Paper 6 Chem Cleaning Edta Bhel

Advance Techniques in Boiler Chemical Cleaning
Chemical Cleaning of Boilers with EDTA
By:
HC Madan
SS Chauhan
Dhruv Garg
Bharat Heavy Electricals Limited 1
Power Sector: Technical Services
Agenda
1 Need for Chemical Cleaning of Boilers
2 What is EDTA Cleaning?
3 BHEL’s Experience with EDTA Cleaning
4 EDTA Cleaning Process
5 EDTA vis-à-vis HCl Cleaning– Advantages
6 Conclusion
Bharat Heavy Electricals Limited

Need for Chemical Cleaning of Boilers
Bharat Heavy Electricals Limited

Need for Chemical Cleaning of Boilers?
Pre-operative
• Maintaining steam quality at the turbine inlet.
• Minimizing corrosion of the metal surface of
boiler.
Post-operative
• Improving heat transfer in the system.
• Enhancing efficiency of the power plant.
• Minimizing under-deposit corrosion of the metal
surface of boiler.
• Minimizing plant outage due to boiler tube
failures.
Pre-operative Chemical Cleaning System

• Evaporator System
¾ Economizer
¾ Downcomers
¾ Bottom Ring Headers
¾ Water Walls
¾ Boiler Drum (Only water touched surface)

Iron metal surface with corrosion layers

What is EDTA Cleaning?

What is EDTA?
EDTA or Ethylene Di-amine Tetra acetic Acid is a strong
chelating agent having ability to form stable complexes
with transition metal ions present in boiler such as of Iron
and Copper etc.

EDTA and EDTA-Fe Complex Structure
EDTA EDTA-Fe Complex

EDTA Pickling & its Reaction

Magnetite Layer
• A protective layer of Magnetite (Fe3O4) is formed

on the water touched metal surfaces in the
steam generator.
• Magnetite layer acts as a coherent media that

stops further corrosion of the base metal.
• Magnetite is a combination of FeO and Fe2O3.

BHEL’s Experience with EDTA Cleaning

EDTA Process - World Scenario
• EDTA process is at present executed by :

Dow chemical Co – USA
Halliburton Services – UK
Alstom, MHI, & Siemens
• Process details & chemical formulations

especially inhibitor for the process are being
held under proprietary rights by these
companies.

EDTA Process - World Scenario
• BHEL has joined the select band of few

companies in the world to possess &
establish this advanced cleaning process.
• BHEL has marked the giant leap by

developing its own inhibitors and chemical
formulations for EDTA Cleaning Process.

Inhibitors
• EDTA Process developed by R&D Centre of
BHEL-Trichy; involved in-house development of
inhibitors:
BHEL MAX
BHEL SOL
• These inhibitors are patented by BHEL:

Patent Nos.: 177 & 332 / 2004
• These inhibitors act by forming an invariable

layer between the base metal surface and the
chemical solution as the deposits are removed.

Experience with EDTA Cleaning
• EDTA Cleaning Process was introduced in BHEL in
2003-2004.
• Chemical cleaning of boilers with EDTA completed in 43

projects of different ratings, till Feb 2009.
Year No. of Projects
2003 – 2004 1
2004 – 2005 3
2005 – 2006 3
2006 – 2007 7
2007 - 2008 13
2008 - 2009 16
Total 43
Experience with EDTA Cleaning
Rating wise –
2003-04 to 2008-09 (upto Feb 2009)
Rating No. of Projects
500 MW 4
250 MW 22
210 MW 9
75 / 120 / 125 MW 8
Total 43

Exceptions during reigns of EDTA Process
Besides EDTA Cleaning, BHEL has also conducted HCl

cleaning at following 7 projects during the same period.
Rihand # 4 (500 MW)
Vindhyachal # 9 (500 MW)
Vindhyachal # 10 (500 MW)
Sipat # 4 (500 MW)
Sipat # 5 (500 MW)
Kahalgaon # 6 (500 MW)
Kahalgaon # 7 (500 MW)

Projects expected in 2009-10
Rating No. of Projects
500 MW 9
250 MW 11
210 MW 1
125 MW 6
Total 27

EDTA Cleaning Process

Alkali Flushing
¾ Alkali Flushing
¾ Hot Water Flushing
¾ Cold Water Rinse
EDTA Cleaning
¾ EDTA Pickling & Passivation
¾ Treated DM Water Rinsing
Inspection
SH Back Flushing

Alkali Flushing - Purpose
Alkali Flushing
– Removes polar organic materials such as oil,
grease etc. from the metal surface.
– Alkali reacts with polar organic materials to form
soluble glycerols and salts.
– Loose deposits, dust etc. are also removed.
– TSP and DSP is used as alkali.
Hot Water Flushing
Cold Water Rinse

Alkali Flushing- Procedure
Alkali Flushing
¾ Alkali solution made by adding TSP(0.1%) & DSP
(0.05%) with DM water.
¾ Solution is filled into boiler through bottom ring
header & economizer drains up to NWL.
¾ Boiler is fired. Water temperature is raised to 140ºC
and boiler tripped.
¾ Solution is allowed to cool till 95ºC and then drained.

Alkali Flushing- Procedure (Contd..)

Hot Water Flushing
¾ System is filled with DM water and temperature
raised to 1400C and allowed to cool to 950C and
drained subsequently.
Cold Water Rinse

¾ System is filled with DM water and drained. The
process is repeated till phosphate level is less than
10 ppm.

Preparing EDTA Solution
EDTA solution is prepared for total boiler volume by
mixing.
1.EDTA Ammoniated (40%) : 4%

2.BHEL MAX (inhibitor) : 0.15-0.2% w/v
3.BHEL SOL (inhibitor) : 0.15-0.2% v/v
4.Hydrazine hydrate : 1000 ppm
5.Ammonia : for setting pH as 9.5-9.8

EDTA Pickling and Passivation

The system is filled with EDTA solution upto drum NWL
The boiler is lighted up and temperature raised to 1400C

and maintained for 4 hours and sample solution
checked for iron, pH and EDTA concentration every ½
an hour.
The boiler is tripped on achieving 3 consecutive

readings of iron concentration.
The solution is allowed to cool till 950C and drained.

Treated DM Water Rinsing
A solution of hydrazine (0.01-0.02%) and ammonia

with DM water is prepared (pH 9.5 – 9.8) and the
system is filled with this solution.
Boiler is fired and temperature raised to 120⁰C.
Boiler is tripped and allowed to cool. When the

temperature comes down to 95⁰C, the solution is
drained.

Inspection
¾ Boiler drum
¾ Bottom ring headers
¾ Water wall tubes
Super heater back flushing

Super heater is filled with a solution of hydrazine
(N2H4 >50 ppm) & Ammonia (pH>9.5) in DM water
through SH drain header. When the solution comes
through SH openings in the drum, the back flushing is
continued for 10-30 minutes and drained.

EDTA Cleaning Results



EDTA vis-à-vis HCl Cleaning-Advantages

EDTA vis-à-vis HCl Cleaning–Advantages
HCl Cleaning Process
• Preliminary Cleaning – Alkali Cleaning
¾ Hot Water Flushing
¾ Alkali Boil-out
¾ Cold Water Rinsing
• Acid Cleaning
¾ HCl Cleaning
¾ DM Water Rinsing
¾ Citric Acid Rinsing
¾ DM Water Rinsing
¾ Neutralization
¾ Passivation (1st and 2nd Stage)
• Inspection
EDTA vis-à-vis HCl Cleaning–Advantages
Disadvantages of HCl Cleaning Process
• Lot of temporary piping required.
• More number of chemicals (12 Nos.) required.
• Nitrogen gas in huge volume & its piping system required.
• Auxiliary steam required in huge quantity, which is a problem in
green field projects.
• DM water and fuel consumption is very high.
• Process handling is difficult and hazardous due to corrosive nature
of chemicals.
• Large cycle time (17 days).
• Effluent treatment & disposal requires huge investments.

EDTA vis-à-vis HCl Cleaning– Advantages
EDTA Cleaning– Advantages
• Technological advantages
¾ EDTA is a strong chelating agent with transition metal ions
and hence has an efficient action as metal remover.
• Process advantages
¾ Use of Nitrogen & its system is eliminated.
¾ Auxiliary steam is not required at all.
¾ DM water and fuel consumption is less.
¾ Shorter cycle time (5 days).

EDTA vis-à-vis HCl Cleaning– Advantages
EDTA Cleaning– Advantages
• Process advantages (contd.)

¾ Less temporary piping required
¾ Less number of chemicals required.
¾ Ease of handling.
¾ Effluent treatment easy.
• Other advantages
¾ Economical.

Conclusion

Conclusion
• EDTA cleaning process ensures efficient cleaning and

passivation of boiler internal surfaces.
• Inhibitor for EDTA cleaning process being used has been

developed by BHEL. Inhibitors are patented as – “BHEL
MAX” and “BHEL SOL”.
• EDTA Cleaning has obvious advantages over conventional

HCl Cleaning with minimum effect on the base metal
surface.

Thank you


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Advance Techniques in Boiler Chemical Cleaning

Chemical Cleaning of Boilers with EDTA

2 What is EDTA Cleaning?

3 BHEL’s Experience with EDTA Cleaning

4 EDTA Cleaning Process

5 EDTA vis-à-vis HCl Cleaning– Advantages

Bharat Heavy Electricals Limited

Bharat Heavy Electricals Limited

Pre-operative Chemical Cleaning System

Bharat Heavy Electricals Limited 5

Iron metal surface with corrosion layers

Bharat Heavy Electricals Limited 6

Bharat Heavy Electricals Limited 7

Bharat Heavy Electricals Limited 8

EDTA EDTA-Fe Complex

Bharat Heavy Electricals Limited 9

Bharat Heavy Electricals Limited 10

• A protective layer of Magnetite (Fe3O4) is formed

• Magnetite layer acts as a coherent media that

• Magnetite is a combination of FeO and Fe2O3.

Bharat Heavy Electricals Limited 11

Bharat Heavy Electricals Limited 12

• EDTA process is at present executed by :

• Process details & chemical formulations

Bharat Heavy Electricals Limited 13

• BHEL has joined the select band of few

• BHEL has marked the giant leap by

Bharat Heavy Electricals Limited 14

• These inhibitors are patented by BHEL:

• These inhibitors act by forming an invariable

Bharat Heavy Electricals Limited 15

• Chemical cleaning of boilers with EDTA completed in 43

Bharat Heavy Electricals Limited 17

Besides EDTA Cleaning, BHEL has also conducted HCl

Bharat Heavy Electricals Limited 18

Rating No. of Projects

Bharat Heavy Electricals Limited 19

Bharat Heavy Electricals Limited 20

Bharat Heavy Electricals Limited 21

 Hot Water Flushing

 Cold Water Rinse

Bharat Heavy Electricals Limited 22

Alkali Flushing- Procedure

Bharat Heavy Electricals Limited 23

Alkali Flushing- Procedure (Contd..)

 Cold Water Rinse

Bharat Heavy Electricals Limited 24

1.EDTA Ammoniated (40%) : 4%

Bharat Heavy Electricals Limited 25

EDTA Pickling and Passivation

 The boiler is lighted up and temperature raised to 1400C

 The boiler is tripped on achieving 3 consecutive

 The solution is allowed to cool till 950C and drained.

Bharat Heavy Electricals Limited 26

 A solution of hydrazine (0.01-0.02%) and ammonia

 Boiler is fired and temperature raised to 120⁰C.

 Boiler is tripped and allowed to cool. When the

Bharat Heavy Electricals Limited 27

 Super heater back flushing

Bharat Heavy Electricals Limited 28

Hot Water Flushing

Cold Water Rinse

Cold Water Rinse

The boiler is lighted up and temperature raised to 1400C

The boiler is tripped on achieving 3 consecutive

The solution is allowed to cool till 950C and drained.

A solution of hydrazine (0.01-0.02%) and ammonia

Boiler is fired and temperature raised to 120⁰C.

Boiler is tripped and allowed to cool. When the

Super heater back flushing