KURITA (SINGAPORE) PTE. LTD.

DATE

DOCU NO.
15 February , 2008

KSP-TOI-01032008

NO. 30 JOO KOON ROAD, SINGAPORE 628984 CONTRACT NO. 00

TEL: 68612622 • TELEX: RS 26225 KWISPR • FAX: 68614768 JOB NO.

FOR TOTAL SHEETS

MCC PTA India Corp. Private Limited
Attention: Mr. Watanabe Vice President

TECHNICAL PROPOSAL

BOILER SYSTEM

CHEMICAL WATER TREATMENT PROGRAM

FOR

MCC PTA India Corp. Private Limited

(Oct. 2000 Turnaround

NO. TITLE
ATTACHED DWG
NO. TITLE
DRAWING NO.
NO. TITLE
TITLE

REVISION DATE APPR'D CHECK'D MADE DESCRIPTION

0 15 Feb08 Woon Tien Teck Woon Tien Teck T. Tamura Proposal

0
1

4
 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 2 OF 12

TABLE OF CONTENTS

1. INTRODUCTION 3

2. BOILER SPECIFICATIONS
2.1 Operating condition 4
2.2 Heat exchangers information 5

3. CHEMICAL TREATMENT PROGRAM

3.1 Corrosion inhibitor for feed water and steam condensate line 6
3.2 Oxygen Scavenger 7
3.3 Chemical preparation 8

4 STANDARD CONTROL RANGE (JIS B82232006) 9

5. ADDITIONAL ANALYSIS 10

6. ESTIMATED CHEMICAL CONSUMPTION 10

7. START UP BOILER TREATMENT

7.1 Treatment program 11
7.2 Water quality control range 11
7.3 Procedure 12
7.4 Remarks 12

<ANNEX-1 Flow diagram>

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 3 OF 12

1. INTRODUCTION

The Waste Heat Boiler (WHB) for Messer’s. MCC PTA India Corp. Private Limited (MPI) is
composed of several materials, such as Titanium, Stainless steel, Carbon steel, and it has been
operated without deaerator since start-up in 2000. The crack in the WHB E-1765 A1 was found
in 2006 and plugged. The crack in the WHB E-1765 A2 was found in 2007 and also plugged.
The many defects were found inside of the tubes by eddy current test, and the coming out
impingement baffle was identified during shut down.
The inspection was conducted and the investigation has been continued.

We would like to propose the KURITA Boiler Treatment Program to improve the situation,
taking the current & past operating condition for Indonesian plant and other Mitsubishi Chemical
PTA plant.

The chemical treatment program recommended hereafter is specified based on the following
given operational data. Therefore, if the actual conditions changed, this program should be
reviewed and adjusted accordingly.

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 4 OF 12

2. BOILER SPECIFICATIONS

2.1 Operating conditions

Please refer to the attached flow diagram.(Annex-1)

  

 

   

  

  

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KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 5 OF 12

2.2 Heat exchangers information

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KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 6 OF 12

3. CHEMICAL TREATMENT PROGRAM

Based on the experience in Indonesian plant and as per the request from MPI, we would like to
recommend volatile treatment for the waste heat boiler system.

3.1 Corrosion inhibitor for feed water and steam condensate line

Volatile amines are typically applied to inhibit the feed water line or the steam condensate line
from the corrosion. They inhibit the corrosion by controlling pH within target range.
Volatile amines are also used to control the pH in boiler water.
OXYNON M-601 is volatile amine basis chemical, which is able to control pH of feed water,
boiler water and steam condensate.
This product has low volatility; therefore, it has stronger pH buffering effect against acetic acid
contamination and the amount transferring to steam when it is started up is smaller.

Chemical Name OXYNON M-601

Main Ingredient Volatile Amine
Function 1. Control pH of the feed water, boiler water,
steam and condensate lines.
2. Prevent all water lines, the feed water to the
steam condensate from corrosion.
3. Neutralize dissolved carbon dioxide caused by
the thermal decomposition of M-alkalinity in
the feed water
Dosage Initial charge -
Maintenance 2 ppm against feed water quantity
Method of Dosing The chemical is continuously injected by a metering
pump with/without dilution water
The injection point is feed water line.
Dosing control Based on online pH/EC meter

(Remarks)
It is recommended to install additional online pH&EC (Electric Conductivity) meter in the boiler
feed water line and boilers. Please refer to the recommended installation point in the attached
flow diagram (Annex-1) and relation ship between OXYNON M-601 concentration and pH/EC.
(Annex-2&3)

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 7 OF 12

3.2 Oxygen scavenger

An oxygen scavenger is strongly recommended based on the experience in Indonesian plant.

The root cause of the tube crack has not been identified yet, however, it is highly suspected the
crack might be occurred due to the presence of corrosion product. (Hematite, Fe2O3) and there
has been no problem in Indonesian plant since we applied for oxygen scavenger.
An oxygen scavenger is a chemical, which removes dissolved oxygen in water by reduction
reaction, and thereby inhibit the corrosion caused by oxygen.
It is recommended to apply for a hydrazine basis oxygen scavenger, OXYNON H-104, which has
been applied in Indonesian plant for long time.
This also form thin and strong corrosion protective film of magnetite (Fe3O4) on the surface.

The some heat exchangers are composed of Titanium and stainless steel, which make self
oxidation protective film, therefore, it is essence to control dissolved oxygen in proper control
range by checking dissolved oxygen. (Do not remove all!)

Chemical Name OXYNON H-104

Main Ingredient Hydrazine
Function 1. Removal of residual oxygen
2. Reduction of iron oxide
Dosage Initial charge -
Maintenance 1 ppm against feed water rate
Method of Dosing The chemical is continuously injected into the steam
drum by a metering pump with dilution water
Dosing control Based on online DO meter &
Residual hydrazine concentration

(Remarks)
It is recommended to install online DO (Dissolved Oxygen) meter in the boiler feed water line
and boilers. Please refer to the recommended installation point in the attached flow
diagram.(Annex-1)

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 8 OF 12

3.3 Chemical preparation

Based on the given information, we would like to suggest the following preparation.
This can be changed depending on the operation condition.

Injection point G-1792 suction F-1792

Boiler feed water rate 175.0 158.1
Tag No.
Pump manufacturer
Pump max. Pressure - MPa
( kgf/cm2)
flow rate 1.05kg/h
Max flow rate 200kg/h
Flow meter 0-20kg/h
Pump capacity - 9.4L/h
Pump stroke - 10%
Pumping rate - 0.95L/h
Tank capacity 300 L 300L
Top up frequency Every week Every week
<Preparation>
OXYNON M-601 40kg 40kg
OXYNON H-104 20kg 40kg
Demineralized water 60L 60L

*: It shall be checked and adjusted later

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 9 OF 12

4. STANDARD CONTROL RANGE

Items - Feed Water Boiler Water Frequency

pH - 9.0 – 9.8*1 9.6 – 10.3*2 Daily
Electrical Conductivity µS/cm <30 < 60 Daily
Hardness mg CaCO3/L Not detected - -
*3
Oil mg/L - Monthly
Total Iron mg Fe/L < 0.3 <0.6 Weekly
Residual hydrazine mg/L - 0.1-1..0*4 Daily
Chloride Ion mg Cl-/L - <2 Weekly
Silica mg SiO2/L - <5 Weekly

Remarks:

*1: Target pH for feed water shall be more than 9.3, in order to inhibit the carbon steel from
corrosion with the condition there is no cupper and copper alloy materials in the system.
*2: Target pH for feed water shall be more than 9.8, in order to inhibit the carbon steel from
corrosion with the condition there is no cupper and copper alloy materials in the system.
*3: Desirable to maintain at the lowest level
*4: Target residual hydrazine concentration in boiler water is 0.05-0.3mg/l considering titanium
tube corrosion inhibition. However it is desirable to adjust it based on the DO measurement
results (Target DO in boiler =1-10ppb), because the operating condition and DO balance may be
different plant by plant.

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 10 OF 12

5. ADDITIONAL ANALYSIS

It is recommended to analyze below items periodically, in order to know the abnormality, such as
contamination from the process side. (At least, once a month)

Items - Min. detection limit

Items - Feed Water Boiler Water
Electrical Conductivity mS/m(uS/cm) x0.1( x1) -
pH - x0.1 -
Chloride Ion mg/L <0.05 -
Sulphate ion mg/L <0.05 <1
Calcium ion mg/L <0.05 -
Magnesium ion mg/L <0.05 -
Silica mg/L <0.01 <0.1
Total iron mg/L <0.01 <0.1
Acetic acid mg/L <1 -

6. ESTIMATED CHEMICAL COMSUMPTION

Following table is the estimated chemical consumption based on the given operating condition.

Chemical OXYNON M-601 OXYNON H-104

Dosage(mg/l)
20 1.0
Consumption(kg/month)
478 238
24 hours x 30days operation
Consumption(kg/year)
5,276 2,622
330 days operation

Remarks: Boiler feed water quantity is 333.1t/h.

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 11 OF 12

7. START UP BOILER TREATMENT(Main/Tracing boiler)

7.1 Treatment program

As per request from Messrs. Mistubishi Chemicals Corporation, the following program is
recommended as a volatile treatment.

Chemical OXYNON M-601*2 OXYNON H-104*3

Dosage(mg/l) *1
30 40

Remarks:
*1: The dosage is injected against holding water volume.
*2: As the volatile amine is contained in feed water, the actual dosage to obtain pH>10 may be
lower than the above figure.
*3: When it is resumed the operation(without blow down), overdose of oxygen scavenger is not
favorable, as high concentration of hydrazine may go to the steam side and disturb the formation
of self oxidation film of Titanium and stainless steel. Therefore, it shall be controlled strictly, the
initial residual hydrazine concentration is around 10mg/L and maintain more than 1mg.L.

7.2 Water quality control range

The following is the water quality control range during idling.

Items Unit Main/Tracing boiler water

pH
- >10
Electric conductivity
mS/m(uS/cm) <10(<100)
Residual hydrazine
mg/L >1
Total iron
m/L No increasing trend

Remarks:
Although the volatile treatment corrosion inhibition (pH buffering effect) is weaker than non-
volatile treatment (Alkaline + sufficient hydrazine.), if is controlled properly, the corrosion can
be reduced to acceptable level.

KURITA (SINGAPORE) PTE. LTD.

 JOB
KSP-TOI-01032008
NO.
MCC PTA India Corp. Private Limited KSP-TOI-01032008

ISSUED PAGE 12 OF 12

7.3 Procedure

1) In order to adjust the water quality as indicated above, the specified chemicals shall be dosed
before stoppage of the boiler.
2) Before the boiler become vacuum condition, N2 gas shall be injected from gas phase of the
boiler, pressurize and preserve the boiler. N2 gas pressure shall be maintained more than
0.05MPa (0.5kgf/cm2).

7.4 Remarks

1) Boiler water quality check shall be conducted more than once a month. (pH, Electric
conductivity, residual hydrazine and total iron) It is desirable to analyze more than once a
week, when the treatment program is changed to check the tendency.
2) If the water quality is out of the control range, it shall be adjusted by dosing OXYNON M-
601 and/or OXYNON H-104 additionally. After the dosing, it shall start the firing and
increase the pressure up to around 0.4MPa(4kgf/cm2) in order to homogenize the dosed
chemical concentration.
3) In case N2 gas sealing is not available, it can be pressurized by burner/tracing line to preserve
the boilers. However, the steam main valve shall be closed and maintained the volatile amine
and steam in the boiler like a closed system. It is advised to increase the frequency of the
water quality checking, as the residual hydrazine is consumed faster than N2 gas sealing.
4) In order to avoid entering steam condensate from steam line, the steam main valve shall be
closed during idling.

KURITA (SINGAPORE) PTE. LTD.