Process Design of Industrial Deaerators

Jayanthi Vijay Sarathy, M.E, CEng, MIChemE, Chartered Chemical Engineer, IChemE, UK
The primary purpose of an industrial 3. The saturation temperature, (i.e., boiling)
deaerator is to purge feed water in process of water is 1000C at 1 atm. When feed water
facilities of any oxygen (as air). Oxygen in comes into contact with the stripping
feedwater is a common cause for corrosion in steam, chances are that the feedwater can
industrial equipment. The presence of any vapourize and would be vented with the
carbon dioxide in feed water exacerbates steam. Therefore to prevent loss of
corrosion by forming carbonic acid which feedwater through venting, it is imperative
lowers the pH of the water. With time, pitting to supply feedwater below its saturation
corrosion sets in & perforates the equipment. temperature, say between 800C to 900C.
To attend to the issue of oxygen in feedwater, Typically, the feedwater must be deaerated
a deaerator collects the returning feedwater upto 0.02 mg/litre (ppm)
containing non-condensables (including air) 4. Deaerators can operate under pressurized
and is stripped out using steam. The following or vacuum conditions. For pressurized
article explains the process design steps for a deaerators, typical operating conditions
deaerator. would be between 0.2 to 0.5 barg. The
deaerated water collection vessel would
have a holdup time of 10 to 15 minutes or
higher depending on the process
requirements. Since the steam is suppled
via a control valve, steam pressures can
range from 5 barg to 10 barg. The returning
feedwater supply pressure must be atleast
2 barg to ensure sufficient atomization
occurs and the water droplets come into
contact with the steam inflow.
Figure 1. Deaerator Schematic [4]
General Notes 5. To minimize steam consumption and
1. The solubility of gas in a solvent depends on increase efficiency, the feed water must be
its pressure and temperature and is hot as possible, but below saturation
governed by Henry’s Law. At higher temperature. However since this is not
temperatures, the solubility of gas possible during a plant start-up, the
decreases. However at higher pressures, feedwater tank must be provided with
solubility increases which dictates the heating coils for plant start-up purposes.
necessity to operate a deaerator at lower 6. The deaerator can also be insulated to
pressures. minimize heat losses. During venting, along
2. In actual practice, feedwater is both with air / non-condensables, some amount
chemically (such as sodium sulphite) and of water is also expected to be lost due to
thermally treated to expunge any dissolved entrainment. Turndown ratios are typically
gases to maintain a pH between 8 and 9 to around 5:1. The control system must
avoid corrosion. include steam control, water level control
and manual venting provisions.
Page 1
Problem Statement temperature would be lower than 105.1010C
A deaerator operates at 0.2 barg with feed at 0.2 barg, i.e., 1000C. Therefore the reduction
water supplied at 800C from condensate tank in steam temperature in the deaerator is,
in a process facility. The non-condensables is ∆𝑇 = 𝑇!"#$% − 𝑇&'()*"#$% %',"-(# (6)
taken to be only air. It is assumed that the ∆𝑇 = 105.101 − 100 = 5.101℃ (7)
deaerator is insulated well with no heat losses The steam released with per litre of air is,
and the air is assumed to be completely /00)&'(%
carried by the steam to the vent. The Air % in 𝑚!"#$%/$'( = &'(%
(8)

total volume of air-steam mixture a.k.a., 𝑚!"#$%/$'( =

/00)/2.405
= 5.095 𝑙𝑖𝑡𝑟𝑒𝑠 (9)
/2.405
volume of air to steam in mixture at 0.2 barg is
taken to be 16.408% from figure 2. The density of air is calculated using Ideal gas
Alternatively the online calculator from Ref equation. Considering the operating pressures
[6], can be used to determine the Air% in total are low at 0.2 barg, the compressibility factor
volume of air-steam mixture. The boiler [Z] is taken to be 1.0.
$%
supplying steam operates at 5 barg with a 66!"# [8$($] × ;<[ ]
𝜌$'( = &) .+!#
$&'(
(10)
supply flow of 5 tonnes/hr. = × >0.05?/4
$&'(.,
@ × A[B]

+.,+/+0 × 20.3-
𝜌!"# = + × ,.,04+/ × (+,,6274.+8) = 0.947𝑘𝑔/𝑚4 (11)

From steam tables [8], the specific volume

[vsteam] of steam at 1000C is 1.41385 m3/kg
from which the steam density is calculated as,
+ + => >;
𝜌:&%!; = < = +./+408 = 0.7073 ;& 𝑜𝑟 ) ?
* (12)
!"#$%

Therefore the steam released by 0.9467 gms of

air is,
𝑚!"#$% (#C#$!# = 𝑚!"#$%/$'( × 𝜌𝑠𝑡𝑒𝑎𝑚 (13)

𝑚:&%!; #%E%!:% = 5.095 × 0.7073 = 3.6 𝑔𝑚𝑠 (14)

To estimate the air released from the
Figure 2. Volume of Air to steam in mixture [7]
returning feed water at 0.2 barg and 800C, the
From the data given, the venting rates can be solubility of air in water is estimated as,
calculated as, - -

𝑆𝑡𝑒𝑎𝑚 𝑆𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑇 𝑎𝑡 0.2𝑏𝑎𝑟𝑔 = 105.101℃ (1) 𝐾50℃ = 0.0079 × 𝑒 EF?G0×H).).-.)/0).-.IJ (15)

; %KC
The partial pressure [PPair] of air in steam is, 𝐾50℃ = 0.0002024 $"% 𝑜𝑟 C'".$"% (16)

𝑃𝑃!"# = 𝑃$%!%#!&'# − 6
("# %
× 𝑃$%!%#!&'# 8 (2) The solubility at 0.2 barg and 800C is,
+,,
L%
+-./,0 𝑆50℃ = 0.0002024 × 28.96 = 0.00702 C'"
(17)
𝑃𝑃!"# = 1.21325 − 6 +,,
× 1.213258 (3)
Taking 1000 L of water = 1000 kg of water,
𝑃𝑃!"# = 1.01418 𝑏𝑎𝑟𝑎 (4)
L% M.0F L%
𝑆50℃ = 0.00702 = /000 NL KO P$"#( (18)
𝐴𝑖𝑟 𝑆𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑇 𝑎𝑡 1.0142 𝑏𝑎𝑟𝑎 = 100℃ (5) C'"

With the presence of air in steam, there would i.e., For every 1000 kg of water at 0.2 barg and
be a reduction in the saturation temperature 800C, 7.02 gms of air is released. The steam
of steam since air is a poor conductor of heat. released with 7.02 gms of air is,
M.0F×?.2
As a result the deaerator operating 𝑆50℃ = = 26.71 𝑔𝑚𝑠 (19)
0.Q42M
Page 2
Therefore the total air and steam vented per (𝑚8K'C#( ℎ/ ) + e𝑚! ℎL f = (𝑚8K'C#( + 𝑚! )ℎF (23)
1000 kg of deaerator capacity is, Where,
𝑚 F,:&%!;/!"# ;"I = 7.02 + 26.71 = 33.73 𝑔𝑚 (20)
mboiler = Max boiler output at initial T [kg/h]
In practice, the flow rate of the order of 30 or h1 = Enthalpy of feedwater at supply T [kJ/kg]
40 gms of steam-air mixture is very low to be
ms = Steam flow rate [kg/h]
vented / regulated, and also must be purged to
avoid re-entrainment. For this reason hg = Enthalpy of steam supplied [kJ/kg]
manufacturers recommend a venting rate h2 = Enthalpy of feedwater at final T [kJ/kg]
between 0.5 to 2.0 kg of steam-air mixture per Re-arranging the energy balance equation,
1000 kg of feed water [3]. [R )R ]
𝑚! = 𝑚8K'C#( × SR / )R- T (24)
% /
Steam Requirements
To estimate the steam requirements for the Therefore, for an effective/max boiler capacity
deaerator, it can be made based on the boiler’s [mboiler] of 4,662 kg/h, the enthalpy of the
capacity and feedwater requirements. For this, returning feedwater supply [h1] at 800C is
the boiler’s maximum useful steaming rate has 334.501 kJ/kg. The enthalpy of steam supplied
to be determined which depends on the initial at the upstream of the control valve [hg] at 5
feedwater temperature. The maximum boiler barg is 2756.23 kJ/kg. The enthalpy of
output [mboiler] is estimated as, feedwater at a final temperature [h2] of
K' $"% × L'"E%# M!N!O"&P 105.1010C is 440.19 kJ/kg.
𝑚J'"E%# = Q R Q0##12$"#- 3#%4#-$"/-#
(21)
)*+,#- .-#!!/-# [440./Q)??4.G0/]
𝑚! = 4,662 × [FMG2.F?)440./Q] = 213 𝑘𝑔/ℎ (25)
Where,
Therefore, the steam flow required at 5 barg at
𝝺1 atm = Latent heat of vapourization [kJ/kg]
the steam control valve upstream is 213 kg/h,
Hboiler = Specific Enthalpy at Boiler
Pressure
and a downstream pressure of 0.2 barg, i.e., the
Pressure [kJ/kg]
operating pressure of the deaerator. The
Hfeedwater = Specific Enthalpy at
Temperature saturation temperature of air-steam mixture
feedwater temperature [kJ/kg] in the deaerator operating at 0.2 barg is
For a boiler pressure of 5 barg at the inlet of 105.1010C, which reduces to 1000C due to the
the steam control valve and 5,000 kg/h of presence of 16.408% Air in the steam.
steam, the latent heat of vapourization [𝝺] at 1 Steam Control Valve Size
atm is 2,258 kJ/kg [9]. The specific enthalpy at To regulate steam into the deaerator, a steam
the inlet of the steam control valve [Hboiler P] is control valve is placed in the line from the
2,756.23 kJ/kg for 5 barg. The initial feedwater boiler to the deaerator. The boiler generates
specific enthalpy [Hfeedwater T] at 800C is steam at 5 barg which is reduced to 0.2 barg at
334.501 kJ/kg. Therefore the maximum or the downstream of the control valve
effective boiler output [mboiler] is, (assuming line losses are neglected). For a
FFG5 × G000
𝑚8K'C#( = FMG2.F? )??4.G0/ = 4,662 𝑘𝑔/ℎ (22) steam flow rate of 213 kg/h, the control valve
coefficient [Cv] is calculated as,
To estimate the steam requirements, an
energy balance is made such that the initial " , -
𝐶! = # f f (26)
$%.'×)e ×*f × + .×/0
amount of heat in the feedwater and heat
added by the injected steam is equal to the Rearranging to calculate mass flow rate ‘m’,
final amount of heat in the feedwater and ,×;<
𝑚! = 𝐶U × 94.8 × 𝐹6 × 𝑃/ × 𝑌l (27)
condensed steam. The energy balance is, A- =-

Page 3
Where, Based on ANSI/ISA S75.01 method, for a
𝑌 = 1 − ?V
,
(28) piping geometry factor (Fp) of 1.0, i.e., no pipe
, W2
N
fittings, 6” control valve size, equal percentage
𝐹B = /.4 (29) characteristics and a steam flow of 213 kg/h,
𝑥 = (𝑃/ − 𝑃F )⁄𝑃/ (30) the control valve Cv is estimated to be 3.14.
ms = Steam Mass flowrate [kg/h] Appendix A
CV = Flow rate coefficient at rated capacity [-] Air Solubility in Water
P1 = Upstream absolute pressure [bara] The solubility of air in water [S] can be
P2 = Downstream absolute pressure [bara] estimated based on Henry’s Law [1] which is
calculated as,
MW = Gas molecular weight [kg/kmol]
𝑆 =𝐾×𝑃 (35)
T1 = Control valve inlet temperature [K]
Where,
k = specific heats factor [Cp/Cv]
S = Solubility [g/L]
Z = gas compressibility factor [-]
K = Henry’s constant [mol/lit/atm] or [M/atm]
∆P = Pressure drop at rated flow [bar]
P = Partial pressure of the gas in solvent [atm]
Fp = Piping geometry factor (Fp = 1)
Henry’s constant is dependent on temperature
FK = Ratio of specific heats factor [=k/1.4] [-]
and can be adjusted to the de-aerator feed
x = Pressure drop ratio [-] water temperature using the correlation
XT = Choked flow ΔP factor (Ref 12) [-] similar to Van’t Hoff equation [1] as follows,
Y = Gas expansion factor [-] 3∆5'( 6 - -
E H ) 8 IJ
∆6 𝐾 [𝑇 ] = 𝐾 0 × 𝑒 7 2 2 (36)
𝐼𝑓 > 𝐹N 𝑥A 𝑡ℎ𝑒𝑛 𝑥 = 𝐹N 𝑥A (31)
6- Where,
∆6 ∆6
𝐼𝑓 6-
< 𝐹N 𝑥A 𝑡ℎ𝑒𝑛 𝑥 = 6-
(32) K[T] = Henry’s constant at feedwater
𝐼𝑓
∆6
> 𝐹N 𝑥A 𝑡ℎ𝑒𝑛 𝐶𝑟𝑖𝑐𝑡𝑖𝑐𝑎𝑙 𝐹𝑙𝑜𝑤 (33) temperature [M/atm]
6-
∆6 K0 = Henry’s constant at reference
𝐼𝑓 < 𝐹N 𝑥A 𝑡ℎ𝑒𝑛 𝑆𝑢𝑏 𝑐𝑟𝑖𝑐𝑡𝑖𝑐𝑎𝑙 𝐹𝑙𝑜𝑤 (34)
6- temperature of 293.15 K [M/atm]
Table 1. Steam Control Valve Sizing
T = Feedwater Temperature [K]
Parameter Value Units
T0 = Reference Temperature of 293.15 [K]
Inlet Pressure [P1] 5.0 barg -ΔsolH / R = Enthalpy of Dissolution [M/atm]
Outlet Pressure [P2] 0.2 barg Considering air consists of oxygen and
Inlet Temperature [T1] 3.60 0C nitrogen predominantly, the enthalpy of
dissolution [-ΔsolH/R] can be calculated from
Steam MW 18.02 kg/kmol
known data [2], i.e., the solubility of air [K0] in
Ratio of Specific Heats
1.2986 - water is ~7.9 x 10-4 at 200C and 1 atm and a
[k = CP/CV]
Gas Compressibility Factor [Z] 0.9497 - rejection rate of 5.9 grams of air per 1000 kg
of water [0.0002024 mol/litre] at 800C
Piping Geometry Factor [Fp] 1.0 -
[353.15 K] and 1 atm. Therefore, for a de-
Control Valve Characteristics Eq % - aerator feedwater pressure of 1 atm and 200C,
P"%Eg:
Control Valve Size Chosen 6 inch 7.9 × 10R/ = 𝐾 , × 1 F⎯⎯H 𝐾 , = 7.9 × 10R/ (37)
Rated ΔP Factor [xT] 0.78 - And Henry’s Constant [K] at 800C and 1 atm,

Page 4
 h566 7
𝐾[𝑇] = =
,.,,,2,2/
= 0.0002024 𝑀/𝑎𝑡𝑚 (38) 9. https://www.engineeringtoolbox.com/sat
i$"% +
urated-steam-properties-d_457.html
Re-writing the temperature dependent
10. https://www.spiraxsarco.com/resources-
Henry’s constant equation, the enthalpy of
and-design-tools/steam-tables/saturated-
dissolution of air in water is,
water-line?sc_lang=en-GB
,[2] 8.888/8/;
)∆5'( Y C[E 8 J C[E
8.888<0
J 11. https://www.thermexcel.com/english/tabl
= -
,
- = - - = ~2350 (39)
Z E ) 8J
2 2
E )
).).-. /0).-.
J es/vap_eau.htm
The Van’t Hoff equation in the above form 12. “Control Valve Handbook”, Emerson’s
though is valid for a limited range, but the Fisher’s Handbook, 5th Edition
value of -Δsol/H does not vary change much
with temperature variation of the order of
around 20K [1]. Therefore, for the low
operating temperature of the deaerator [0.2
barg] and feed water temperature in the range
of 800C to 900C, the enthalpy of dissolution [-
ΔsolH/R] can be taken as 2350.
References & Further Reading
1. https://en.wikipedia.org/wiki/Henry%27s
_law
2. https://www.vaia.com/en-
us/textbooks/chemistry/chemistry-the-
science-in-context-5-edition/chapter-
10/problem-60-the-solubility-of-air-in-
water-is-approximately-7/#step-by-step-
solution
3. https://www.spiraxsarco.com/learn-
about-steam/the-boiler-
house/pressurised-deaerators?sc_lang=en-
GB
4. https://chemicalengineeringworld.com/de
aerator-working-principle-types-and-
process-control/#google_vignette.
5. https://www.ewt-
wasser.de/en/product/vacuum-
deaerator.html
6. https://toolbox.tlv.com/global/TI/calculat
or/temperature-drop-steam-air-
mixture.html?advanced=on
7. https://cincinnatitriplesteam.org/docume
nts/SteamTables.pdf
8. https://toolbox.tlv.com/global/TI/calculat
or/steam-table-
pressure.html?advanced=on#
Page 5
Appendix B: MS-Excel Spreadsheet

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