Proceedings of PWR2006:

ASME Power
May 2-4, 2006, Atlanta, Georgia, USA
PWR2006-88153
INSTALLATION OF A NEW DEAERATOR FOR BOILER FEEDWATER SUPPLY
ACHIEVES BETTER EFFICIENCY AND OPERATING STABILITY


Barbara Signo, M.S.E; Jose F. Alvarez, P.E.; Blas Marin, Jr.; Dennis Sellers
Sugar Cane Growers Cooperative of Florida
1500 West Sugar House Road
Belle Glade, Florida
Tel: (561) 996-5556
Email: bsigno@scgc.org



ABSTRACT
Sugar Cane Growers Cooperative of Florida (SCGC), a
sugar processing mill with six power boilers, achieved higher
reliability, higher overall efficiency, and better operating
stability by replacing the 29 year old parallel flow horizontal
Deaerator and installing a new Feed Water Storage Tank. This
paper presents the selection process for the new Counter Flow
Two Stage Spray-Tray Deaerator, instrumentation, automation,
and system modifications which led to saving 8,000,000 Btu/hr
(2,340 kW/hr), and reducing the use of sulfite for boiler oxygen
scavenging purposes while reducing system pressure and
temperature fluctuations.

INTRODUCTION
The removal of dissolved gases from boiler feed water is
an essential process in a steam system. Oxygen and Carbon
dioxide are the two dissolved gases of primary concern. The
presence of dissolved oxygen in feed water causes rapid
localized corrosion in boiler tubes. Carbon dioxide will dissolve
in water, resulting in low pH levels and the production of
corrosive carbonic acid. Low pH levels in Feed Water causes
severe acid attack throughout the boiler system. While
dissolved gases and low pH levels in the Feed Water can be
controlled or removed by the addition of chemicals, it is more
economical and thermally efficient to remove these gases
mechanically. This mechanical process is known as deaeration
and will increase the life of a steam system dramatically and
improve the efficiency. Mechanical deaeration is based on
Henry's Law which states that the gas solubility in a solution
decreases as the gas partial pressure above the solution
decreases. In general, the solubility of gases in a solution
decreases as the temperature of the solution rises and
approaches saturation temperature. [1]
Deaerators serve to degasify feed water by utilizing steam
as the scrubbing agent and therefore reduce the effect of
corrosive gases on the equipment. The steam serves as a
scrubbing agent when it mixes with the water bringing it to
boiling point and causing air bubbles to come out of solution.
Deaerators are the central component where condensate and
steam can be recovered to increase the efficiency of the plant.
By raising the temperature of the Feed Water, the deaerator
achieves substantial energy savings.
The installation of a new deaerator, system modifications,
and system automation at Sugar Cane Growers Cooperative of
Florida led to higher reliability, better overall efficiency and
system operating stability.
SITUATION ASSESSMENT
An assessment of the operational reliability of SCGC of
Florida, a sugar processing mill with six power boilers and total
steam production capacity of 980,000 lb/hr at 450 psig,
highlighted the need for the improvement of the 29 year old
parallel flow horizontal Deaerator which supplied all the Boiler
Feed Water.
SCGC depended on a Horizontal J et Tray Parallel Down
Flow type Deaerator rated for deaerating 1,300,000 lb/hr of
Feed Water supply. Feed water storage was provided by two
identical and interconnected tanks. The West Storage tank
connected directly beneath the deaerator provided a storage
capacity of 1,500 ft
3
or 11,220 gallons for the boiler feed water
pumps suction. Additional water storage capacity was
accomplished with a second similar Storage Tank (East)
connected to the West Storage tank as can be seen in Figure 1.
The total effective water storage capacity of both tanks was
16,800 gallons (8,400 lbs) of water to the 70% diameter normal
water line level. Both Storage Tanks were connected to the
1 Copyright 2006 by Sugar Cane Growers Cooperative of Florida

common suction header for the Boiler Feed Water Pumps
feeding all six boilers. During visual and ultrasonic inspection
of the Deaerator and storage tanks, it was found that the 40 year
old West tank was in satisfactory condition and it did not
require replacement. However, it was desirable to increase the
water storage capacity to provide for full Boiler Feed Water
pump needs as recommended by the Heat Exchanger Institute
(HEI). [2]


Temperature: Heating to full saturation temperature.
Turbulence: A complete agitation or mixing of the water and
the steam is required to remove all the dissolved gasses. This
scrubbing action is required so that the water overcomes the
surface tension and viscosity that retain the dissolved gases.
Figure 1. Original Deaerator with Storage Tanks

The flow into the deaerator consisted of scrubbing steam,
condensate #1, and make-up water which could be softened city
water or condensate #2 held in an atmospheric holding tank.
The temperature and pressure of the available steam ranged
between 285F and 350F at pressures between 15 and 25 psig
respectively. During normal milling operations, Condensate #1
and Make-up combined prior to entering the Deaerator.
Condensate #1 flow accounts for 75% of the total water flow or
750,000 lbs/hr. The other 25% (250,000 lbs/hr) was Make Up
Water which consisted of softened water and/or stored
Condensate #2. The softened water temperature ranged from
40F to 80 F and was supplied at 70 psig. Condensate #2 from
the sugar cane process was normally at a temperature of 217 F.
However, it was being directed to atmospheric holding tanks
where it flashed loosing temperature to about 190 F prior to
being pumped to the deaerator.
Pressure fluctuations and water hammer at the deaerator
and incoming water piping had been observed intermittently. It
was determined that this was partially due to the two
connecting storage tanks arrangement and primarily due to the
inlet control valve arrangement where the hot Condensate #1
was mixing with the cooler Make-Up water. Another
contributing factor was that the pressure drop across the
Condensate #1 control valve was allowing the Condensate #1 to
reach saturation conditions resulting in cavitation.
DEAERATOR OPERATION PRINCIPLES
The deaerator should meet the following benefits:
The deaerator and feed water tank provide storage, positive
submergence, and surge protection for the boiler feed water
pump(s) suction. Per the HEI, the Feed Water Tank at the
design overflow level (85% of diameter) must provide
capacity for the Boiler Feed Water for ten minutes.
Water effluent from the deaerator should be at the
saturation temperature corresponding to the steam pressure
within the heater section.
Reduction of O
2
in effluent to 0.005 cc/liter (7ppb) or less
when tested at the outlet of the Deaerator in accordance
with American Society of Mechanical Engineers (ASME)
PTC 12.3.
Reduction of the free CO
2
in effluent to 0 ppm when tested
by the American Public Health Association (APHA)
method (titration method).
The deaerator shall offer safe and reliable operation under
the conditions over the full load range from 0% to 100% of
the specified capacity. The deaerator and storage tank shall
operate quietly, without rumble or hammer from minimum
to maximum capacity. [2]

In order to meet the desired performance, the deaerator
design must take into account the following requirements:
Thin film: Increase surface area for water-steam contact and
scrubbing effectiveness.
Time: The longer the water is at full saturation temperature,
mixing and in contact with the scrubbing steam, the more
effective the deaeration process is.
Venting: Sufficient venting is necessary to allow separated
gases to leave the deaerator quickly.
Stability: Large load swings adversely affect the deaerator
performance. [3]

DEAERATOR DESIGN
A number of different deaerator designs were considered.
Sterling horizontal counter flow two stage spray-tray deaerator
design was selected. This design fit the limited vertical space
available for installation. The performance offered by this type
of design supports wide load ranges at competive cost.
In accordance with Henrys law, the quantity of a gas
dissolved in a given quantity of liquid is directly proportional to
its partial pressure surrounding the liquid. Therefore, by
reducing the partial pressure of the unwanted gases in the
surrounding atmosphere, the gases are diminished. These
2 Copyright 2006 by Sugar Cane Growers Cooperative of Florida

partial pressures are reduced by spraying the liquid into a
countercurrent flow of steam. The steam, which is free of non-
condensable gases, is the liquids new atmosphere and Henrys
law prevails. Using steam as the scrubbing agent is
advantageous also because the solubility of a gas in a liquid
decreases with an increase in temperature.
The first stage of deaeration of a Counter Flow Two Stage
Spray-Tray Deaerator is shown in Figure 2. The prime element
in the vent condenser zone is the self-adjusting spray valves
that allow incoming water to discharge as a thin-walled, hollow
cone spray (see Figure 2A). The water to be deaerated is
sprayed in thin films in order to increase the surface area of the
liquid in contact with the steam.
Because steam flows counter currently, intimate water to
steam contact occurs with consequent latent heat transfer. Most
of the dissolved oxygen and free carbon dioxide have been
removed at this point. Since nearly all of the steam has been
condensed, the non-condensable gases and the small amount of
transport steam exits through the vent piping

Figure 2. Counter Flow Two Stage Spray Tray Deaerator [1]


Figure 2A. Spray Valve Figure 2B. Tray Area

The partially deaerated water enters the second stage of
deaeration, that is, the tray stack at saturation temperature. The
heated water flows down over the trays, zigzagging as shown in
Figure 2B through counter-flowing steam. This arrangement
provides additional retention time to allow a final oxygen strip
by the purest steam. The two-stage tray deaeration technique is
the most reliable method for meeting critical performance over
a complete wide load range. [1]
The existing operating pressure of the steam entering the
deaerator was between 20 and 28 psig. To avoid additional
major system changes, this pressure range was maintained as
the design pressure for the new installation. Utilizing a design
pressure of 42.70 psia (28 psig), the heat balances for the full
range of design conditions are tabulated in Table 1.
VENT
WATER

FLOWING MEDIA Flow (lb/hr) T (F) Btu/lb
M-U Softened Water 600,000 40 8
Steam 150,000 275 1,173
Vent -750 271 1,171
Feedwater Outlet 749,250 271 240
Condensate #1 800,000 260 229
M-U Condensate #2 452,842 195 163
Steam 46,908 275 1,173
Vent -750 271 1,171
Feedwater Outlet 1,300,000 271 240
Condensate #1 600,000 260 229
M-U Softened Water 555,349 40 8
Steam 145,401 285 1,178
Vent -750 271 1,171
Feedwater Outlet 1,300,000 271 240
H
E
A
T

B
A
L
A
N
C
E

1
H
E
A
T

B
A
L
A
N
C
E




2
H
E
A
T

B
A
L
A
N
C
E




3

FIRST STAGE
SPRAY AND
VENT
CONDENSIN
G AREA
STEAM
SECOND
STAGE
TRAY AREA
Table 1. Deaerator Design Conditions Heat Balances [4]
Basically, the amount of steam required to deaerate
condensate or make up in a spray-type or tray-type deaerator
can be calculated by using a mass and energy balance around
the deaerator (See Figure 3). If the deaerator is assumed to be
100% efficient, then it can be assumed that the outlet Feed
Water (M
3
) temperature will be at the saturation temperature of
the steam pressure. Initially the amount of steam vented can be
assumed to be negligible. [5]

3 Copyright 2006 by Sugar Cane Growers Cooperative of Florida

4 Copyright 2006 by Sugar Cane Growers Cooperative of Florida
DEAERATOR
Condensate or Make Up
M1
Feedwater M3
Steam M2

Figure 3. Deaerator Mass and Energy Balance
Referring to Figure 3, a mass and energy balance around
the deaerator yields the following equations [5]:
M
3
=M
2
+M
1
(equation 1)
M
3
h
3
=M
2
h
2
+M
1
h
1
(equation 2)
where,
M =Mass flow rate of steam or water, lb/hr
H =enthalpy of steam or water, Btu/lb
When the outlet feed water flow rate (M
3
) is known we can
solve the mass balance equation for M
1
:
M
1
=M
3
M
2
(equation 3)
and substituting the above equation for M
1
into equation 2 then
M
3
h
3
=(M
3
M
2
)h
1
+M
2
h
2
(equation 4)
and solving for M
2
, we obtain,
M
2
=M
3
(h
3
h
1
) /( h
2
h
1
) (equation 5)
When the inlet flow rate (M
1
) is known, we can solve the
energy equation for the steam flow rate (M
2
) by substituting

equation 1 for M
3
in equation 2:
(M
1
+M
2
)h
3
=M
2
h
2
+M
1
h
1
(equation 6)
M
2
h
3
M
2
h
2
=M
1
h
1
M
1
h
3
(equation 7)
M
2
=M
1
(h
1
h
3
) / (h
3
h
2
) (equation 8)

SYSTEM DESIGN AND AUTOMATION
The new Deaerator storage tank was designed to cover the
site full deaerated water storage need for boiler feed water
pump suction per HEI recommendations. The new tank is 11
feet in diameter and about 46 feet long with 2:1 elliptical heads.
It holds 27,853 gallons (216,746 lbs) of water up to the
overflow situated at 85% of the total tank diameter or 24,758
gallons (192,663 lbs) of water up to the normal water line at
75% of diameter. The normal water line capacity can provide
more than eleven minutes of feed water capacity at the nominal
site operating rate of 980, 000 lb/hr of steam.
The deaerator and storage tank were designed,
manufactured, tested and stamped in accordance with the Heat
Exchanger Institute Standards and Typical Specifications for
Deaerators (HEI) and ASME Section VIII, Division 1. The
deaerator and water storage sections were registered with the
National Board of Boiler and Pressure Vessel Inspectors and so
stamped. Both the deaerator and storage tank were designed
for 100 psig and full vacuum at 650F. This installation required
constructing a new support structure designed to withstand the
weight of the new Deaerator and Storage Tank (Figure 4).
Vent


Figure 4. Installed Deaerator

The inlet water piping to the Deaerator was modified to
improve thermal energy efficiency. The Condensate #2 piping
was routed to be able to bypass the holding tanks and to
connect directly to the Make-Up and Condensate #1 piping
entering the Deaerator (See Figure 5). Control valves for the
Condensate #1 and Condensate #2 were chosen with low
pressure drop and anti-cavitation devices.
A Rosemount Model 499 TrDO Dissolved oxygen sensor
and Amperometric Analyzer were installed to continually
monitor the dissolved oxygen level of the Feed Water. Other
instrumentation installed includes level indicators, switches,
and alarms for the deaerator, pressure and temperature
transducers at the Deaerator and at the Storage Tank, pressure
gages and transducers for the incoming Condensate #1,
Condensate #2, Make-Up water, and steam. Conductivity
meters were installed on both the Condensate #1 and
Condensate #2 lines to monitor sugar contamination. A
NALCO TRASAR

fluorescence meter was installed on the

Condensate #2 line to monitor sucrose.
Each of the three sources of water has its own automatic
control valve with an independent PID loop used to control the
storage tank water level at 75% to 80% of full tank diameter.
The control scheme was designed to give the flow from
Condensate #1 first priority, Condensate #2 is given second
priority, and Make-Up is given last priority. Each valve can be
set within a specific range.

5 Copyright 2006 by Sugar Cane Growers Cooperative of Florida



Figure 5. Deaerator Automation Control Screen

With all valves in Auto mode, Condensate #1 will attempt
to maintain the Deaerator Tank level. If valve #1 continues to
open to 100%, valve #2s set point will become the same as
valve #1s set point as it tries to maintain the desired level. This
will also happen if Condensate #1 is not available. If
Condensate #1 or Condensate #2 is not available the Make-Up
valve set point will become the same as the set point for valve
#1 to maintain the water level. Condensate #1 control valve
was programmed to close at high levels of conductivity. The
Condensate #2 valve will close if high levels of conductivity or
high levels of Reflective Fluorescence Units (RFU) are
detected.
The Deaerator Overflow Valve will open when the
Deaerator Tank Level reaches 90% and will close when the
Deaerator Tank Level reaches 85%. Low-Low, Low, and High
alarm levels were also programmed. The installed
instrumentation and system automation help improve the
stability of the system and minimize fluctuations.

OVERALL EFFICIENCY IMPROVEMENTS
Having the condensate #2 bypass the holding tank and mix
directly with the condensate #1 before entering the deaerator
saves at least 5,600 lbs/hr of steam required for the deaeration
process. This savings are calculated using equations 1 and 8
and tabulated in Table 2 for the 200,000 lb/hr flow of
condensate #2 and normal temperature and pressure operational
parameters. [5]

Condensate #2 Flow (lb/hr) 200,000.00 200,000.00
Temperature Condensate #2 (F) 190.00 217.00
Temperature Steam In (F) 335.00 335.00
Pressure of Steam In (psia) 40.00 40.00
Feed water Flow out (lb/hr) 216,120.97 210,513.24
Enthalpy Steam (Btu/lb) 1,204.51 1,204.51
Enthalpy Condensate #2 (Btu/lb) 157.95 185.10
Enthalpy Feed water (Btu/lb) 236.012.00 236.01
Feed water Temperature (F) 267.24 267.24
Steam Flow Needed (lb/hr) 16,120.96 10,513.242
Steam Savings (lb/hr) 5608
Table 2. Calculated Steam Savings with Condensate #2
Bypassing Holding Tank

The above calculations assume that the outlet Feed Water
(M
3
) temperature is at the saturation temperature of the steam
pressure; that is, it assumes 100% Deaerator efficiency. The
installed deaerator appears to be close to 100% efficient since

the observed temperature 268 F of the Feed water corresponds
to the saturation temperature (268.27 F) at the steam pressure
26 psig (40.7 psia). However, the old deareator did not achieve
this high efficiency as can be seen in Table 3. The maximum
Feed Water temperature from the old Deaerator was 260 F.

Steam
Pressure
(psig)
(psia)
Feed water
Temperature
(F)
Feed
water
Pressure
(psig)
(psia)
Enthalpy
h
(Btu/lb)
[6]
New
Deareator
26
40
268
28
42.7
237.10
Old
Deaerator
26
40
260
28
42.7
228.96

Table 3. Comparison of the Old and New Deaerator
Flow Properties

Higher Feed Water temperatures and Btu savings are
currently being achieved. The difference between the enthalpy
of the Feed Water from the new deaerator (237.11Btu/lb) and
the enthalpy of the Feed Water exiting the old deaerator (228.98
Btu/lb) indicates a reduction in required heat input of 8.15 Btu
per pound of net steam. This represents a reduction of 1% in the
heat input required for net steam at 560F and 430 psia.
Theoretically, if the boilers are 100% efficient, this represents a
savings of about 8,000,000 Btu/hr or 2,340 kW/hr in the
production of 980,000 pounds of net steam per hour.
A plate heat exchanger was also installed to heat the Make-
Up water to about 130F. This also increased the thermal
efficiency when Make-Up water is used since the temperature
of the Make-Up water before this installation was as low as 40.
Now, even when the condensate #1 flow is being supplemented
with Make-Up water instead of Condensate #2, the temperature
of the Feed Water is not affected significantly. The system has
become more stable and fewer fluctuations are observed.

BENEFITS
Improved reliability and safety.
The available feed water supply capacity at the normal
water line (75% of diameter) of the Feed Water Storage
Tank has increased to 11.5 minutes for the normal 980,000
lb/hr steam production versus the original 8.5 minutes of
capacity.
Connecting the condensate #2 directly to the Condensate
#1 piping going to the deaerator reduced the steam
requirement for deaeration by at least 5,600lb/hr.
A Higher Feed Water outlet temperature saves about 8 Btu
per pound of net steam produced (8,000,000 Btu/hr or
2,340 kW/hr).
Boiler water quality improved.
Use of sulfite for boiler oxygen scavenging purposes was
reduced by 40%.
Water hammer has been eliminated at the Make-Up and
Condensate Deaerator inlet valves.

CONCLUSION
Sugar Cane Growers Cooperative of Florida improved the
operational safety and reliability by replacing the 29 year old
deaerator with a new counter flow two stage spray-tray
deaerator and installing a feed water tank that provides more
feed water storage capacity allowing more reaction time. The
higher efficiency deaerator allowed the amount of steam
required to complete the deaeration process to be reduced by at
least 5,600lb/hr. The use of required sulfite for boiler oxygen
scavenging purposes was reduced by 40%. The Higher Feed
Water temperature saves about 8 Btu/lb of net steam produced;
that is about 191,700.000 Btu (56,200 kW) saved per day.
The system modifications, the installation of state of the art
instrumentation, and the process automation combined to
protect the equipment from sugar contamination, prevent water
hammer, minimize system fluctuations, and provide quiet
operation without rumble or hammer from minimum to normal
operating capacity.
ACKNOWLEDGMENTS
The authors would like to acknowledge with appreciation
the following companies and individuals who contributed to
this project and/or to this presentation: Sterling Deaerator
Company; Key Controls; ECS Engineering, Inc.; Pala-
Insterstate, LLC; Sugar Machinery Engineering; Merchant
Transport; Thermal Analysis Systems, LLC; NALCO
Company; Romilio Alvarez; J aime Carrillo; Carlos Marin; J ose
Mena; and Marcy Tellechea.
REFERENCES
[1] Sterling Deaerator Company, Installation, Operation, &
Maintenance Manual For: 96-HTHS-5737-1120329
Deaerator, 2004.
[2] Heat Exchanger Institute Standards and Typical
Specifications for Deaerators, 2001.
[3] White Paper of the Deaerator Manufacturers Group of the
American Boiler Manufacturers Association, 2005.
[4] Sterling Deaerator Proposal#103-4779.1-R1, February 24,
2003.
[5] Thermal Analysis Systems, LLC, 725 Parkview Circle,
Elk Grove, IL 60007, Deaerator
[6] NIST, Thermophysical Properties of Fluid Systems, 2005.







6 Copyright 2006 by Sugar Cane Growers Cooperative of Florida