HALF A CENTURY OF CONDENSATE POLISHING
by Eli Salem & Terrance LaTerra, Graver Water Systems, Inc.
Introduction
The use of in place regenerated mixed bed
demineralizers for condensate polishing
originated in the 1950’s. By the end of the
decade, Graver Water had patented a method
of transferring the resins to an external
regeneration system and designed the first
system for Louisiana Power & Light’s Little
Gypsy Station. This was the first high
pressure (2400 psig) drum boiler to employ
100% deep bed type condensate polishing.
Over the next 40 years, many innovations to
the external regeneration concept were
introduced including Graver’s Seprex and
SepraEight (see figure 1) processes.
In addition, a radically different concept,
Powdex, was invented by Graver Water in
1962. This process utilized finely ground
ion exchange resin in a disposable precoat
format and eliminated the necessity of
chemical regeneration altogether. This
technology evolved into today’s state of the
art Powdex process employing advanced
precoating techniques, Air Surge backwash
and an enhanced flow distribution tube.
Figure 2 is a schematic diagram of a Powdex
system with an enhanced flow distribution
tube, Air Surge type backwash, and
advanced precoat system. During the
service mode, figure 3a, condensate enters
the service vessel at the center of the bottom
head and is directed to the chamber above
the tube sheet. At this point, some of the
condensate enters the filter chamber below
the distribution tube while the balance enters
above the distribution tube. This split
insures that the condensate is distributed
equally to the top and bottom of the filter
elements and avoids localized high
velocities which could disrupt the precoat.
Treated condensate passes through the filter
elements and proceeds through the tube
sheet to the Powdex vessel outlet. Likewise,
figure 3b depicts the precoat cycle in which
the direction of flow is the same as the
service mode. During the backwash cycle,
the vessel is partially drained (figure 3c).
Then Air Surge is applied using a short burst
of air introduced to the plenum to displace
the water between the tube sheet and the
tube sheet downcomers (figure 3d). This
process is repeated several additional times
at different water levels in the filter chamber
as implied in figures 3e & 3f. This
technique insures the filter elements are
restored to their low initial pressure drop
with minimal water consumption.
Both the SepraEight external regeneration
type systems and the Powdex precoat type
systems are applied to meet the condensate
polishing requirements of today’s high
pressure boilers. As a world leader in
condensate polishing technology with
hundreds of installations including both
external regeneration and precoat type
systems, this paper will discuss Graver’s
views on condensate polishing and the
relative advantages and limitations of these
two technologies.
 CATION TRANSFER LINE CATION TRANSFER LINE
RESIN RESIN AIR
INLET INLET INLET

XT XT
XT XT
XE XE
XE XE
ANION ANION
TRANSFER TRANSFER
LINE LINE
BACKWASH RESIN BACKWASH RESIN
INLET DRAIN DRAIN DRAIN OUTLET DRAIN DRAIN DRAIN
INLET OUTLET

Separation & Anion Cation Regeneration Mix & Hold Vessel Separation & Anion Cation Regeneration Mix & Hold Vessel
Regeneration Vessel Vessel Regeneration Vessel Vessel

Fig. 1a - Receive Exhausted Resin Charge Figure 1b - Transfer Regenerated Resin

to Service Vessel

CATION TRANSFER LINE CATION TRANSFER LINE

RESIN RESIN
INLET INLET

XT XT
XT XT
XE XE
XE XE
ANION ANION
TRANSFER TRANSFER
LINE LINE
BACKWASH RESIN BACKWASH RESIN
INLET DRAIN DRAIN DRAIN DRAIN DRAIN DRAIN
OUTLET INLET OUTLET

Separation & Anion Cation Regeneration Mix & Hold Vessel Separation & Anion Cation Regeneration Mix & Hold Vessel
Regeneration Vessel Vessel Regeneration Vessel Vessel

Figure 1c - Hydraulic Classification of Figure 1d - Transfer Cation Resin to

Exhausted Resin Cation Regeneration Vessel

CATION TRANSFER LINE CATION TRANSFER LINE

RESIN RESIN
INLET INLET

NaOH ACID RINSE RINSE

XT XT
XT XT
XE XE
XE XE
ANION ANION
TRANSFER TRANSFER
LINE LINE
BACKWASH RESIN BACKWASH RESIN
INLET DRAIN DRAIN DRAIN INLET DRAIN DRAIN DRAIN
OUTLET OUTLET

Separation & Anion Cation Regeneration Mix & Hold Vessel Separation & Anion Cation Regeneration Mix & Hold Vessel
Regeneration Vessel Vessel Regeneration Vessel Vessel

Figure 1e - Regenerate resins with Acid & Figure 1f - Settle & Rinse Resins
Base

Figure 1 - SepraEight Regeneration Process

 CATION TRANSFER LINE CATION TRANSFER LINE
RESIN RESIN
INLET INLET

XT XT
XT XT
XE XE
XE XE
ANION ANION
TRANSFER TRANSFER
LINE LINE

BACKWASH RESIN BACKWASH RESIN

INLET DRAIN DRAIN DRAIN INLET DRAIN DRAIN DRAIN OUTLET
OUTLET

Separation & Anion Cation Regeneration Mix & Hold Vessel Separation & Anion Cation Regeneration Mix & Hold Vessel
Regeneration Vessel Vessel Regeneration Vessel Vessel

Figure 1g - Transfer Cation Resin to Mix Figure 1h - Transfer Anion Resin to Mix
& Hold Vessel & Hold Vessel

CATION TRANSFER LINE

RESIN
INLET
Color Key:

- Mixed Resin
XT - Anion Resin
XT
XE
XE - Cation Resin
ANION
TRANSFER
LINE
BACKWASH RESIN
- Liquid Stream
INLET DRAIN DRAIN AIR
OUTLET

Separation & Anion Cation Regeneration Mix & Hold Vessel

Regeneration Vessel Vessel

Figure 1i - Air Mix & Backflush Resin Figure 1j - Color Key

Transfer Lines

Figure 1 - SepraEight Regeneration Process

Purpose

Condensate polishing is installed to control • faster start ups

corrosion transport and condenser in-leakage • reduced chemical cleaning.
in order to maintain cycle purity and
efficiency. As presented by Black and For a 360 Mwe plant the annual savings
Veatch1 at an EPRI conference in 1997, the were reported to exceed $500,000 after
key benefits, in order of importance, are: subtracting the annual fixed charges on
• improved availability capital and operating cost.1
• turbine efficiency loss prevention
 FEED
VENT OUT AUXILIARY WATER
DISTRIBUTION TANK IN SLURRY
FEED IN TUBE AIR WATER TANK
IN IN

ELEMENTS

SUMP

SUMP
SERVICE
VESSEL
HOLD PUMP

DRAIN PRECOAT INLET

SUMP PRECOAT
RECYCLE
PUMP PRECOAT
INJECTION
PUMP SUMP

Figure 2 - Powdex Process with Advanced Precoat System

For those systems with copper bearing
alloys, the need for condensate polishing is
even more pronounced. Without condensate
polishing, it is not unusual for a 400 MW
unit to lose 10 % of its generating capacity
in six months due to turbine deposits.2
For co-generation facilities operating above
1000 psig, it is strongly recommended that
condensate polishing be installed to provide
very low boiler feedwater iron and copper
and provide high purity steam.3,3b
and selection is based on system design and
operating parameters as well as
environmental requirements.
Those conditions that favor deep beds
include:
• use of high TDS cooling water such as
sea water or high TDS cooling towers
• the requirement to operate long term
with small condenser leaks
• the inability to control excessive air in-
leakage.

Most end users interested in condensate
polishing must choose between precoat filter
demineralizers and externally regenerated
deep bed (mixed bed) type polishers. Each
have their own benefits and disadvantages
If deep beds are selected, SepraEight can
consistently provide the highest degree of
regeneration and ion exchange resin
utilization.4
 Vent Vent
Distribution Distribution
Tube Tube

Precoat Element Precoat Element

Inlet Outlet Inlet Outlet

Figure 3a - Powdex Service Mode Figure 3b - Powdex Precoat Mode

Vent Vent
Distribution Distribution
Tube Tube

Precoat Element Precoat Element

Air Inlet Air Inlet Air Inlet Air Inlet

Inlet Outlet Inlet Outlet

Figure 3c - Drain prior to Air Surge Figure 3d - Air Surge

Vent Vent
Distribution Distribution
Tube Tube

Precoat Element Precoat Element

Air Inlet Air Inlet Air Inlet Air Inlet

Inlet Outlet Inlet Outlet

Figure 3e - Drain prior to Air Surge Figure 3f - Air Surge

Fig. 3 - Powdex Service, Precoat, and Air Surge Backwash Modes

At times, the difficulty in producing
satisfactory results with deep bed condensate
polishers, as reported in China4b, would lead
one to believe that the simplicity of Powdex
would overcome many of the difficulties
encountered. Those conditions that favor
Powdex include:
• low TDS cooling water
• titanium condensers
• limited operator availability and training
(regeneration of deep beds is a complex
regeneration sequence and involves the
use of strong acids and base)
• need to avoid handling and neutralizing
large quantities of acid and base
• frequent start ups and restarts (precoat
filters provide superior crud removal and
offer the most cost efficient means for
controlling corrosion transport)
• need for rapid start up
• need to minimize pressure drop
requirements for condensate polishing
• operating policy of orderly shut down
and repair in the event of a condenser
leak
• need to minimize costs including
equipment, installation, and operating
costs.
• Limited space availability
Powdex precoats can perform these
functions since they are composed of highly
regenerated, finely divided ion exchange
resins which provide enhanced kinetics for
dissolved solids removal and excellent
filtration properties. There is no need to
worry about the degree of regeneration as
with deep bed polishers.5 Powdex precoat
systems can remove over 90 % of all metals
from the condensate.
Graver has been a leader introducing
innovative improvements to condensate
polishing. Many of these improvements,
such as the distribution tube6,7, advanced
precoating system6,7 (constant slurry
concentration), body feed6, Air Surge
backwash6,8 and positive element installation
hardware (SealFast™)6, have been
incorporated into recent Powdex systems.
Data will be presented on some of these
plants as well as older installations.
The key benefits of precoat condensate
polishing include:
• Reduced start-up and restart time
• Improved cycle chemistry
• Clean-up of cycle before firing
• Reduced make up requirements.
• Allows for orderly shut down for repairs
• Allows for operation during minor in-
leakage
• Minimizes any deposition within boiler
or turbine
• Improved availability
Crud Removal
Contaminant levels during start up are high
due to construction materials and corrosion
products associated with new equipment.
Under these conditions, new units may
require chemical cleaning during the first
scheduled outage because of inadequate crud
removal. The bulk of any corrosion transport
takes place during start up and restarts. This
is partly due to the ingress of oxygen into the
cycle.
The Powdex process combines superior
filtration with ion exchange by using finely
ground, highly regenerated resins precoated
onto specially designed elements. The
precoated elements are contained in a system
which is designed for uniform precoating
using an enhanced flow distribution tube and
element cleaning using Air Surge. In many
newer systems, advanced precoating is
supplied to provide for a more uniform
precoat. There are many precoat materials
available. Those consisting solely of ion
exchange material and those containing ion
exchange material and fibers for improved
filtration capacity. A discussion on the
various precoat materials available is a topic
of a separate discussion.
In contrast, deep bed condensate polishers
offer limited crud removal efficiency relative
to Powdex. The removal efficiency for deep
beds is typically 90% removal of black iron
oxides (magnetite - Fe3O4) and 50% removal
of yellow (Fe2O3) and red iron oxides. With
Powdex systems the removal efficiency for
all oxides is typically >95%. Figure 4
compares the Millipore stains, before and
after condensate polishing, obtained with a
deep bed system and with Powdex. An
additional benefit of Powdex is its ability to
hold on to the retained crud during flow
surges. With deep beds, crud may be
released into the condensate during a flow
surge. It should be noted that heater drains
that cascade to the deaerator and not the hot
well are not treated with condensate
polishing and could be a source of
contaminants in the cycle. Figure 5 provides
a convenient chart to quickly estimate the
concentration of iron oxides in condensate.
Silica and Dissolved Solids Removal
Control of silica and dissolved solids within
the boiler and turbine manufacture’s limits is
required to operate the system efficiently.
Condensate polishing is an effective means
to achieve the desired conditions for a rapid
startup or restart. One advantage of Powdex
over deep beds is its ability to remove
colloidal silica. Since Powdex resin is
composed of highly regenerated, finely
divided ion exchange resins, it can
effectively remove silica and other ionic
contaminants to very low levels. Depending
on the operating pH, removal efficiencies of
up to 99% can be achieved. To maximize
the utilization of anion resin, it is important
that air in-leakage be controlled. Air
contains about 400 ppm of carbon dioxide
that can react with amines when it enters the
condenser to form a salt. The salt can then
only be removed with ion exchange.
Another advantage of Powdex is the ability
to vary the precoat dosage and composition
to help effect the desired result (i.e., use
hydrogen form resin to lower pH).
Economic Considerations
Table 1 compares the capital equipment and
operating costs for both full flow mixed
beds and Powdex. The lower cost for
Powdex is due primarily to the fact that the
system is skid assembled and has no
chemicals, minimizing installation cost. The
capital and operating costs are only rough
approximations based on US data and
should be adjusted for local conditions.
Case Histories
Typical Once Through Boilers
Some of the installations were discussed
earlier.9 Texas Utilities operates twelve
supercritical, once through steam generators
(8,125 MWe installed capacity). All the
stations use Powdex for condensate
polishing. The units operate with once
through cooling using fresh water and
typically have stainless steel condensers.
In 1991 Texas Utilities’ Monticello station
was retrofitted with the distribution tube and
an advanced precoat system. These
improvements resulted in more uniform
 Mn. Cond. Pump MB Polisher Out Powdex Inlet Powdex Outlet

Figure 4a - Millipore Samples before and after Deep Beds (mixed beds) and Powdex

Mn. Cond. Pump MB Polisher Out Powdex Inlet Powdex Outlet

Figure 4b - Millipore Samples before and after Deep Beds (mixed beds) and Powdex

Mn. Cond. Pump MB Polisher Out Powdex Inlet Powdex Outlet

Figure 4c - Millipore Samples before and after Deep Beds (mixed beds) and Powdex

Figure 4 - Three Sets of Millipore Filter Stains*

*Data from Allegheny Power Fort Martin Station which has Deep Bed and Powdex condensate polishers
 Fe3O4

Fe2O3

Fe2O3 +
Fe3O4 (1:1)

Figure 5 - Iron Determination by Membrane Filters

The color and density of the stains on this chart are approximately the same as those produced when one
liter of water containing the indicating concentration of suspended Iron in parts per billion (Fe) is passed
through white filter membrane having a pore size of 0.45 microns.
 TABLE 1 - ECONOMICS

Plant Design Basis:

Plant Capacity 600 MW Coal Fired

Type Boiler Supercritical with Oxygenated Treatment
Condensate pH 8.5
M/B Resin Ratio 1.5/1 C/A
Design Pressure 40 Bar

Design Data Mixed Bed Powdex

Number of Service Vessels Three x 50% Three x 50%

Number of Regen Vessels Three One Precoat System
2
Velocity Through S/V 50 gpm/ft (120 m/hr) 3.5 gpm/ft2 (8.4 m/hr)
Capital Costs
Estimated Equipment Cost $2,000,000 $1,200,000
Estimated Installation Cost $1,000,000 $ 600,000
Total Capital Costs $3,000,000 $1,800,000

Annual Operating costs

Total Regens/Precoats per Yr 24 30
Acid Consumption 10 metric tons N/A
Acid Cost @ $0.2/kg HCl $2000 N/A
Base Consumption 10 metric tons N/A
Base Cost @ $0.30/kg $3000 N/A
D/M Water Consumption 4000 m3 1000 m3
Cost of D/M Water @ $.5/m3 $2000 $500
Cost of Precoat Material N/A $32,000
Resin Replacement @ 20%/yr $15,000 N/A
Maximum Pressure Drop 50 psig (3.3 bar) 30 psig (2 bar)
Pressure Drop Penalty @ $.03/kwh $20,000 $0

Total Annual Operating Cost $42,000 $40,500

Net Present Value (Capital + $3,412,362 $2,197,635

Operating Costs over 20 yrs @
8%)
 TABLE 2 - TYPICAL OPERATING DATA

Plant Velocity Precoat Effluent Quality

Type gpm/ft2 type Cond. Na+ Silica Cl- Fe End Pt.

(m/hr) µmho/cm ppb ppb ppb ppb days
Drum 3.5 (8.4) Ecodex < 0.3 <1 <5 < 0.2 35-45
SC* 2.9 (7.0) 1C+1A < 0.09 < 0.5 <5 <1 50**
SC* 3.5 (8.4) Ecodex < 0.08 < 0.5 <5 <1 < 0.1 60**
Drum 3.3 (8.0) Ecodex < 0.3 <1 <5 DP
SC* 3.0 (7.2) 1C+1A < 0.1 <1 <5 <1 90**

* Supercritical with oxygenated treatment

** The end point termination is administrative.

precoat and flow distribution which
produced a greater than two fold
improvement in precoat ulilization.7
Typical systems currently operate with
oxygenated treatment which allows for a
relatively low pH in the condensate (8.0-8.5)
and lower levels of crud. Air in-leakage is
controlled at <0.5 scfm/100 MW. Typically
the run lengths on the Powdex units are in
excess of 50 days. The normal precoat
dosage is 0.2 lb/ft2.
Recent typical data from several US utilities
is provided in Table 2.
Typical Drum Boilers
Data on San Miguel Electric Cooperative
(drum boiler) was first reported at the 44th
International Water Conference.10 The rated
capacity is 410 MW at 2400 psig. Internal
treatment consists of coordinated phosphate
during start up and all volatile treatment at
full load. Cooling towers are used and
operate with well water.
The system was retrofitted with Powdex
(with Air Surge) condensate polishing in
1982. This decision was made because start
ups were taking longer than expected due to
the time required to attain proper boiler
water quality as well as the large volume of
blowdown required. Due to the low
pressure drop across the Powdex units, the
existing condensate pumps were found
capable of handling the additional head
without any modification. In addition, the
space required and installation cost were far
less than a deep bed system.
Upon installation, improved boiler water
chemistry was realized as well as a drastic
reduction in start up time. Start up times
were reduced by 11 to 15 hours while
consistently maintaining the desired silica
levels in the cycle. The precoat filters at that
time were only used for restarts. Air in-
leakage at that time was a problem and
contributed about 150 ppb of carbon dioxide
to the condensate. This ingress of air limited
the run length of the Powdex units to about
10 days.
A typical restart, after less than a 24 hour
shut down, requires no more than two
precoats to reach full power. Each precoat
uses 9 boxes of Ecodex P303N costing
about $700. When the cost savings (faster
start up, greater availability, etc.) were
applied, the pay back period was less than
one year. More recent data indicates that
San Miguel has solved the air in leakage
problem and now uses the Powdex units
continuously to polish the condensate.
Most drum boilers operate with stainless
steel or copper alloy condensers. Air in
leakage is controlled to < 1 scfm/100 MW.
Typical precoat run lengths are between 30
to 45 days and are terminated due to
pressure drop. The precoat dosage is
normally 0.2 lb/ft2. The pH of the
condensate is typically about 8.8-9.2.
Effluent quality is typically <0.3 µmho, <1
ppb Na, <5 ppb silica and < 0.2 ppb crud.
Recent Powdex Installations
Huaneng Power International - Fuzhou
Power Station, Peoples Republic of China
includes two 66” diameter Powdex units for
each of two 350 MW units, complete with
Air Surge, body feed, advanced precoat, Seal
Fast elements and an enhanced flow
distribution tube. Each vessel is sized for
full flow. Unit 3 started up during the
summer of 1999. End points of 60 ppb
silica and 0.3 µmho were initially
established due the short runs encountered
during the plant startup phase. At last
report, run length had reached one week
using 14 bags of Ecodex P-202 and
alternative precoat materials were being
considered.
International Generating Company -
Rocksavage Power Company, England -
This is a combined cycle, 750 MW power
station, operating at 1650 psi with drum
boilers and cooling towers. The conductivity
of the cooling tower water is about 2,500
µmho/cm. The condensate contains 0.6 to 1
ppm ammonia with a pH of 9.3 - 9.5. The
condensate polishing system consists of two
48” diameter Powdex units. Each vessel is
sized for 50% of flow. The plant started up
in the summer of 1998. Currently, during
normal operation, Powdex run lengths are
about one month and shorter during start up
conditions. They experience about 20
restarts/year. Precoat end points are usually
due to pressure drop. Typical effluent
quality values are a cation conductivity of
0.12 µmho/cm, and silica concentration of 3
ppb. The precoat dosage is normally 9
bags/vessel. Annual precoat consumption is
about 12 precoats for each vessel/year.
Conclusion
The extensive use of condensate polishing
world wide is testimony to the usefulness of
this technology. While deep bed systems
offer extended condenser leak protection,
Powdex can be a cost effective alternative
where local operating conditions permit.
References
1. B.A. Larkin, et al., “Condensate Polishing
Cost Benefit Analysis”, EPRI 5th
International Cycle Chemistry Conf., 1997
2. D. Daniels, “Turbine Deposits Rob
Megawatts, But You Can Catch a Thief”,
Power, p. 83, March/April 1999
3. M. Wisdom, H. Weed, “Condensate
Considerations in the Development of High
Pressure Co-Generation Facilities”, Power-
Gen International, December 1997
3b. K. Sheilds, R. B. Dooley, et al, “Copper
Transport in Fossil Plants”, EPRI 5th
International Cycle Chemistry Conf., 1997
4. M. O’Brien, E. Salem, “Deep Bed
Condensate Polishing Separation
Technology Requirements for Operation in
the Amine Cycle”, EPRI Condensate
Polishing Workshop, Scottsdale, AZ, 1991
4b. Z. Chengxin, C. Long, “The Special
Problems Might be Encountered with the
Operation of Condensate Polishing Systems
in China”, International Water Conf., 1998
5. J. Duff, J. Levendusky, “Powdex a New
Approach in Condensate Purification”,
American Power Conference, 1962
6. E. Salem, M. O’Brien, “Design
Improvements - Powdered Resin
Equipment”, BWR Owner’s Group,
Condensate Committee Meeting, New
Orleans, La., 1991
7. L. Morris and M. O’Brien,
“DistributionTube & Advanced Precoat
About the Authors
System Plant Trials at TU Electric
Monticello”, EPRI Conference on Filtration
of Particulates in LWR Systems, King of
Prussia, Pa, 9/91
8. L. Nolan, “Evaluation of Filter /
Demineralizer Precoat Materials on
Monticello Nuclear Power Station
Condensate System”, International Water
Conference, 1979
9. P. Gross, J. Longo, M. Wadlington, “150
Million Megawatts Hours of Condensate
Polishing”, International Water Conf., 1981
10. E. Lange, D. Johnstone, P. Gross, “San
Miguel: A Case for Drum Boiler Condensate
Polishing Retrofit”, International Water
Conference, 1983
Eli Salem
VP of Technology
Education
BChE 1957 - CCNY
MChE 1967 - Polytechnic Institute of Brooklyn
MBA finance 1977 - NYU
Employment - Joined Graver Water in 1957 and has
held various positions leading to VP of Science and
Technology. Recognized as an expert in ion
exchange and water treatment. Authored and
presented numerous papers and holder of 21 patents
in the field of ion exchange and water treatment.
E-mail: sales@graver.com
Terrance LaTerra
VP of Sales & Marketing
Education
BS Engineering 1969 - Boston University
MBA 1994 - The Wharton School, U. of Penn.
Employment - Joined Graver Water in 1971 and has
held various positions leading to VP of Sales &
Marketing. Authored and presented numerous papers
and holder of 3 patents in the field of ion exchange
and water treatment. Has traveled to the Peoples
Republic of China since 1985 and has made several
presentations on Condensate Polishing in the 1990’s.
E-mail: sales@graver.com