DREW AMEROID (M) SDN. BHD.

Drew Ameroid (M) Sdn Bhd (19162-P)

Lot 304, 2nd Floor, Kompleks Penchala
50 Jalan Penchala, 46050 Petaling Jaya
Selangor Darul Ehsan, Malaysia
Tel: (603) 7781 2777/860/880 Fax: (603) 7782 6889

WATER TREATMENT

FOR

PALM OIL MILLS

TOPICAL STUDY

1. WATER TREATMENT APPLICATION

2. SOFTENER OPERATION
3. VACUUM DEAERATOR OPERATION
4. BOILER WATER TREATMENT APPLICATION
5. STUDY QUESTIONS

PREPARED BY: CV NG/L Y YAN

 1. WATER TREATMENT OPERATION

Water source is an important factor in determine the locality of the mill location.
Generally, predetermined capacity pond is made to receive water from river,
swamp, surface runoff, spring water, lake and artificial stream from the estate. As
pond is in the lower position to receive the water from various sources, it is
important to take into some consideration to maintain water quality:
1. Provide overflow to prevent stagnant water which overtime will bring about
changes in the water quality particularly the organic matter. This
contribution is from empty fruit bunch spread across the estate as natural
fertilizer, commercial fertilizer used and unknown seepage in the locality (if
any).
2. Provide gate to release sedimentation cumulated underneath especially
where river water source become muddy whenever after rain.
3. Beware of activities around the pond area which inevitable will affect the
water quality. Activities such as effluent pond (if it geography location is
above the water pond or potential seepage), seed growing, sand dredging
or other activities that can cause changes to water appearance and quality.
4. Beware of seepage from sea if the pond is near to the shoreline.
Underground water table will reduce if water replenishing is not
sustainable especially in dry weather. The symptom of sea water intrusion
is the conductivity chloride and total hardness increase in many folds.
5. Beware of sea water back flow if the river is near to the shoreline when it
is high tide and rain.
6. Aware of the effect of rain where it tend to wash along many unwanted
matters into the pond especially the suspended solids. It not only change
the water appearance and thus increase the chemical usage, it also
gradually reduce the pond depth.
7. Beware of sudden pH swing (more common in acidic range) of the water
which indicated contamination such effluent overflow or leak and other
man make cause.
8. Beware of soluble iron from underground water and man make activities
such as seed/plant growing farm (fertilizer contain iron compound) that
can cause increase in iron content in water. High iron above 0.5 ppm will
cause light brownish appearance to the water.
9. Beware of other soluble organic matter comes from animal and human
fecal matter or its degradation products, industrial waste water and
agriculture pesticides and herbicides upstream of the water source.

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Raw Water problem and Common Treatment Methods

Raw Water Problem Common Treatment Method

Bacterial contamination Chlorination or other form of
disinfection (boiling, iodine).
Fine sand, clay or other sediments Mechanical fine screen or sand
filtration.
Odor and taste other than rotten egg Activated carbon filters.
smell
Hydrogen sulfide gas Chlorination followed by sedimentation
or use an oxidation filter followed by
activated carbon filter to remove
excess chlorine.
Small amounts of dissolved iron and Softener
manganese
High amounts of dissolved iron and Oxidizing agent such as potassium
manganese permanganate or chlorine followed by
mechanical screening or sand filtration.
Suspended iron and manganese Mechanical screening or sand filtration

Hard water Softener

Acid water(pH less than 5.0) Soda ash

Alkaline water(pH greater than 9.0) Use acetic acid or white vinegar

Tannin(humid acid) Chlorination with detention tank or

special anion exchange unit
Volatile organic compounds, certain Activated carbon filter. Others include
pesticides, trihalomethanes, and radon RO or distillation.
Nitrate, heavy metals, high total RO or distillation. Nitrates can be
dissolved solids, sodium, sulfates. removed with an anion exchange unit.

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Water Treatment Operating Data

The following information is important to operate water treatment plant effectively

and sustainable desire water quality.

Water flow rate

Determine the clarifier volume at the normal operation level (overflow to the weir)
and water flow rate yearly. Calculate the retention time by dividing the clarifier
volume over the pump flow rate. He standard design retention time is 2 to 4
hours.

Practical approach to determine the water pump rate is to determine the time
required for water in the clarifier rise to within a predetermined height. The flow
rate is then calculated based on the predetermine volume over the measured
time.

Step to determine pump flow rate

Diameter of channel to channel
1. Drain the clarifier water level 2” to 4”
H below the bottom of overflow channel
while stop the water pump.
2. Mark the upper and lower point at the
overflow channel- distance of 100 mm
should be adequate.
3. Determine the diameter between the
two overflow channels and calculated
the volume.
4. Start the pump and observe the water
level, once it reached the lower marking
activate the timer and stop when it
reached the upper marking point.
5. The flow rate = volume/time

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Chemical Injection Point
It is advisable to feed the chemical as far up stream as possible from the clarifier
to allow maximum mixing time. The longer the mixing time the better coagulation
would be for flocs formation. The sequent of dosing is generally soda follow by
alum.

Record the chemical tank volume and determine chemical injection rate in L/hr.
The chemical injection rate can be determined by using the 1000 ml measuring
cylinder. Take out the suction end tubing and immersed in the cylinder fill to the
top of the say solution, start the chemical pump and record the volume drop over
time. This test must be conducted while water pump is running.

Clarification
Most of the mill use upflow type clarifier. The upward velocity of the flow in the
clarifier works contrary to the settling velocity of the suspended particles.
Referring to the following figure, the vector sum of the velocities for any given
particle is its terminal settling velocity minus the upward velocity of the flow at the
level of the particle. At high upward velocities (near the bottom of the cone),
virtually all particles and flocs are swept upward with the flow. As the cross
section of the area increases, the upward velocity of the water decreases, and
the vector sum of the velocities reaches zero; the particles stop and suspended
at the height of the cone. At this point, a particle is considered removed from the
water. Obviously, larger particles with greater settling velocities become
suspended nearer the bottom of the cone where upflow velocities are higher.
Particles whose settling velocity is exceeded by the upflow velocity at the top of
the cone are swept on upward and into the overflow of the tank.

Particles collect at position dictated by their settling velocities until a solids

blanket is formed, creating a concentrated suspension, even if the original
suspension was diluted. The creation of the solids blanket is an important part of
upflow clarification. Very small particles, which would normally swept out of the
clarifier, must first pass through the concentrated zone. In flocculating
suspensions, the chances are excellent that enmeshment in the sludge blanket
will occur so that even very small particles or flocs will be removed. Thus the
blanket acts similarly to a filter for solids removal.

The elevation of the sludge blanket in the cone is determined by the

concentration of the solids in the blanket, higher concentration resulting in a
greater rise. The concentration, and thus the elevation, of the solids blanket are
controlled by the drawing off excess sludge once the desired concentration and
height have been reached.

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 At section b-b, the upflow is equal
to the settling velocity of the
particle. The net velocity is zero,
Cylindrical and all particles with this settling
Section velocity remain suspended in the
flow at this point.

b b
Conical
Section
Upflow Settling
Velocity Velocity a a
of particles
At section a-a, the upflow
velocity exceed the settling Upflow
Settling Net
velocity of the particles. The net Velocity
Velocity Velocity
velocity of the particles is in the of particles
direction of flow, and the
particles are swept upward at
the net velocity.

-5-
Periodically to check the internal structure integrity as over time part of it might
have corroded or broken that could cause short circuiting of the separation
principle. Typical parts that corroded are ejector or upflow pipe, outer well, weir
etc/

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Coagulation

There are three forces that affecting the particle agglomeration.

i. Electrostatic rebellion due to like charge of particles (mostly negative).
ii. Van der Waals force, an attraction force, supports contact. Once the
particles overcome the energy barrier, at close distance and become
attractive, contact between particles take place.
iii. Brownian force, random movement of smaller colloids because of
molecular bombardment, may produce enough momentum for particles
to overcome the energy barrier and thus collide.

Aluminium sulfate, an inorganic coagulant, is used widely in the palm oil industry
for clarification of raw water. Aluminum sulfate ionized in water to produce SO42-
and Al3+. The Al3+ cations react with water to form a variety of aquometallic ions
and hydrogen. The last product being formed is aluminium hydroxide, Al(OH)3 ,as
following:

Al3+ + 3 H2O → Al(OH)3 + 3H+

The Al(OH)3 is in amorphous form, gelatinous flocs that are heavier than water
and settle by gravity. Colloids mat become entrapped in a floc as it is formed, or
they may become enmeshed by its sticky surface as the floc settle. The process
by which colloids are swept from suspension in this manner is known as sweep
coagulation.

Al3+ adsorbed onto the surface of the colloid where they neutralize the surface
charge. Once the surface charge has been neutralized, the ionic cloud (negative)
dissipates and the electrostatic potential disappeared so that contact occurs
freely under vander Waal and Brownian force. If more Al 3+ is formed, the charges
on the particles become reversed and the ionic cloud (positive now) and charge
rebellion take place.

As from the equation, hydrogen ion is produced which will lower the pH of the
water. Soda ash is used to raise the pH and supply the required alkalinity to form
aluminium hydroxide.

Property of Alum

• Al2(SO4)3; SG=2.710, solubility 40.5%.

• 1 ppm reduces 0.45 ppm Total Alkalinity.
• 1 ppm increases 0.16 ppm Total solids.
• 1 ppm increases 0.4 ppm CO2.
• pH range 5.5-8.0. Less restrictive as coagulant dosage increases.
• pH range 4.8-5.5 for color/organic water. Very sensitive to pH

Property of Soda

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 • Na2CO3; soda ash, solubility=35%.
• 1 ppm Soda = 0.65 ppm Total Alkalinity.
• Increase pH without significant increase in Total Alkalinity.

Note:
A. 1 ppm alum would only contribute 0.16 ppm total solid.
B. 1 ppm alum consumed 0.45 ppm total alkalinity.
C. 1 ppm also releases 0.4 ppm CO2. To much CO2 will disrupt the blanket.
Do not slug alum direct into the clarifier.
D. 1 ppm soda ash will increase 0.65 ppm total alkalinity. At equal quantity of
Alum and soda, the net effect is 0.2 ppm total alkalinity increment.
E. 1 ppm soda ash increases significantly the TDS of the treated water to the
point of almost 1 to 1 ratio.
F. If pH of the treated water is below 5.5 and alum usage is high, PAC might
be a better choice since it does not reduce pH significantly compared to
alum.

Troubleshooting of clarifier

Problem Possible Causes Suggested Action

Excessive Floc Low Density Floc Increase Flocculants Dosage
Carryover Chemical Feed Check pump settings/operation
Problem
Short circuiting Check clarifier internals
Loss of sludge bed Ensure good bed. Check the max and
min indicator pipe for comparison of
water appearance.
Excessive sludge bed Reduce bed through blowdown
Floating Floc Air entrainment Check if polymer pump is sucking air.
Also, inject the polymer below the
surface of the water.
Overfeed of polymer Reduce feed of polymer. Max of 3
ppm application.
Turbid water in Insufficient coagulant Increase feed of coagulant
centerwell feed
Overfeed of anionic Reduce feed of polymer
polymer
Excessive shearing of Reduce agitation/flow is too fast/less
floc than 2 hour retention time.
Turbid water in Improper chemical Adjust feed rates of alum and soda
centerwell addition ash.
Low sludge blanket Reduce sludge drainage to build it up
Note: Always check the water flow rate from time to time to reduce error in dosage application.

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 3. JAR TEST PROCEDURE

Prepare solution as follow:

i. 1 % Alum = 1gram alum /100 ml water
ii. 1 % Soda = 1gram soda / 100 ml water
iii. 0.1% polymer =0.1 gram / 100 ml water

Chemical Dosage Chart in ppm

Adding 1 ml of % 1000 ml raw water 500 ml raw water

Solution
1% 10 ppm 20 ppm
0.1% 1 ppm 2 ppm

Steps
1. Measure and record pH and TDS of raw water sample.
2. Select the volume of sample and record planned dosage for jar testing.
Use 3 or more jars for evaluation.
3. First to determine the optimum pH range for alum to function effectively.
Generally, the practice is to maintain a pH of 7.0. However, there may be
case where pH need to adjust to > 7.0 or < 7.0, depend on water quality,
to allow good coagulation.
4. Once suitable pH range is established, dose in different alum dosage to
determine the best effect.
5. Add the planned alum dosages into the jars at the predetermined soda
ash dosage to get the targeted pH value.
6. Turn the mixing speed to 100 rpm and allow rapid mixing for 2 minutes.
7. Reduced the speed to 30-50 rpm at the end of rapid mixing for 1-3
minutes slow mixing to allow flocculation. Do not add in polymer at this
time as the objective is to determine the optimum alum and soda ash
dosage that would yield the lowest turbidity figure.
8. At the end of the slow mixing, turn off the speed and allow the flocs to
settle.
9. Record the condition of floc in term of its size(1 = poor, 5 =excellent),
settling time and final clarity. Record the TDS also for later determine the
impact upon contribution to the treated water’s TDS.
10. Select among the jar test the two best result and fine tune the dosage by
repeating 5-9.
11. Once the final alum and soda dosages are determined. Proceed to repeat
step 5-6 with the final dosages.
12. Add in the planned dosage of polymer (0.5 ppm to 3 ppm) when the
speed is reduced to 30-50 rpm. Allow for 1-3 minutes flocculation.
13. Turn the speed off and observed the floc size, settling time and final
clarity.
14. Choose the least amount of polymer dosage that yield good result.

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Based on the jar test result, the dosage of alum, soda and polymer are
determined. Use the following equation to calculate the required chemical
quantity.

Chemical required,kg/hr= Chemical dosage, ppm pumpflowrate, m3 /hr 0.001

--------- EQ 1
Two approaches to set the chemical injection for the required dosage. For
example if:

Alum dosage from jar test = 60 ppm

Raw water pump flow = 60 m3/hr.
Chemical tank size = 250 L

Approach 1 (fixed injection rate; varies chemical dosage)

Determine the amount of alum required for 8 hours (1 shift) using EQ 1

Alum required for 8 hours = 28.8 kg say 30 kg
Set injection rate to last 8 hours = 250 L/8 hrs = 31.25 L/hr

This approach is practical for operator but need to vary chemical dosage
in the event adjustment is required.

Approach 2 (varies chemical concentration and injection rate)

Raw water pumprate, L/hr  Dosage, ppm

Injectionrate, L/hr =
10 x Chemical Concetration, %
--------- EQ2

Alum concentration in tank = 50 kg in 250 L water = 20%

Determine the injection rate from EQ 2 = 18 L/hr

This approach is more versatile as it can adjust the chemical

concentration as well as injection rate to get the right dosage. A chart can
be established to guide operator for the various adjustment required.

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Case Study 1 –WATER TREATMENT PLANT 8.6 m

Calculated Volume = 240 m3

2.7 m
Measured flow rate = 56 m3/hr
Retention time 4.3 hr-More than adequate
(This is just enough for 45 T mill throughput excluding estate)

4.5 m
Dosing System and Recommended Improvement

3 x 400 L tank
71 cm Ø x 100 cm Propose Improving Mixing
To add static mixer after the alum
Flocculant

and soda injection points to promote

Soda

Alum

mixing.

3 x Duplex
Piston pump
23 L/hr 22 L/hr 12 L/hr

To clarifier 56 m3/hr

This line is not in used

Flocculant
Soda Alum

Static Mixer
10” pipe x 1 m To clarifier
8” pipe length

A series of jar tests was conducted on during dry and wet to determine the
required dosages.

Climate Dry Wet

pH 6.4 6.5
Total alkalinity, ppm CaCO3 20 20
Total hardness, ppm CaCO3 14 14
Silica, ppm SiO2 6.5 7.0
Total dissolved solids (TDS), ppm 40 40
Chloride, ppm Cl 28 21
Total iron, ppm Fe 0.8 0.5
Water Appearance Yellowish Light yellowish

-11-
The water appearance become darker with increase turbidity; however, not much
change in its quality as showed in table above.

The result was as following:

Test# Alum Soda Polymer pH TDS Remarks

27/7/09. Dry weather. River water observed clearer than the suction well.
1 60 40 1 7.0 70 Small floc and less clear after
settled.
2 100 60 1 6.8 120 Denser floc and clear after settled.
3 100 80 1 7.0 140 Slightly improve clarity than #2
28/7/09. Wet weather after overnight rain. Both river and suction well are turbid
4 100 40 1 6.8 120 Denser floc and clear after settled
5 60 40 1 7.0 100 Small floc. Not working well.

Dosing Set Up

The following use for the calculation of dosage, chemical pump rate and
chemical required.

Q, m3 //hr x ppmproduct
Chemical pump rate, L/hr =
10 x % Conc product

Q = Raw water pump Flow

ppm product = Result of ppm of chemical apply in jar test
% Conc product = the weight percentage of chemical dissolved in tank
(kg*100/400L)
Chemical pump rate = Measured chemical pump rate

For alum application based on 56 m3/hr. The calculated product required as

below:

Product Pumping rate ppm product % Conc product Kg product/400 L

Alum 22 L/hr 100 25 100
Soda 23 L/hr 60 15 60
Polymer 12 L/hr 0.1 0.1 0.4

Issues

Two appearance issues observed:

1. Wet weather especially after heavy downpour, would lead the yellowish
color no matter what dosage apply.
Troubleshooting Approach

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• Visit to the water intake resulted in immediate conclusion as to the cause
of poor treatment quality during wet weather.
• River water is channel by gravity directly to a retention pond; no water
outlet available.
• River water become muddy after heavy rain and floods the retention pond
to the similar effect.
• No sequential trap or settling pond to systematic reduces the high
suspended solids.
Solution
• Make new partition pond with sufficient storage capacity that is higher than
the flood level and use pump to draw water to the 1 st pond (settling) and
overflow to the 2nd pond (water intake to clarifier).
• Stop drawing river water during muddy condition and resume only after
water return to norm.

2. On normal day, treated water has carryover issue. Floc is seen rising at
certain zone.
Troubleshooting Approach
• Reconfirm dosage, flow rate, retention time and dosing rate still unable to
resolve the issue.
• Check clarifier internal and found out the ejector cone was corroded and
distorted which disturbing the clarification process.
Solution
• Short term solution is temporarily removing the faulty part and operates
back. Operating higher sludge blanket to aid in containing the carry over
effect.
• Long term solution is to replace the ejector cone or modify the raising flow
to a straight pipe and extend the current outer well downward.
• Install inline static mixer to promote greater mixing of chemical for
optimum result.

Tips
• Know the water source nature and its topographical location
• Clarifier volume, pump flow, dosing rate, solution tank volume and the
injection point.
• Always carry out jar test to assure the right one if doubting the dosage
• Take opportunity to inspect clarifier internal during annual shut down for
any faulty parts.

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 2. SOFTENER OPERATION

Ion exchange principle using cation resin in sodium form in which dissolved
hardness is removed by the exchange of hardness ions for sodium ions.
When the resin exhausted its capacity, regeneration needs to carry out to
remove the
hardness and
restore it to
sodium form. Salt
is used for the
regeneration
process. The
regeneration
process involved
four steps as
depicted in the
chart below.

i. Backwashing-To loosen the resin bed and flush out the mud and
foreign debris. Backwash until water is clear.
ii. Brining- To introduce salt water at 8-10% to remove the hardness and
restore the resin to sodium form. Generally, it takes 30-45 minutes to
complete.
iii. Slow rinsing – To complete the brining process by flushing out the
remaining salt in the resin. It should take the same amount of time as
brining.
iv. Fast rinsing – To flush out the hardness at the end of slow rinsing.

The entire regeneration process should not take more than 2 hour to
complete. Prolong regeneration would not improve the condition as law of
diminishing apply (loss of exchange capacity as regeneration prolong).

Resin capacity can be estimated by the following equation:

66  Resin vol, L x Efficiency

Exchangeab le Volume, m3 =
Total hardness, ppmCaCO 3
Where
▪ Efficiency of softener regeneration = Generally regard as 80%
▪ The above equation is based on 0.16 kg salt per 1 L resin volume
application.
▪ Number of hour of softener operation is the exchangeable volume divide
by boiler feed water rate.

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Troubleshooting Guideline
Symptom High Hardness leakage
Possible Causes Remedies

Testing error Check procedure or hardness test. If original reading

incorrect, replace or repair reagent especially ammonia
buffer and hardness indicator.

Valve leakage. Check and adjust all valves.

Inadequate regeneration. Check regeneration sequence and adjust if required.

Uneven distribution. Check bed stability during regeneration and rinse. Check
flow rates and distribution system for blockage (pressure
drop).

Insufficient resin in vessel, Check resin bed depth. Add resin to correct bed depth as
necessary

Flow rate above normal. Reduce flow or change to larger bead resin.

Channeling due to no or insufficient

Regenerate again with no backwash.
backwash

Channeling due to suspended

Adjust backwash time and frequency.
solids in the influent.

Channeling due to iron, aluminium Clean resin, air spurges and backwash, or replace as
and manganese precipitation. appropriate.

Channeling due to resin oxidative Take sample and confirm with resin analysis and replace
damage. resin if necessary.

Channeling due to compacted bed. Extended backwash or air-lance during backwash.

Increase backwash rate to expand bed to a point 15-30 cm

Channeling due to resin fines.
(6 - 12") below the outlet header.

Channeling due to biological

Clean entire system and pre-treat to control organisms.
growth.

Channeling due to flow rates lower Make sure the service water flow rate is appropriate for the
than distributor design. distributor design.

Increase service water flow rate to minimum to prevent

Low service water flow rate.
channeling.

Oil fouling on resin. Clean or replace as appropriate. Review pre-treatment.

Take sample and confirm with resin analysis, clean or

Flocculant aid fouling.
replace resin as appropriate.

Chemical clean or replace as appropriate. Review pre-

Resin fouled with iron.
treatment.

Confirm regenerantion quality. Must be 8-10%

Poor salt quality.
concentration in contact with resin.

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Symptom: Increase pressure drop/restricted flow
Possible Causes Remedies

Valve(s) partially closed. Check and adjust all valves.

Internal distributor blocked. Repair/clean distributor.

Flow rate above normal. Reduce flow or change to larger bead resin.

Low feed water temperature. Reduce flow or change to larger bead resin.

Increased amount of suspended Increase backwash time and frequency.

solids in the influent.

Iron, aluminium and manganese Clean resin, air spurges and backwash, or replace resin as
fouling. appropriate.

Resin oxidative damage. Take sample and confirm with resin analysis replace resin if
necessary.

Compacted bed. Extended backwash or air-lance during backwash.

Resin fines. Increase backwash rate to expand bed to a point 15-30 cm

(6 - 12") below the outlet header.

Biological growth. Clean entire system and pre-treat to control organisms.

Inappropriate resin choice. Replace with correct resin type.

Excessive resin volume in vessel. Re-adjust volume according to design guidelines.

General Softener Internal

Layout
Note: Some softener with
proper size strainer will
choose to not have the
S/3 under bed media or use
Freeboard
single media layer to fill in
more resin.
S
2-2.5’
resin 2S/3
depth

1.2-2.4 mm fine sand 4”

2.4-4.8 mm coarse
sand
4”
12-19 mm gravel 4”

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Symptom: Loss of throughput capacity
Possible Causes Remedies

Increase in influent hardness. Obtain a current water analysis to confirm. Increase

frequency of regeneration or evaluate potential for
upgrading system.

Channeling due to blocked internal Repair / clean distributor.

distributor.

Channeling due to high flow rate. Reduce flow or change to larger bead resin.

Channeling due to suspended

Adjust backwash time and frequency
solids in the influent.

Channeling due to iron and Clean resin, air spurges and backwash, or replace as
manganese precipitation. appropriate.

Channeling due to high pressure

Take sample and confirm with resin analysis. Replace resin
drop associated with resin
if necessary.
oxidative damage.

Channeling caused by a
Extended backwash or air-lance during backwash
compacted bed.

Channeling caused by high levels Increase backwash rate to expand bed to a point 15-30 cm
of resin fines. (6 - 12") below the outlet header.

Channeling caused by pressure

drop associated with biological Clean entire system and pre-treat to control organisms.
growth.

Channeling due to flow rates lower Make sure the service water flow rate is appropriate for the
than distributor design. distributor design.

Measure resin bed depth. Add more resin as required. If a

Resin loss. sudden high loss of resin occurs, check vessel and
distribution system for leaks.

Insufficient regenerant amount. Make sure regenerant dosage is at the correct level.

Regeneration flow rate. Check flow meter and adjust if required.

Sample the regenerant at the point it enters the vessel,

Regenerant concentration. measure concentration and compare to levels
recommended by operating manual.

Change in water composition. Obtain analysis and reset regeneration parameters

Resin fouled with iron/aluminium Clean and pre-treat to remove iron.

Leaking / by-pass of regenerant

Check and adjust all valves.
valves.

Take sample and confirm with resin analysis. To clean or

Resin degradation.
replace resin as appropriate.

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Elution Study

Elution study is using hydrometer to measure specific gravity (SG), convert to

salt concentration using the chart below, at the discharge end to quantify the
efficiency of the regeneration process. The data can plot in a chart and compare
to the ideal chart to find area that required improvement.

The recommended parameters are listed below and should be compared to

values calculated in the elution study.

Parameter Recommended time Recommended

Service Flow Rate Not Applicable Up to 40 times resin volume per hr
Backwash 10-15 mins 12 L/hr per 1 L resin
Brining rate 30-40 mins 8 L/hr per 1 L resin volume
Slow rinse 30-40 mins 4 to 8 L/hr per 1 L resin volume
Fast Rinse 10-15 mins > 12 L/hr per 1 L resin volume

SG VS % salt

26.0

24.0

22.0

20.0

18.0

16.0

14.0
% Salt

12.0

10.0

8.0

6.0

4.0

2.0

0.0
0.98 1 1.02 1.04 1.06 1.08 1.1 1.12 1.14 1.16 1.18 1.2
SG

-18-
Case Study 2-Softener

A 2000 L resin capacity SS softener which serves the need for the boiler feed
water consumption. The actual resin volume estimated only about 1000 L. Based
on 20 ppm incoming hardness, service flow rate of 35 m3/hr and 80%
effectiveness, this will yield a treated water capacity of 2640 m 3 or 3 x 24
operation hours.

66  ResinVol(L )x Efficency
Exchange Capacity, m3 =
Total Hardness, ppm

Design Specification for Regeneration

Service flow rate 40 x resin vol per hr

Salt requirement 0.16 Kg salt/ 1 L resin
Brining 4-8 x resin vol per hr
Slow rinse 2 x resin vol per hr
Fast Rinse 8-10 x resin vol per hr
Contact time at 8-10% salt Min 20 minutes

OBSERVATION

From the elution curve as compared to the ideal one, the following are noted:

1. Brine draw is acceptable but is on the low side as compared to the design
rate (salt water pump rate is 3 m3/hr). Fine tuning might required before
finalize an acceptable flow rate.

Actual Required Actual Required

Brining 35 mins 30-40 mins 1.4 m3/hr 4-8 m3/hr
Slow rinse 15 mins 30-40 mins 8 m3/hr 2 m3/hr
Fast rinse 3 mins > 10 mins 30 m3/hr 8-10 m3/hr

2. Contact time is about 19 minute which is at the edge of the required 20

minutes. This can be improved by reducing the slow rinse flow rate to about
the same as brining so that the contact time could be prolong at the required
salt concentration.

3. Fast rinse flow is too fast and short. Reduce the flow by throttling the water
main valve to get the required flow rate.

REFINE PROCEDURE

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 1. Drain the water completely from the bottom of softener after backwashing.
There is a 2” plug available. Recommend to change to a ball valve for
easy maneuver.
2. Prepare the salt water to 10% concentration with the required amount of
salt (0.16 Kg per 1 L resin). 7 x 25 Kg salt for 1000 L resin. The 10% salt
concentration has a SG value of 1.070 (estimated water level is 83 cm
height at the salt tank).
3. Open the required valve and keep the drain valve opening at half to
regulate a slower flow.
4. Start the pump at full speed; it will take about 20 minutes to fill up to the
overflow outlet. An additional 15 minutes of pumping before reaching the
lowest salt water level at tank.
5. Open ¼ or less (maintain the same flow rate as salt pump) of water main
at the end of salt pumping to start the slow rinse process. Ideally, use the
pump to slow rinse will ensure the same flow rate (relocate the salt water
suction outlet to the bottom of tank). Rinse this for about the same time as
brining ( 35 mins)
6. Open ½ of water main to start the fast rinse process. Do that for 10
minutes or until hardness reached less than 1 ppm.

ELUTION CURVE

% Salt In Regeneration

12
Ideal Regeneration Curve

10 Actual Regeberation curve Ideal Contact

time

Actual contact time

8 is 19 min
% Salt

6 Brining Slow rinse

0
12:00 12:06 12:12 12:18 12:24 12:30 12:36 12:42 12:48 12:54 13:00 13:06 13:12 13:18 13:24 13:30
Mins

-20-
DATA

XXX POM Elution Study on June 28, 04

Salt Used 225 Kg
Salt Tank 1900 L Ø 1.45m x 1.15 m
Pump Rate 3 m3/hr
Softener Ø 0.78m x 1.8m SH
Resin 1000 L Bed Depth 540 mm Current
2000 L 600-760 mm Design
Service flow will be slow(by gravity) if resin volume increase
Specification Design Actual
Brining 4-8 1.4 m3/hr
Slow rinse 2 8 m3/hr
Fast Rinse 8-10 ~30 m3/hr
Service 40 30-35 m3/hr

Time % Salt
12:01 Start with Salt concentration of 11.5%
12:22 0.12
12:23 0.26
12:26 6.1
12:29 7.4 Flow. m3/hr 1.3 Brining via pump
12:32 7.7 3
Flow. m /hr 1.4 Brining via pump
12:35 8.8 12:36 End of brining. Total Vol = 1.76 m 3
12:38 9.1 Start Gravity drain
12:41 9.1
12:44 10.1
12:47 10.7
12:50 9.4
1/4 valve
12:53 7.4 Flow. m3/hr 8 opening
12:56 7.2
13:02 6.9 12:59 resume rinse
13:05 1
13:08 0.4 Fast rinse
13:13 0.12 Flow. m3/hr 35-40 Fully opened

-21-
 3. VACUUM DEAERATOR OPERATION

Vacuum and thermal deaerator are used in the palm oil industry, the former is
widely used compare to the latter, for removing the dissolved oxygen.

Operation of Vacuum Deaerator

Air vent
pipe

It used life steam through a steam ejector to create vacuum for withdrawing the
release gases from the water spraying in the deaerator at saturation temperature.
The steam ejector size selected must befitting the steam pressure otherwise
mismatching can affect maintaining of required vacuum.

The arrangement of the system is showed in the LAYOUT plan attached above.
The spray through the nozzles is controlled by the diaphragm valve V1 through
the water inlet pipe (2 or 3; normally one is main inlet with larger pipe size while
the other smaller). Regulate this valve to maintain the required water level in the
deaerator vessel. It is normally maintain at ½ to ¾ height of the level gauge. The
head required for spraying is supplied partly by the external static head (elevation
of feed water tank. The recommended height for most vacuum deaerator is 6 m
(B = inlet pipe from tank) for maximum 87oC water temperature), and partly by
the vacuum within the deaeartor.

The vacuum in the deaerator correspond to the feed water temperature and is
maintained by a single stage ejector mounted on top of the vessel. The length of

-22-
between the vessel and the ejector is determined by the supplier as it could
affect the vacuum effectiveness. The steam inlet/outlet piping and ejector are
arranged in as straight line as possible to provide free flow of the steam flow. The
operating condition of the deaerator is maintained 22”-24” (-53 to -61cm) Hg at
60-70oC.

The deaerated water is withdrawn from the base of the vessel by the extraction
pump and discharge into the boiler feed water pump suction end. The capacity of
the extraction pump must be in excess of the normal requirement of the boiler
feed pump and a percentage of the deaerated water is therefore recirculated
through the line G (bypass) with a positive pressure indicated in its gauge.
Therefore, a positive pressure is maintained throughout the suction end of the
boiler feed water pump. This line should be free of any obstruction to allow
recirculating of excess water in the event of back pressure develop in boiler feed
water pump and continue supply of bypass feed water to the boiler feed water
pump if and when the extraction pump failed.

The extraction pump and it suction line is connected to the vent pipe to release
vapor developed in the water to maintain proper operation of the pump and the
deaerator. Please note that the vent pipe is feed to the vacuum outlet of the
deaerator and it is important to ensure this pipe is not leaked since it is passing
through the bottom of the deaerated water tank.

Ensure water level is maintained at the required height at all times, low water
level can damage the pump especially the mechanical seal (faulty when leak
observed). Annually check the impeller and the motor rotation to ensure the
integrity of the pump performance.

The possible causes of faulty operation of the deaerator can be traced to one or
more of the following sources:
1. Steam ejector
2. Deaerator vessel
3. Extraction pump and motor
4. Water inlet

Steam ejector if not operating satisfactory will not be able to maintain the
required vacuum in the deaerator. If It performance is suspected, check the
vacuum against the water outlet temperature in the following Chart of Solubility of
Oxygen in Water below.

If the two correspond (one saturation temperature correspond to its vacuum) then
it is working in good order, otherwise proceed to trouble shoot the fault by
considering the following points:

i. Low steam pressure

ii. High superheat

-23-
iii. Wet steam
These are related to the life steam itself and can be easily
checked and must be rectified at source.
iv. Leaking joints
Regularly check all joints especially the suction end of the pump
where any leakage can draw in air into the deerated water.
v. Worn, blocked or partially blocked steam nozzles
Blocked nozzle will result in no vacuum. However, less than
desire vacuum could cause by worn or partially blocked nozzles.
Clean the blocked nozzle and replace nozzle in which the bore
has increased by more than 10%.
vi. High discharge pressure
Two causes bring about this effect, Firstly, the discharge pipe is
too small and secondly the discharge piping is submerged too
deep in the feed tank. Both these conditions will cause
excessive back pressure resulting in less than desire ejector
performance. Rectification of discharge pipe size is obvious but
the submersion of discharge pipe requires reference to the
original design. Normally, it should not be more than 3 feet
submersion using large bore pipe (please check the design to
confirm).
vii. Worm combining tube (steam inlet/outlet of ejector, deaerator
vent)
Change to new tubing if leak observed.

-24-
 STEAM EJECTOR

High pressure steam is fed,

at relatively low velocity,
into the motive fluid connector, 1 .

The motive high pressure steam

enters the nozzle and issues into
the suction head as a high velocity,
low pressure jet

A low absolute pressure at 2 (inside suction head)

entrains all of the adjacent gases in the vacuum vessel,
accelerates them to a high velocity and sweeps them I
nto the diffuser.

In the final stage the high velocity stream, passing through the diffuser,
is compressed and exhausted at the pressure of the discharge line.

Solubility of Oxygen in Water

-25-
Deaerator Vessel
If the deaerated water is not within specification (more than 0.1 ppm O 2), this
could due to incoming water is not being sufficiently atomized by the spray
nozzles. The cause of this is worn or partially blocked nozzles or leakage part in
the nozzle thread. This can be verified by viewing through the sight glass with
light to observe the spray pattern for any irregularities. The spray arm housing
the nozzles also need to check for any leakage especially the lower portion.
Leakage at this portion can compromise deaeration efficiency and high water
level in the vessel.

Pump and Motor

Both pump and motor performance can be deteriorated in its performance. The
pump can cause trouble (airlocked, reduced discharge volume etc) because of
leakage through glands/mechanical seal. Meanwhile, Trouble from the motor is
due to variance of its design speed. This is because the total head generated by
the pump is related directly to the rpm of the motor. Therefore, pump should be
extensively maintained on regular basis.

Inlet Water
The deaerator is design with inlet water at specific temperature and should be
maintain always. If the performance is suspected, the vacuum-water temperature
check will reveal whether the water temperature is the cause of reduced
efficiency. Higher water temperature above the design figure will lower the head
across the spray (reduced vacuum) and pass less water. Due to reduction in
quantity of the spray water, the extraction pump suction head (NPSH) will reduce.
Ones the extraction pump can not supply the required demand of the boiler feed
water pump, the feed water (undeaerated) will bypass directly via the line G to
the boiler feed water suction main. In addition, the deaerator vacuum will be
reduced as its absolute pressure increased.

Inlet water temperature below the design range will increase the head across the
spray so that more water is passed into the deaerator vessel. This will affect the
performance as the load increase the gas release become less effective and
consequently flood the deaerator vessel.

It is important to maintain as consistent as possible the feed tank water

temperature to avoid unwanted condition that can impair the performance of the
deaerator.

It should be noted that under correct operating condition, the deaerator vacuum
will vary according to the water inlet temperature.

-26-
The following is guideline for troubleshooting
Problem Probable cause
Low temperature Low feed water temperature
(out of range) Faulty steam ejector
Low vacuum Inadequate steam pressure
(out of range) Faulty steam ejector
Low water level Bypass
(< ½ level gauge) Spray nozzle block
Degrading pump
performance
Faulty check valve
High outlet oxygen Spray nozzle enlargement
Spray arm leakage
Bypass and flooding
Suggestive Action
Maintain 60-70oC
Faulty diffuser
Maintain -50-61 cm Hg
Faulty diffuser
Mass imbalance
Clean, replace or add nozzle
Check/replace Mechanical
seal/packing, impeller etc.
Check and rectify
Replace as per design
Patch and rectify
Mass imbalance, troubleshoot
to deduce probable cause

-27-
Case Study 3a-Vacuum Deaerator

FINDING
Test was carried out at the discharge side of the deaerator extraction pump at
location showed in FIG 1 as testing point 1.

Boiler in Operation Boiler 2 (Mechmar)

Bypass line
Feed water modulating valve
Feed Water temperature
Water Inlet valve to deaerator
Vacuum
Water level gauge
Equipped with valve
In operation.
Between 68-72oC.
Three valves all ½ opened
-450 mm Hg to 500 mm Hg (max achievable)
Suspected improperly connected

Deaerator Bypass Findings O2, ppm

Condition valve
Testing Point 1 when
-450 mm ½ open Low water level in deaerator. 0.4-0.6
Hg@68 C o

-500 mm Hg@ ½ open Adequate and steady water level in 0.2-0.3

72oC deaerator
-500 mm Open Flooding especially when back 0.6-1.2
Hg@68oC pressure developed.

Based on above observation and finding, the best condition for the deaerator was
when water level in the deaerator tank was steady at ½ to ¾ height of the cone
bottom with vacuum of -500 mm Hg and water temperature of 72oC plus 1/2
opened of bypass valve. Even with this optimum operating condition, it is not
steady. There were occasion during the course of testing when
i. Open full all three water inlet to deaerator will bring about flooding. In
addition, water was not properly spray upward rather throwing violently
side way like cyclone effect as seen from the side glass. After
readjusted to ½ opening the spraying returned to normal.
ii. Water level inside deaerator will drop to very low level, at the tip of the
cone section of the bottom of deaerator (hollow echo when knocked),
when bypass happened especially when there were high demand of
water.

This level of residue oxygen indicated the deaerator was not operating at its
desired level. Typical dissolved oxygen level for a well operated deaerator is less
than 0.05 ppm (theoretical value is 0.007 ppm). However, practically, dissolved
oxygen of less than 0.1 ppm is considered acceptable.

-28-
Conclusion

The study showed that the deaerator performance was not at its best due to vary
complication that cause residue oxygen fluctuates from as low as 0.2 ppm to as
high as 1.2 ppm. Drew strongly suggested that the plant to look into the following
possible rectification to improve the operating efficiency:
i. Maintaining feed water temperature between 68-75oC. This was not an
issue as it was easily managed during the course of testing.
ii. Plant to first look into steam ejector whether it is the right size for
operating the current state of mill throughput and steaming rate.
Increasing steam flow through steam injector during the course of
testing did not improve any further the vacuum. Ideally the vacuum
needs to maintain between 510 to 600 mm Hg. The highest achievable
was 500 mm Hg.
iii. Rectify the water level gauge connection. Please see attached drawing
as highlighted in circle for reference.
iv. Rectify the cooling tubing connecting the within the pump. Please refer
to drawing s highlighted in Square box for reference.

Drew will reevaluate the removal efficiency after the above rectification.
Additional recommendation will make then. This will help in the progress work to
close in to the real cause.

Meanwhile, continue to adjust oxygen scavenger dosage until the required

reserve is maintain. Adjust ± 0.5 Kg/day for each adjustment.

-29-
 Testing Point 1

Bypass valve

FIG 1 Deaerator Lay out.

-30-
Case study 3b-Deearator

Finding
Test was carried out at the discharge side of the deaerator extraction pump at
location showed in FIG 1 as testing point 1 and 2. If no water bypassing, residue
oxygen level in both location should be the same otherwise testing point 2 would
have higher residue oxygen. The Operating condition during testing was as
following:

Deaerator operating condition 68 cm Hg @ 70oC. All water inlet valves were

fully opened. Water spraying was seen from
sight glass.
Feed water modulating valve Not in operation.
Water level gauge Not sighted. Indicated low water level.

Findings
Testing Point 1 (before bypass line)

Residue dissolved oxygen recorded for this location stayed around 0.05 ppm.
Minimum variation of the dissolved oxygen reading was observed which
indicated deaerator was in good operating condition. Typical dissolved oxygen
level for a well operated deaerator is less than 0.05 ppm (theoretical value is
0.007 ppm). However, practically, dissolved oxygen of less than 0.1 ppm is
considered acceptable.

Testing Point 2(After bypass line)

Residue dissolved oxygen recorded for this location was around 0.6 ppm which
was 10 times more than that at location 1. This was due to partial continuous
bypass as a result of inadequate water supply through the vacuum pump. Water
bypass deaerator clearly showed that deaerated water supply was inadequate
and thus drawing water through the bypass line to meet the boiler feed water
demand. The fact of low water level inside deaerator (knocking at the lower half
of deaerator showed that it was not filled with water) is an indicator of inadequate
deaerated water supply. If a pressure gauge was installed at the bypass line, it
would had read zero (positive pressure of about 10 psig should maintain that
indicated no bypass).

-31-
 Testing Point 1

Bypass line To Boiler

Testing Point 2

Chemical
injection point

FIG 1 Front View of deaerator.

Conclusion

Based on the study, the deaerator is capable to reduce residue oxygen to 0.05
ppm which is considered good at the present operating condition. However,
water bypass due to inadequate deaerated water supply caused higher residue
oxygen of 0.6 ppm.

Recommendation

1. Service the water inlet pipe (size reduction), spray arm and nozzles to ensure
no blockage that could reduce water flow to deaerator for removing oxygen. A
water level of ½ to ¾ height is to maintain at the level glass.

2. Increase oxygen scavenger dosage from 1.0 kg to 1.5 kg per shift to ensure
adequate reserve is maintained. Adjust further by ±0.15 kg/shift for every ±10
ppm sulfite.

-32-
 4. BOILER CHEMICAL APPLICATION AND CONTROL

The objectives of boiler water treatment are to:

1. Prevent corrosion/pitting.
2. Prevent scaling.
3. Prevent carryover.

Prevent Corrosion
Corrosion is an electrochemical process in which a difference in electrical
potential develops between two metals or between different parts of a single
metal. A potential difference would then develop where the difference in potential
allow current to pass through the metal causing reaction at anodic and cathodic
sites (A corrosion cell). The anode is the region of low potential compare to
higher potential at cathode. In general the lower the potential at anode the
greater is the corrosion as metal ions at anode site oxidized (loss metal).

Reduction of ions Metal ions

or oxygen e.g. Fe++
Ionic
migratio
n
Cathod e Anode
e Electron migration

Corrosion Cell

Corrosion is a complicated process that involved chemical and physical factor.

Chemical factor are water composition, pH, total dissolved solids, dissolved
gases, suspended matter and microorganism. And physical factor are relative
metal areas, temperature, heat transfer surface, velocity of flow medium and
dissimilar metals.

Corrosions are classified into general corrosion and localized corrosion. General
corrosion is a uniform attack over the entire surface. However, corrosion involved
more than just uniform corrosion. Localized corrosion is due primarily of
dissolved oxygen. Pitting is the most common cause of metal failure of metal.
Therefore, it is absolute important to remove dissolved oxygen prior to it entering
the boiler water system.

-33-
To minimize general corrosion in the boiler internal, the boiler water need to
maintain the pH between 10.5-11.5 as can be seen from the iron corrosion rate
vs. pH chart above.

In order to control pitting, mechanical and chemical treatment is required to keep

oxygen corrosion to minimum. Deaerator is the key pretreatment to reduce the
dissolved oxygen to the practical lowest level (theoretical value is 0.007 ppm).
The residue dissolved oxygen is tackle by sodium sulfite, an oxygen scavenger,
to form sodium sulfate by the following reaction.

2 Na2SO3 + O2 →2 Na2SO4

The stoichematic of this reaction show that it takes about 7.9 ppm of pure sodium
sulfite to scavenge 1 ppm of dissolved oxygen. A residue of 30-50 ppm as SO3 is
maintained to impetus for the chemical reaction.

It is important when utilizing sodium sulfite or any oxygen scavenger, it is

essential to achieve complete chemical deaeration before the feedwater reaches
the boiler. This is because any residue dissolved oxygen in the feedwater when
reaches the boiler will flash into the steam phase while the sulfite remained in the
water phase since it is nonvolatile.

Prevent Scaling
Precipitation Program
The main culprits in the boiler water treatment are hardness and silica. Softener
is normally used to remove hardness before it enters the boiler, and phosphate is
used chemically to precipitate the hardness within the boiler water. This is
generally referred to as phosphate program. The principle behind this approach
is to provide a favorable condition for the sludge to form rather than scale. The
sludges formed are the reaction of phosphate and calcium, and magnesium,
hydroxide and silica by the following equation.

-34-
Sludges
10 Ca2+ + 6 PO4-3 + 2 OH- →3 Ca3(PO4).Ca(OH)2↓ calcium hydroxyapatite

3 Mg2+ + 2 SiO32- + 2 OH- + H2O →2 MgSiO3.Mg(OH)2.H2O↓ Serpentine

Scale
Ca2+ + SO42-→ CaSO4↓

Ca2+ + 2 HCO3- → CaCO3↓ + CO2↑ + H2O

Ca2+ + SiO32- → CaSiO3↓

Mg2+ + 2 OH- → Mg(OH)2↓

Mg2+ + SiO32- → MgSiO3↓

Mg2+ + 2 PO43- → Mg3(PO4)2↓

From the reaction above, it is important to maintain sufficient phosphate and

caustic alkalinity to ensure the desired sludges are formed. Insufficient of
phosphate and caustic alkalinity may lead to formation of undesired scale.

In addition, a sludge condition should incorporate in phosphate treatment to

facilitate non adherence of the sludges to the inner tube surface. Effective
blowdown is necessary to remove the sludges from the boiler internal to prevent
sludges build up that may choked the tube.

Solubilizing Program
Continues development has brought forth the multi-polymer antiscalant that
move away from the precipitation treatment into solubilization treatment. In other
word, the polymer treatment will not generate sludges as in phosphate program.
There can be divided into two categories.
i. Stoichiometrical(one to one) reaction with impurities to change their
chemical structure. Chelant is one of the common ingredients where it
chelates the impurities and renders them not available for reaction to
form scale.
ii. Substoichiometrical(one to many) reaction with impurities to change
the behavior of the impurities. There are multi-polymer blend that could
distort the crystal structure and disperse the small particles of colloids.
By doing so, the scale would not growth.

Silica scale
Generally silica could only be managed by keeping it in soluble formed
through a healthy 2.5 ratio of caustic alkalinity to silica. Silica should be kept
between 150-200 ppm in order to avoid formation of silica scale. This would
mean adjusting the Total dissolved solids to the level where silica is not

-35-
 exceeding the allowable limit. Antifoam may required in order to prevent
carryover of caustic alkalinity maintain more than 400 ppm as CaCO3.

There are unconventional approaches to tackle the silica problem facing in

area where silica content in the feed water is high and is not feasible to
control via lowering the TDS level. The following are some approach that has
been used to control silica with mixed result.
i. Desilicizer- Using the strong anion resin in OH- to remove all the anion
in the feedwater. The approach is not to reduce silica to zero level,
rather to manage the silica in feedwater to the acceptable level. This
means partial silica removal. This anion resin is set after the softener.
It required regenerating with sodium hydroxide in a right temperature
and concentration for effective regeneration. Duet to its OH - form, the
effluent tends to be in high pH range between 10-12. pH correction
might require lowering it to acceptable level for boiler water use as too
high a pH would cause foaming and carryover problem.
ii. Adding magnesium oxide to react with silica and caustic to form
serpentine. This approach required precision in controlling the amount
of magnesium feeding into boiler water, as overdose might form
magnesium scale.
iii. RO and demineralizer are other possible approaches. The economy
and maintenance need in depth study to justify the necessity.

Prevent Carryover.

Carryover into the steam of substances dissolved in boiler water is caused both
by
i. entrained of small droplets of boiler water into the steam leaving the drum
ii. Volatilization of dissolved salts that is soluble in the steam.

Mechanical entrainment is primarily a function of the design of the steam

separators and method of operation of the boiler. The entrainment process may
be divided into two categories:
i. Priming. is the result of sudden reduction in boiler pressure caused by
rapid increase in the steam load. This caused bubble to form throughout
the mass of water in the boiler. Increased water volume raised the level in
the drum, flooding separator. It may also result from an excessive high
water level following a rapid load reduction.
ii. Foaming. Is the buildup of bubbles on the water surface in the steam
drum, this reduces the steam release space and by, and by various
mechanisms, causes mechanical entrainment.

CONTROL PARAMETERS ADJUSTMENT GUIDE

The following are typical control limit for boiler water treatment operating under
low pressure boiler

-36-
Boiler Operating pressure 300-450 psig 450-600 psig
Parameter Control Limit Control Limit
pH 10.5-11.5 10.5-11.5
Hydrate Alkalinity, ppm CaCO3 200-400 ppm 200-400 ppm
Sulfite, ppm SO3 30-50 ppm 20-40 ppm
Phosphate, ppm PO4 30-50 ppm 20-40 ppm
Total Dissolved solids, ppm < 2000 ppm < 1500 ppm
Silica, ppm SiO2 150-200 ppm < 100 ppm
Total Hardness, ppm CaCO3 < 5 ppm < 5 ppm
For boiler operating pressure above 450 psig, control limit would be customized
base on local water quality.

Estimated Blowdown rate for 8 m equivalent length

Boiler Pressure Estimated Mass flow rate for pipe size, kg/s
bar 20 mm 25 mm 32 mm 40 mm 50 mm
20 2 3.9 6 10 18
25 2.3 4.2 7 12 20
30 2.8 5 8 13.5 24
35 2.9 5.5 8.9 14 27
40 3.1 6 9.9 16 31

Some equation for estimating feed water and blowdown rate.

Steming rate x Cycles

Feed water rate =
Cycle - 1
Blowdown = Feed water rate - Steaming rate,
or
Steaming rate x TDS in Feed water
Blowdown =
Max TDS Allow in boiler - TDS in Feed Water

Steaming rate
Boiler Volume(Water tube only) =
1.15

For a 22.7 T/hr steaming rate @ 20 bar boiler operating with feed water TDS of
100 ppm, in order to maintain 2000 ppm TDS, the blow down calculated is as
following:

Estimated Boiler volume = 19.7 T

The required blow down rate = 1.2 T/hr

-37-
If only one blow down per hour is carried out then 1.2 T or 6.1 % of boiler water
must be removed and replace with fresh feed water. The TDS would have risen
to 2122 ppm if the blow down is not being done in that hour span.

For blow down pipe of 50 mm, the blow down rate =18 kg/s

Therefore, the duration of blow down within every hour required = 1200/18 =67 s
or about 1 minutes to remove the volume of water to keep TDS at 2000 ppm.

Blow Down Frequency per hour based on available blow down rate of 18 kg/s
TDS % Blow Down Time Frequency
ppm Increase kg/s s
2000-2099 5 985 55 3 x 10 s / 30 mins
2100-2199 10 1970 109 3 x10 s / 15 mins
2200-2299 15 2955 164 3 x 10 s/10 mins
2300-2399 20 3940 218 3 x 10 s/ 8 mins
2400-2499 25 4925 273 3 x 10 s/ 6.5 mins
2500-2599 30 5910 328 3 x 10 s/5.5 mins
Frequency maybe adjusted to longer period to bring the TDS down

From the estimation blow down over one hour span, blow down frequency has to
increase rapidly once the TDS exceed the allowable limit. Therefore, it is
important to keep the TDS under control with regular prescribed blow down
frequency. Failure to observe the blow down would lead to increase frequency
that needs to execute in order to control TDS at the allowable limit within an hour
span.

This is why when TDS reached above 2300 ppm, it will be difficult to reduce the
TDS in short span unless increase the blow down rate available (restricted by
pressure and the pipe size).

Procedure for simplify chemical correction required:

1. Ensure TDS/silica is not above the limit and blow down sufficiently before
applying the adjustment dosage.
2. Determine the feed water rate (FW) by Steaming rate x cycle /(cycle -1)
3. Determine the cycles of concentration (N) by dividing the chloride in boiler
over the feed water chloride.
4. Determine the quantity of chemical reserve and the amount required to
increase to the required level. Adjustment required in ppm is the average
of control limit minus the test result (ADJ).
5. Calculate the ADJ NEED as below
6. Record the current dosage (CUR) and per hours (F = 8 if the dosage is
per 8 hours)
7. Prepare adjustment dosage (ADJ DOS) which is the CUR + ADJ NEED

-38-
 8. Retest result after the F hours and make necessary adjustment as
prescribed until reserve is maintained.

Product Parameter ppm Ave ADJ ADJ NEED

tested ppm
Adjunct HLM Caustic 150 300 150 1.6 x ADJ x FW x F /N
Adjunct HDM Caustic 150 300 150 6.4 x ADJ x FW x F / N
Amertrol 1123 Phopshate 20 40 20 3.4 x ADJ x FW x F / N
Adjunct B Phosphate 20 40 20 1.5 x ADJ x FW x F / N
SG Sulfite Sulfite 20 40 20 1.6 x ADJ x FW x F / N
Adv+ 1400 CUR + 0.5 kg per every 1 ppm hardness above 5 ppm. Please
Drewplex 505 call Drew engineer when total hardness > 15 ppm.

Example
Cycle = 10, FW = 24.6 T/hr, SO3 tested = 15 ppm ( Ave control limit = 40 ppm)
current dose (CUR) = 1.0 kg/8 hrs.

1.6 x 25 x 8 x 24.6 x 0.001

ADJ NEED = = 0.78 kg
10
Therefore, the adjustment dosage for SG Sulfite required:

ADJ DOS =CUR + ADJ NEED

ADJ DOS = (1.0 + 0.78) kg/8 hrs = 1.78 kg/8hrs

For charging the boiler after refilling with fresh softened water, follow the
following guideline:

Determine the normal operating level of water volume. Typical estimation for
water tube boiler is by dividing the steaming rate /1.15 = V, m3.

Product Parameter ppm required, P Dosage, kg

Adjunct HLM Caustic 300 1.6 x P x 0.001 x V
Adjunct HDM Caustic 300 6.4 x P x 0.001 x V
Amertrol 1123 Phosphate 40 3.4 x P x 0.001 x V
Adjunct B Phosphate 40 1.5 x P x 0.001 x V
SG Sulfite Sulfite 40 + 60 1.6 x P x 0.001 x V
Adv+ 1400 As product 200 P x 0.001 x V
Drewplex 505 As product 200 P x 0.001 x V
Additional 60 ppm for sulfite is accounted for the high oxygen content in the cold
water.

-39-
Study Question 1

Estate
River

Underground culvert
to divert the water to
the pond Effluent Pond

Pond
Sea
To clarifier
Estate Mill

Topography gradient

Facts
1. The pond has no overflow, water always clear and is at same level as the
river
2. The pond level drop but never go dry even though at the extreme dry
period experienced in one of the calendar year.
3. The TDS and chloride in crease tremendously in the extreme dry weather.
4. Periodical sand dredging activities along the up steam of the pond intake.
It is an ongoing activity.

Recently, the treated water chemistry has seen some changes as recorded
below:

Parameters Extreme Dry Normal Current issue Current Pond

TDS, ppm 460 80-200 290 170
Chloride 190 20-40 47 NA
Total hardness 60 15-40 80 40

Observation:
i. Softener breakthrough faster than normal.
ii. The pond appeared cloudy (whitish). Normally it is clear and colorless
iii. Whitish lump of soil observed at the bank near the sand dredging area.
iv. Rain season and river water running depth and rapid.

Details approaches to determine the cause of such water chemistry

changes.

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Study Question 2

SYSTEM INFORMATION

Number of softener 2 nos (1 run, 1 standby)

Resin volume 1200 L each
Total hardness, ppm CaCO3 Average 20 ppm
Estimated Feed water demand 27 m3/hr
Salt tank volume 1100 L

Data Collected During Elution Study

Process Recommended for 1200 L resin Softener B(Actual)

Service 30 to 50 m3/hr No data
Back wash >20 m3/hr No data
Brining 5 to 10 m3/hr 5.0 m3/hr
Brine draw 1.3 to 1.9 m3/hr 1.8 m3/hr
Slow rinse 5 to 10 m3/hr 12 m3/hr
Fast rinse > 15 m3/hr No data

Elution Chart
Softener B Elution Curve-May 14 2010 (Salt in Tank = 13%)

10.0

Ideal
9.0 Regeneration
Ideal Contact time
Curve
20 min @8-10% salt
8.0

7.0

6.0

Slow rinse
% Salt

Brining
5.0

4.0

3.0

2.0

1.0

0.0
0:00 0:05 0:10 0:15 0:20 0:25 0:30 0:35 0:40 0:45 0:50 0:55 1:00

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TEST RESULT

SOFTENER B DATE TESTED MAY 14, 2010

SALT USED 6 X 25 KG TANK SIZE 1.2MX1.2MX0.9M
BRINE VOL 1100 L ACTUAL HT 0.81M
BEGINNING LEVEL 1100 L
END LEVEL 200 L
TOTAL CONSUMED 900 L
TIME CONSUMED 30 MIN
BRINE DRAWNDOWN 1800 L/HR
SALT CONCENTARTION AT TANK SG =1.09 OR 13. %
TIME TIME, SG %
MIN SALT
9:45 0:00 1.000 0.4 BRINE DRAW DOWN START
9:50 0:05 1.000 0.4 BRINING RATE AVERAGE 5 M3/HR
9:55 0:10 1.006 1.3
10:00 0:15 1.010 1.8
10:05 0:20 1.026 4.1
10:10 0:25 1.030 4.7
10:15 0:30 1.036 5.5 BRINING END. SLOW RINSE START
10:20 0:35 1.038 5.8
10:25 0:40 1.018 3.0
10:30 0:45 1.008 1.6 RINSE RATE AVERAGE 12 M3/HR
10:35 0:50 1.006 1.3
10:40 0:55 1.006 1.3
10:45 1:00 1.004 1.0
10:50 1:05 1.000 0.4

Based on the data and chart, comment and suggest corrective action as
per following:

1. Brine concentration in tank

2. Backwash
3. Brining
4. Slow rinse
5. Fast rinse

Others comments (if any)

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STUDY QUESTION 3

Scenario

The plant has upgraded the boiler from 20T/hr @ 250 psig to 25 T/hr@ 300 psig
in 2009. All other equipments remained. Subsequently, the deaerator had bypass
issue where the sulfite usage had increased three fold yet still had difficulty to
maintain the reserve.

The following was result conducted on Nov 28, 2009.

Time Gauge Vacuum O2 Remarks

TempoC - cm Hg ppm
3:30 70 56 3.60 Deaerator tank flooded.
3:47 70 56 0.72 Deaerator tank water level return to norm
3:52 72 53 0.50 Tank level maintained at < ½ of the
3:53 74 50 0.40 gauge glass with water temperature
4:00 76 48 0.28 rising.
4:02 76 48 0.22
4:05 74 57 0.26 Steam pressure drop in boiler water
4:07 70 56 0.40 leading to flooding in the deaerator tank.
4:10 70 56 3.60

It was found out that the water supply to the deaerator is inadequate due to
greater demand now from increase steaming capacity. Mill make effort to extend
the spray chamber to allow housing 4 additional units of nozzle in an attempt to
increase the flow as low water level in tank always observed. After getting feed
back from supplier regarding replacing the spray nozzle from 2 cutting to 4
cutting to increase the water spray volume, the mill decide to do its own cutting.

After making the correction, the performance improved at about 0.2 ppm residue
oxygen and sulfite usage is back to norm dosing between 0.5 to 1 kg/shift.

However, low sulfite reserve was reported again beginning April 2010 and the
dosage of oxygen scavenger have increased from1 to 2 kg per shirt. Dissolved

Result conducted on June 24, 2010

Time Gauge Vacuum O2 Remarks

TempoC - cm Hg ppm
10:43 60 48 1.30 Low to no water level seen in level
gauge
10:50 60 48 1.15 Water inlet valve fully opened
11:00 62 46 1.10 Water level at about half of gauge

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The mill serviced the spray nozzle, steam ejector and rectify the steam leakages
at the steam ejector immediately after this finding. However, after putting back
into service, not change as to sulfite usage as well as the deaerator vacuum. The
vacuum recorded at 18” Hg at 65oC with water level about ¼ heights.

The above were series of study and follow up test result for a vacuum deaerator
of a palm oil mill.

List down the potential faults and its causes, and then go through the
process of elimination to zero in the cause. Suggest solution for the causes
identified.

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STUDY QUESTION 4

1. Boiler water TDS and chloride cyclically increased every time the boiler
resumed its operation after the off day. Please list down what are your
approaches to determine the possible cause of this occurrence?

2. The phosphate reserve is below 30 ppm and the softener hardness is under
controlled as the point of testing. Please list down the possible cause of low
phosphate reserve.

3. The TDS of a 25T/hr boiler required to maintain at 1500 ppm in order to limit
the silica in the boiler water to 200 ppm. Given the cycle of 6, calculate the
following
i. Blow down. Can this blow down be sufficient through manual bottom
blow down? If not what is the alternative to aid in blow down to
maintain consistency of TDS controlled?
ii. Boiler feed water
iii. Design the resin volume required for a softener to last 6 days at an
average 20 operation hours with an average make up water hardness
of 45 ppm. Assuming 80% efficiency of regeneration. Please provide
the amount of salt required per regeneration and the salt tank capacity
to hold the saturated salt solution.

4. Design the clarifier capacity for a 100 T mill (Assuming 1.6 T of water per 1
Ton of FFB processed). If the jar test result showed that 60 ppm alum and 45
ppm sod ash are required to achieve clear water, what are the tank volume
and chemical injection rate required?

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