CONDENSATE CHEMISTRY
DISCUSS
MUHAMMAD AWAIS
INTRODUCTION
Boiler protection against corrosion and fouling is an ongoing issue for thermal power plants.
This may have significant impact on plant’s overall performance and availability.
Various damage mechanisms observed in Boiler tubes, are due, to their water/steam cycles or to
operational aspects including inadequate water chemistry monitoring and control.
Basic chemistry control to reduce contaminants in the boiler water, is provided by blowdown of
the boiler and good feedwater control chemistry, including make-up water.
ONCE THROUGH BOILERS
In these boilers, the entire quantity of incoming feed water is evaporated in the tube and there is
no drum to contain and concentrate the solids entering the circuit. these boilers therefore require
water of a high purity and boiler water is treated with all volatile chemicals like ammonia and
morpholine.
CONTENTS
Sources of CO2
Dissolved Oxygen
CO2 SOURCES
Breakdown of feed water Bi-Carbonate and Carbonate alkalinity in the Boiler
Carbon dioxide not harmful until it dissolves in condensate and later forms carbonic acid
Small quantity of Carbonic Acid can significantly lower condensate pH, and increase its
corrosivity upon ferrous metals.
CO2 goes along with steam from boiler and when steam condenses CO2 dissolves in condensate
forming carbonic acid which attacks metal
CO2(g) ⇌ CO2(aq)
CO2(aq) + H2O ⇌ H2CO3 (Carbonic Acid)
H2CO3 + H2O ⇌ HCO3− (Bi-carbonate ion) + H3O+
HCO3− + H2O ⇌ CO32− (Carbonate ion) + H3O+
Carbonate + Bi-carbonate ion = Anions Alkalinity
• The presence of an alkalizing agent, such as ammonia, makes the situation even more complex,
as it reacts with the carbonic acid and hydrogen carbonate and pulls the equilibria towards the
hydrogen carbonate and carbonate species, respectively. that means even more CO2 is absorbed
in order to form the ionized species.
• 2 H2O ⇌ OH− + H3O+
• NH3(aq) + H2O ⇌ NH4+ +OH−
• Fraction of CO2 present as the aqueous species dependent on temperature and feedwater pH
(alkalizing with NH3).
You can clearly observe level of 25% present as aqueous CO2 is reached
at ~120 °c at pH 9.1,
at ~130 °c at pH 9.3,
at ~145 °c at pH 9.6, and
at ~155 °c at pH 9.8.
CO2 Behaviour in Condensate
CO2 is a non-condensable gas.
At the boiling point, the solubility of the gas in water is extremely low. The solubility of the
CO2 is actually lower in the condensate than it is in the steam.
The solubility of CO2 increases dramatically as the condensate temperature falls below 100 C.
The highest CO2 concentration normally occurs just above the condensate water level. if there is
an area where condensation is occurring and running down pipes or the sides of vessels, the CO2
concentration will be very high and the pH will be about 5.3-5.5 in that location creating high
corrosion rates.
SOURCES OF OXYGEN
Leakage of Oxygen into Boiler feed Pumps
Oxygen present in most makeup waters
Major sources of Oxygen is leakage in condensate system (Condenser drains, Condensate Pump seals, Condensate
polisher (possibly when shutdown), condenser wall cracks, condenser instrumentation and connections )
Prime areas for air to enter a system
Vented services tanks, packing glands of vacuum pumps
Vacuum Breakers
Turbine gland steam condenser
LOCATIONS FOR DISSOLVED OXYGEN
MEASUREMENT
• Continuous analysis of dissolved oxygen is normally made on the boiler feed water, de-aerator
outlet, and condensate discharge.
