Resisting force offered by the
metal; Fatigue - transverse)

Temperature limits
CS – 425 deg C (Eco)
LAS – 525
T11 – 151 (Su.h.coil)
T22 – 585 (Su.h.coil)Corrosion
At about 20 % metal loss, the metal has
to be replaced; if thickness down by
1/3, tube has to be replaced

Failure – Primary factor
Heat flux, Poor circulation etc
Nucleate boiling (steam bubble leave the
place immediately)
Film boiling (In case of steam bubble does
not escape, the bubble together forms film) –
DNB
DNB leads to caustic gauging

Failure Mechanism
Thin lip bulging – Short
term overheating
Thick lip (fish mouth
opening ) – Long term over
heating

In case of failure of super heater
coils
To check the fuel moisture
To check the temperature of flue
gas and as well as the metal
To check attemperation process
Desired temp at su h zone - ?

Boiler – Good example of a welded
device – About 70,000 to 1L
welding is done
(40 % done at manufacturing site-
60 % done at site)
Boiler metal Composition:
75 % CS, 20 % LAS, 3 % ½Mo LAS
2 % 347 ASS (Austentic)

Main causes for Erosion
When flue gae changes its
direcion
When flue gas temperature
reduces than the desired temp
Frequesnt soot blowing
Air ingress
Excess primary air

Importance of welding
Slag or porosity – Radiography
Selection of electrodes
Weld is inferior to parent metal; Avoid
excess welding
Use of excessive current induce HAZ
Pre/Post heating importance
In case of TIG weldiing entrapment of TIG
particle into weld - Leads to galvanic
corrosion and leads to pin hole puncture

Dew point corrosion
Varies with respect SO2 concentration
 Importance of Blower : Primary air (40 %) –
To initiate combustion, Secondary air (60 %)
– to complete the combustion
If primary air is more than the requirement:
S + O2 – SO2
2SO2 + O2 – SO3
SO3 + H2O – H2SO4

Importance ofwater
treatment
 Just as a majority of health problems arise due to the
intake of contaminated water, major problems that occur
in boilers are due to contaminated water/poor water
treatment
 Just as doctors attend to sick patients to make them
healthy, we, the engineers – Industrial doctors set right
the boilers to ensure maximum efficiency
TEAM WORK DIVIDES THE TASKS AND DOUBLES THE
SUCCESSES

OFTEN OVERLOOKED
COSTS
 LOSSES DUE TO BLOW DOWN
 CHEMICAL CLEANING COSTS
 REPLACEMENT COSTS
 COSTS DUE TO PRODUCTION LOSS
But Sciencedoes nothavemercyon us.
An average man like me prays god don’t give
Me problems. But a great men like you prey
God give me power to face the problems

WHY TREAT BOILER FEED WATER
TO ATTAIN
 Enhanced Life of Plant & Machinery
 Enhanced Thermal Efficiency
 Enhanced Plant Availability
Don’t expect the system be a perfect one; but make it to
become a perfect System

ELOF HANSSON
IMPORTANT FACTORS
Control of Corrosion
Control of Scales/Deposits
Control of Carryover

Oxygen corrosion
 METAL LOSS,PITTING
 LOSS OF PROTECTECTIVE OXIDE
FILM
 DESIRED PROTECTIVE FILM IN
BOILER IS MAGNETIC IRON OXIDE,
Fe3O4. OXYGEN DESTROYS THE
PROTECTIVE OXIDE FILM)
 Fe3O4 + O2 6 Fe 2O3

Fe2+
+ 2
OH-
Fe
+ 2 e
-
Fe(OH)2
H2O
OH-
+
H+
2H+
H2
2 e
+
With dissolved oxygen :
4 e-
+ O2 + 2 H2O 4 OH-
OH-
2 e -
Anodic reaction
Cathodic reaction

Fe++
O2
O2
O2
Steel metal
Oxygen does not have access to
the surface under the deposit:
it creates an anodic area.
The cathodic reaction
occurs where oxygen gets
access to the surface.
e-
e-
e-
OH-
OH-
Corrosion by oxygen
BKG Water Solutions - 12.2009

Corrosion by oxygen
in water-tube boiler

CORROSION - CARBON
DIOXIDE
 Sources –breakdown of
bicarbonates, organics, air ingress
etc.
 Causes low pH in after boiler section
 Uniform loss of metal

 Bicarbonates are decomposed into Carbonates by heat
with side-production of CO2
2 NaHCO3  Na2CO3 + CO2 + H2O
 Carbonates are hydrolyzed into Caustic Soda with
production of CO2
Na2CO3 + H2O  2 NaOH + CO2
Formation of carbonic acid
CO2 + H2O  H2CO3: condensates become acidic
Acidic corrosion
in condensate lines

Caustic embitterment
 In case of excess caustic, caustic
got trapped in the tubes – water gets
evaporated; concentration of caustic
increases.
 Crack happens - transverse
direction
4NaOH + Fe3O4 - Na2Fe3O3 + 2NaFe O2 + NaOH

SCALE
 Scale is generally very hard and difficult to
remove. Boiler scale results from the growth of
crystals on tube surfaces and is most severe in
areas where maximum heat transfer occurs.
Riser tubes are most susceptible.
 Scale build-up is usually associated with
compounds which become less soluble as
temperature increases, such as calcium
carbonate or calcium phosphate.
 As a thumb rule 1 mm scale in the heating
coils of a boiler increases the energy cost by
15 %. Acidic cleaning necessary if scale is
400g/m2

SCALE
 Calcium (Ca) scale– Calcium reacts with other
anions to form calcium sulphate, calcium
bicarbonate, calcium carbonate, etc. During
evaporation, these chemicals adhere to boiler
tube walls forming scale. Scale leads to a
decreased heat transfer and can result in tube
failure due to higher tube metal temperatures.
Buildup of scale also clogs piping systems and
can cause control valves and safety valves to
stick.
 Magnesium (Mg) scale – Same issues as with
calcium.
 Thermal conductivity – CaHCO3:metal – 0.01 : 40

Control of Carryover
:
- Volatile Carry over (Sodium, Silica,
salts)
-Mechanical entrainment
- REDUCED POWER GENERATION
-INCREASED COST OF CLEANING
-LOSS OF PRODUCTION

Feed Water Conditioning
Conventional Approach
 Trusts passive magnetite layer for protection
 Uses phosphates for deposit/ scale control.
 Multiple chemicals for corrosion, scale & deposit control
Oxygen scavengers - Sulphite, Hydrazine
Sludge conditioners/Antiscalants - Phosphates
Dispersants - Polymers
pH boosters - Caustic, Ammonia,
Amines

Phosphate Chemistry Control
 Phosphate Salts (a mixture of mono &
trisodium phosphate) are added to the water
to provide “Buffering Capacity” to the water.
In other words to prevent acidic or caustic
conditions from occurring.
 The phosphate salts also convert scale-
forming impurities, such as calcium and
magnesium, to precipitates which may then
be removed by Blow down.

CONVENTIONAL TREATMENTS
PREBOILER SECTION BOILER SECTION
CONDENSATE SECTION
Corrosion Control Caustic /Ammonia
Fouling Control
None
Pitting Control
None
Pump Corrosion None
Corrosion Control TSP / Caustic
Scaling Control
Hydrazine/Sulphite
Pitting Control
TSP / Caustic
Carry over / Foaming None
Corrosion Control CHA / NH3/
Morpholine
Deposits
None
Pitting Control
None
CPU Fouling None
Multiple
Chemicals

DRAWBACKS OF CONVENTIONAL APPROACH
 Higher blow down - Addition of Inorganic salts like TSP
Magnetite layer - Thick & brittle
Hydrazine - break down to NH3 beyond 235 deg C
Ammonia corrodes Copper metallurgy
Precipitated Ca/Mg Hydroxyapatite sludge can form hard
deposits
Requires tight control & monitoring
 No protection against O2 corrosion in condensate system

ELOGUARD
 The one stop solution for boiler feed
water treatment; A complete solution to
overcome corrosion, scaling and carry
over problems

Why go for Eloguard treatment ?
 Single product, cost effective
replacement. Easy to handle
 Energy savings: No TDS addition from
Eloguard. Reduction in blow down.
Savings in D M Water
 Easy to use : Only LP dosing and hence
easier to dose, monitor and control.
Energy costs being incurred for the HP
dosing system can be reduced.
 Updating knowledge – because today’s news
paper will become tomorrow’s waste paper.

 Improved Silica Management :
Sodium free treatment -
Increased Silica tolerance due to
Sodium-free treatment
 Improved heat transfer due to
“Drop wise condensation” on the
nonstick film surface
 Cleaner boiler/TG and increases
TG efficiency
 Safe, non-toxic and non-
carcinogenic product
Why go for Eloguard treatment?

WHAT IS ELOGUARD ?
 Multicomponent aliphatic polyamine
based liquid formulation (100 %
organic)
 Single product replacement for
Sludge conditioner, antiscalent and
oxygen scavenger
 Provides fool proof protection to the
complete boiler/Turbine condensate
system.

ELOGUARD PROGRAM
An extension of the filming barrier-synergistic
multicomponent approach
A well established product based on modern
technology
 Fully organic single formulation
- multiple components
- multiple functions
Feed Water Conditioning
Modern Filming Barrier approach SINGLE
CHEMICA
L
HP DOSING
SYSTEM
ELLIMINATE
D

Eloguard – Functional Constituents
Filming Polyamines - Impenetrable film barrier
Alkalizing & Neutralizing - Low pH protection
amines
Complexing Agents - Binds Silica - water phase
Dispersing Agents - Arrests crystal growth
Scale control Agents - Distorts crystal structure
Deoxygenating Agents - Secondary protection

Filming Polyamines - Properties
 The hydrophilic amine - an affinity to
metals leads to amine adsorption
(chemisorption).
 They form an adhesive,
monomolecular (with thickness of
about 10 Angstrom) protective amine
film on water exposed surfaces with
the N-groups towards the metal.
 The hydrophobic hydrocarbon chains
prevent wetting of the surfaces

Filming Polyamines - Properties
 Amines extract the adsorbed water from the
metal surface and occupy the respective
vacant sites forming an inhibitor film.
 Filming amine - dehydrating agents and film-
forming organic compounds.
 Dehydrating effect is attributed to H
bonding, While chemisorption involves
electron pair donation from the adsorption-
active functional group (N) to the electron-
depleted dehydrated metal surface.

Protected pipe
in water tube boiler

Arrangement of Polyamine molecules
c
s
o
r
a
b
b
c
o
ab = 5.28 Ang.
ac = 4.57 Ang.
ao = 3.04 Ang.
or = 0.40 Ang
Area of circle (o)
= 0.50 Sq.Ang
ab = 5.28 Ang.
ac = 7.48 ang.
rs = 2.20 Ang.
area of circle (o)
= 3.80 Sq.Ang.
a
r
Metal Surface
Active polar
group
Hydrophobic
Carbon Chain

NEUTRALIZING AMINES
 Prevent after-boiler corrosion
caused by low pH. Volatises into
the steam and are distributed
throughout the system.
 Modern programs use more than
two types of neutralizing amines
to ensure protection of the
complete system

Polymers /DISPERSANTS
 Ensure that impurities are well
dispersed and prevent crystalline
growth to reduce scale & deposits.
 Polymers can distort the crystal
growth of the scale by disrupting the
crystalline lattice which causes the
hard dense adherent nature of scales.

Eloguard treatment Conventional (phosphate
based)
treatment
Liquid and easy to handle Combination of both liquid and
solid
100 % organic based chemical; No
sodium or any other inorganic
Inorganic based
Only LP (Low pressure) dosing, As the
HP dosing is not required, the energy
costs being incurred for the HP dosing
system can be saved
Dosing has to be done at both
LP
And HP (high pressure) side
Protection is given to Pre boiler, boiler
and post boiler section
Reactions are only pertaining to
the boiler
It is sufficient to maintain the boiler
water in the range of 8.5 – 9
Boiler water pH has to be
In the range of 9.5 – 10.5
Eloguard and conventional treatment –
A Comparison

ELOGUARD BENEFITS – MONEY
 LESS BLOW DOWN – REDUCED FUEL, WATER.
 LESS CHEMICAL CLEANING
 LESS REPLACEMENTS AND MAINTENANCE
 LESS BREAKDOWNS – MORE PRODUCTION
 Whateverthe treatment - Neverbe proud norbe depressed for what u
are and the position uhold. Becauseafter a game ofchess,the king
and soldiers go into the same box.

 Sodium free product, enhances silica tolerance
 Organic dispersants bind silica to water phase
 Amine film on wetted low pressure side of turbine
prevents Silicate deposits
0
5
10
15
20
25
0.1 0.5 0.9 1.3 1.7 2.1 2.5 2.9 3.3
Silica-Boiler Water (ppm)
Silica-Steam
(ppb)
ELOGUARD BENEFITS - SILICA
Conventional
Eloguard

ELOGUARD BENEFITS – FUEL & WATER SAVINGS
 Fully organic product - results in reduced blow down
 Saves makeup DM water
Before After
0
1
2
3
4
5
6
1 3 5 7 9 11 13 15 17 19 21 23 25
Days
Blow
down
(%)
.

Eloguard-Dosing & Monitoring
Where to dose
- LP dosing at feed pump suction or
at deaerator storage/feed tank
- continuous dosing based on make
up water flow
DEAERATOR
FEED TANK
DEAERATION
STEAM
DEAERATED
WATER
VENT
ELOGUARD
Control & monitoring
- Simple check of return condensate pH,( > 8.3)
- Additional checks are by visual examination
of blow down water & chemical analysis of feed water,
boiler water, steam and condensate

Industries Initial dosage (for
about 10 days)
Regular dosage
Sugar Mills using
only exhaust
condensate and DM
water
20 – 30 ppm
(make up water)
Around 15 - 20
ppm (make up DM
water)
Sugar mills using
vapour condensate
5 ppm (Feed
water)
3.5 – 4 ppm (Feed
water)
Bio mass power
Plant
40 ppm (make up
water)
20 ppm (make up
water)
Paper mill, Refinery 40 ppm (make up
water)
12 - 20 ppm (make
up water)
Integrated pulp and
paper mill
20 ppm (make up
water)
10 – 12 ppm (make
up water)
Eloguard - Dosage

Dosage Calculation
 Avg. steam generation – 100 TPH
 Make up water – 10 % = 10 TPH
 Make up water consumption – 140 TPH
 Eloguard, 15 ppm = 15 X 140/1000 kg
 Eloguard consumption = 2
kg/day

pH :
Feed – 8.6 to 9.2, Drum, Steam and Condensate – 8.5 to 9
Conductivity :
Feed, Steam and condensate - < 10 µS, Drum – < 30 ppm TDS
Silica:
Feed, Steam and condensate - < 0.02 ppm
Drum – This is to be monitored by the control of blow down
in order to maintain the steam silica < 0.02 ppm
Parameters – Eloguard treatment

Regulation of Elogaurd dosage
By monitoring the pH
of the return
condensate. The
dosage should be
adequate to ensure
a turbine/Exhaust
condensate pH of
8.3 – 8.8

Cost of the treatment (66 bar,
65 TPH, 200 TPD make up)
 Dosage : 25 ppm on
make up – About 5
kg/day
 Cost (approximate) –
Rs 180/ kg
 Cost of the treatment –
Rs. 900/- per day.

Cost Benefit Analysis (for a
typical 65 bar pressure, 60 TPH
 Savings in blow down by
eliminating TSP (0.8 kg @ 60
ppm TDS) – 13 TPD
 Heat Energy recovered
(Enthalpy) – Equivalent to
steam = 3874/807 = 4.8 TPD
 Savings @ Rs 450 per t of
steam = Rs. 2160 per day.

Does not increase the salinity within the boiler
Avoids chemical carry-over into
the steam system
PROCESS
EFFICIENCY
Benefits for your Boiler
Treatment


Dosing proportional to the make-up water instead
of feed water
Reduces the volume and cost of
dosing
COST
REDUCTION
Treatment


Lower dosing and no hydrazine, sulphites, phosphates or nitrites
Non-toxic and less blow down
treatment before
discharging to effluent
HEALTH &
ENVIRONMENT
Treatment


Minimizes effluent disposal charges and
environmental impact
HEALTH &
ENVIRONMENT
Treatment


Select Industry References
NTPC- SAIL, Rourkela Power 100 bar
BMM ISPAT, Hospet Power 110 bar
Rourkela Steel Plant Steel 65 bar
Chennai Petroleum Corp. Oil refinery 50 bar
Hindustan Petroleum Corp Oil Refinery 38 bar
Rama Newsprint New sprint 84 bar
SCM, Simbhaoli Sugars Sugar 87 bar
Satyakala Edible oil 67 bar
Tamil Nadu Newsprint Paper 64 bar
Sarda Energy Power 64 bar
Nahar Enterprises Textile 87 bar

WHERE WE STAND TODAY IN
OFFERING FILM BARRIER
SOLUTION
MORE THAN 250 BOILERS USE ELOGUARD
OVER 175 SATISFIED CUSTOMERS
Over 40 customers using Eloguard > 10 years
65 BOILERS WITH PRESSURE > 60 bar
Recommended by CII

Case study 1
Temporary (8 hrs) breakdown of deaerator -
high O2 up to 2000 ppb
No increase in iron levels in blow down was found,
confirming the protection by polyamine film against
oxygen attack.

Case study 2
Leakage in Turbine condenser tubes where sea
water (high hardness) is used
Only soft & easily removable deposits were found, confirming the
non sticky nature of the film and action of dispersants

Case study 3
Rupture of diaphragm in DM plant during
acid regeneration
Very low pH (< 5) of boiler water. No increase in iron levels
in blow down water was found, confirming the protection by
Polyamine film in low pH conditions also

Case study 4
Frequent turbine deposits - low power generation &
frequent cleaning
Reduction in frequency of cleaning and improved power
generation after Eloguard introduction confirming improved steam
purity with Eloguard treatment.

Case study 5
Breakdown of on-line silica meter in 45 bar boiler
High (40 ppm) silica in the boiler water for almost a month. No
hard deposits found on the turbine blades confirming the
action of complexing agents in reducing carryover of Silica.

Eloguard Treatment – Well maintained boiler
internals in Bannari Amman Sugars, nanjangud
(67kg pressure boiler)

Visual Surface Effects using Film Forming Amine
• Qualitative boiling experiments under atmospheric pressure with immersion
heater
• Increased number of bubbles with a comparable heat flux
Increased bubble frequency and bubble detachment diameter less
Na3PO4 Treatment: pH = 10,3 Filming Amine : [FA] = 4 ppm
BKG Water Solutions, Andre de Bache, Cetamine Technology

Conclusion
 Eloguard treatment is a unique cost effective
boiler feed water treatment program and has
proved time and again to have a clear edge over
the phosphate based treatment and it has carved
a niche in boiler water treatment programs. The
same has been practically proved and
experienced by our customers at various
industrial sectors.
 Therefore, it can be concluded that the Eloguard
treatment program controls Corrosion, Scaling
and carry over, due to the film forming capacity

Thoughts of the day
Once, all villagers decided to pray for rain, on the day of prayer
all the People gathered but only one boy came with an
umbrella... THAT'S FAITH
When you throw a baby in the air, she laughs because she
knows you
will catch her... THAT'S TRUST
We plan big things for tomorrow in spite of zero knowledge of
the future or having any certainty of uncertainties. ..
THAT'S CONFIDENCE
We see the world suffering. We know there is every possibility
of same or similar things happening to us. But still we get
married??... THAT'S OVER CONFIDENCE!!

THANK YOU FOR YOUR VALUABLE
TIME AND ATTENTION AND
WE HOPE TO BE YOUR
PARTNERS IN GROWTH

Thanks for Listening
GREAT PRESENTATION???

Eco-Friendly Boiler Water Treatment: Eloguard Conditioning

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