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    The document discusses the role and functions of a condensate polishing unit (CPU) in a power plant. The CPU improves feed water quality using ion exchange to remove impurities from cycle condensate before it is returned to boilers. It can remove copper, iron, and other contaminants down to very low levels. The CPU prevents quality degradation during condenser leaks by maintaining purified condensate. It works through cation exchange and ammonium cycles to continuously treat condensate through ion exchange reactions.

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    Bala

    Uploaded by

    mkgchem
    135 views26 pages
    The document discusses the role and functions of a condensate polishing unit (CPU) in a power plant. The CPU improves feed water quality using ion exchange to remove impurities from cycle condensate before it is returned to boilers. It can remove copper, iron, and other contaminants down to very low levels. The CPU prevents quality degradation during condenser leaks by maintaining purified condensate. It works through cation exchange and ammonium cycles to continuously treat condensate through ion exchange reactions.

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    role of condensate polishing

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    The document discusses the role and functions of a condensate polishing unit (CPU) in a power plant. The CPU improves feed water quality using ion exchange to remove impurities from cycle condensate before it is returned to boilers. It can remove copper, iron, and other contaminants down to very low levels. The CPU prevents quality degradation during condenser leaks by maintaining purified condensate. It works through cation exchange and ammonium cycles to continuously treat condensate through ion exchange reactions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    135 views26 pages

    Bala

    Uploaded by

    mkgchem
    The document discusses the role and functions of a condensate polishing unit (CPU) in a power plant. The CPU improves feed water quality using ion exchange to remove impurities from cycle condensate before it is returned to boilers. It can remove copper, iron, and other contaminants down to very low levels. The CPU prevents quality degradation during condenser leaks by maintaining purified condensate. It works through cation exchange and ammonium cycles to continuously treat condensate through ion exchange reactions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
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    Download as pptx, pdf, or txt
    of 26

    -Role in Power Plant

    R.BALAKRISHNA PATNAIK EMP. NO-103088 TSTPS, KANIHA

    IMPORTANCE
    Both fossil and nuclear Power plants demand pure water for steam generation. Condensate Polishing improves the quality of feed water by using ion exchange process to treat cycle condensate being returned to the boiler as feed water.

    FUNCTIONS OF CPU
    To remove the traces of soluble impurities present in

    feed water entering a high pressure boiler that can be concentrated within the system.
    It is capable of removing copper and iron (soluble and

    insoluble species) to a very low concentration.

    FUNCTIONS OF CPU
    Condensate polishing unit is basically a mixed bed of

    cation exchanger and anion exchanger A filter to remove all types of suspended solids from the condensate It preserves the quality of condensate by removal of the dissolved solids through ion exchange reaction It maintains the quality even during the ingress of cooling water in steam water cycle through condenser

    SOURCES OF CONTAMINATION
    1. Contamination from water treatment plant 2. Use of impure water for dosing system 3. Use of impure dosing chemicals 4. Residues from chemical cleaning 5. Condenser tube leakage.

    PRINCIPLE OF CPU
    In various Power plants steam is used for generating power. The steam after losing its heat condense back into water. While condensing, steam picks a lot of impurities from the environment which should be completely removed before using condensate again. The polishing unit purifies the condensate before using it back it works on ion exchange resin bed to remove the contaminants.

    SERVICE CYCLES IN CPU


    CPU works on two cycles

    1. H+ cycle : when cations in the water phase are exchanged with H+ ions on the resin. 2.NH4+ cycle: when cations in the water phase are exchanged withNH4+ ions on the resin.

    SERVICE CYCLES IN CPU


    At the initial run max part of condensate ammonia is being absorbed by the resin so outlet water is just like DM water with a very less or nil ammonia called H+ cycle.
    So pH is lowered by removal of the ammonia. R-H + NaCl (impurities) RNa +HCl. ROH+HCl RCl+H2O RH + NH4OH RNH4 + H2O

    SERVICE CYCLES IN CPU


    In the ammonium form operation, every sodium ion exchanged results in release of an ammonium ion . This is ammonia displacement effect. And there is a consequent small increase in pH.
    RNH4 + NaCl R-Na +NH4Cl NH4Cl +ROH RCl + NH4OH

    CPU SERVICE
    From CEP

    Flow Transmitter Bypass valve

    DPT

    SG

    Service Vessel

    To dereator

    ACC Resin Trap

    BY PASS VALVE & OTHER INSTRUMENTS

    SERVICE CYCLES IN CPU

    Cation exchange during service cycle:

    R c Na + HCl R c H + NaCl

    Anion exchange during service cycle:


    R a Cl + NaOH R a OH + NaCl
    Rc Cation Exchange Resin ; R a Anion Exchange Resin

    For mixed bed resin the following reaction occur: R c Na + R a Cl + H2O R c H + R a OH + NaCl

    SERVICE CYCLES IN CPU


    It is observed that during the H+ Cycle run the concentration of impurities(chloride & silica) is decreased in CBD but when the ammonia cycle run started their concentration is increased as compared to H + cycle.
    Also known as equilibrium leakage. There are two reasons for this : 1.Water phase ion concentration 2. Ion selectivity of the resin.

    CASE STUDY ON CPU OPERATION AND PERFORMANCE


    Date Time Chloride ( ppb) 10:45:08 AM 9:47:31 AM 125 102 pH Conductivity Lab 06/3/2012 07/3/2012 9.5 9.5 7.8 8 O/l 8.89 9.12 40 34 Silica (ppb)

    08/3/2012
    09/3/2012 10/3/2012 11/3/2012 12/3/2012 13/3/2012 14/3/2012 15/3/2012 16/3/2012 17/3/2012

    9:43:02 AM
    4:50:13 PM 5:56:23 AM 12:37:08 AM 4:14:59 PM 11:28:50 PM 4:17:26 PM 11:27:49 PM 4:56:03 PM 9:20:26 AM

    79
    68 44 35 30 35 40 45 50 52

    9.3
    9.3 9.3 9.3 9.3 9.3 9.3 9.4 9.4 9.3

    5.7
    5.7 4.9 4.9 5.6 5.5 6.6 6 6.9 5.5

    5.86
    5.84 5.12 5.24 5.98 5.75 6.62 6.1 7.81 5.76

    16
    18 20 24 20 25 28 38 45 43

    CASE STUDY ON CPU OPERATION AND PERFORMANCE


    Date 18/03/2012 Time 4:50:03 PM Chloride (ppb) 55 pH Lab 9.3 5.9 Conductivity O/l 5.9 Silica (ppb) 45

    19/03/2012
    20/03/2012 21/03/2012 22/03/2012 23/03/2012 24/03/2012 25/03/2012 26/03/2012 27/03/2012

    4:16:24 PM
    9:33:20 AM 6:05:23 PM 12:38:23 AM 9:27:17 AM 11:53:54 PM 3:43:24 PM 9:42:10 AM 4:14:15 PM

    58
    56 58 58 60 65 70 75 85

    9.3
    9.4 9.3 9.5 9.4 9.4 9.4 9.4 9.4

    6.1
    6.6 5.5 7 7.1 6 7.4 6.8 6.5

    6.34
    7.19 6.54 7.4 7.9 6.3 7.49 6.79 6.68

    48
    50 54 56 57 58 60 76 72

    28/03/2012
    29/03/2012

    12:06:57 AM
    10:04:14 PM

    100
    112

    9.4
    9.4

    6.7
    6.4

    6.73
    6.56

    65
    82

    VARIATION OF CHLORIDE AND SILICA IN CBD


    Chloride Silica

    140 120 100

    Conc. In ppb

    80
    60 40 20 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

    Silica
    16 17 18 19 20 21 22 23 24

    CPU Run TIME IN DAYS

    TYPES OF CPU:
    POWDEX TYPE :These are use & throw type resin

    available in anion , cation & inert form. These are used as coating on a filter candle. These acts mostly as crud filter & also as ion exchanger. They however have shorter shelf life. DEEP BED TYPE: These are regenerative type mixed bed ion exchange resin having special characteristics with respect to temperature, pressure, bead size.

    AMMONEX : After regeneration anion is circulated with NH4OH to convert cross contaminated cation from Na to NH4 + form. SEPREX CONSEP-SEPREX :Used at TSTPS, KANIHA PURESEP : Exhausted resin is passed through series of screen to remove small cation & large anion particle so that effective hydraulic separation will occur.

    AMSEP: It consist of 4 cigar shaped tall vessels & 4 steps of converting resin into ammonium sulfate form viz Resin backwash,ammonium sulfate (1% & 3 % ), 6% regeneration, backwash & (30% ammonium sulfate ) regeneration (anion floatation & transfer.

    CPU REGENERATION SYSTEM


    IRU
    CRU

    ARU

    Alkali Met. Drain Drain

    Heater

    Acid Met.
    From DM Reg Pump

    DESIGN PARAMETERS
    No. of Polisher Units : 2
    Design : Kennicott water system ltd.UK Design flow/vessel : 675 m3/hr Volumetric ratio of resin cation: anion : 1.5:1 Resin type cation/anion : SP 112H /MP500KR Resin quantity of vessel cation/anion : 4100/2900 lit. Regen.Concentration: 4% HCl/4%NaOH

    S.NO

    Parameter

    Units in measure

    CPU I/L

    CPU O/L

    1 2 3 4 5 6 7

    Ammonia Silica Iron Copper Sodium Chloride Cation conductivity Crud

    ppb Ppb Ppb Ppb ppb ppb


    S/Cm

    500 20 5 50 10 10 -

    5 2 5 2 2 0.1

    ppb

    50

    CONSTRAINTS OF CPU:
    The total out put is mostly limited to Hydrogen cycle . Ammonia cycle run is very short till Cation S/Cm conductivity reaches to maximum=0.1 Sometime Drum chemical parameter gets disturbed with respect to pH & chloride Both polishers are kept in service during start up operations till the normalization of chemical regimes of the steam water cycle.

    CONSTRAINTS OF CPU:

    Not able to achieve the designed throughput. Cross contamination during regeneration.

    Air

    mixing device at service vessel. Air filters to be provided for service air. Chloride on line meters to be provided at CPU O/L. Auto operation of LP dosing governed by pH,Conductivity during CPU service. CPU may be run continuously at least in Hydrogen cycle.

    BENEFITS

    Continuous or intermittent service of CPU, keeps steam-water cycle clean. Removes crud and undesirable ions & hence better water chemistry. During, small condenser leakage, Unit can be run for some days with the support of CPU. During cold start up crud carry over from Feed cycle is restricted.

    TELL ME, I MAY REMBER SOME OF IT. SHOW ME, I WILL PROBABLY REMEMBER MOST OF IT,

    BUT INVOLVE ME, I WILL UNDERSTAND IT

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