Introduction to Electrode Boilers in

NZ – Projects, Issues and Solutions

NZPAWS Workshop 2022

David Addison
Principal Consultant, Thermal Chemistry Limited
IAPWS – Power Cycle Chemistry Chairperson
NZAPWS - Chairperson
david.addison@thermalchemistry.com
1 December 2022
Revision 1.0
 Background – IAPWS eBlr Working Group
• Project came out of an International Association for the Properties of Water and
Steam (IAPWS www.iapws.org ) working group

• Issues identified with water/steam chemistry with electrode boilers in Europe and
NZ – Joint NZAPWS and SIAPWS (Scandinavian IAPWS group)

• Limited industry technical guidance and understanding. Limited technical

standards/guidelines available for electrode boiler operation

• Problems occurring with corrosion, steam contamination, internal damage

• Working towards a IAPWS Technical Guidance Document (TGD) for electrode

boilers to compliment current suite of fossil guidance available
 Electrical Boilers
• Three main types of electrical boilers in global market (hot water and
steam)

– Immersion, element type (hot water jug/kettle) – low voltage, hot water/steam

– Immersion, electrode type, high voltage – water as electrical conductor

– Jet, electrode type – water as electrical conductor

• Main applications in NZ are immersion, electrode type, high voltage so

focus will be on these

• Common in nuclear plants and industrial plants for initial start up

steam/heating until main process is underway or industrial plants where
renewable electricity available (Norway chemical plants etc)

• Europe – very common for district hot water heating systems – take over
from fossil/biomass plants when renewable prices are low
Immersion – Element Type
Jet Type – High Voltage
High Voltage Immersion Electrode Type - Steam
High Voltage Immersion Electrode Type - Hot Water
 What is a high voltage immersion electrode boiler?
• Uses electrical energy to generate steam or hot water via resistive heating

• Not an immersion heater – current flows from the electrode through the water
to earth and heating is via the electrical resistance of the water – carried out
in a insulated “basket” (or “bucket”) that is the earth connection – water level
varies to cover more electrode for more current flow hence more
heating/steam generation

• Water is an electrolyte and part of the electrical circuit as well as a heat

transfer medium for the process – very different to conventional boilers

• Steam type and hot water (nitrogen overpressure) – saturated steam only –
need additional heat input to make superheated steam via electrical direct
heating Electrodes and “Bucket”

• Suppliers state electrode boilers are >99% efficient at MCR with almost all
the energy consumed producing steam. Losses are meant to be radiant heat
from the vessel or blowdown/steam leaks only.

• Size ranges from 100’s of kW’s up to 60+ MW’s, high pressure ~100 bar units
reportedly under development
 Electrode Boilers in NZ
• A number of small “domestic/building” type systems around – recently multi boiler
system gone into Auckland Medical School facility

• Two large resistance electrode units currently in operation, both supplied by Energy
Plant Solutions (NZ) – built as alternatives to coal boilers in the South Island

• Synlait – 6 MW output but 12 MW size (recently fully upgraded to 12 MW), ~ 20

m /hr steam flow at ~10 bar – commissioned 2019
3

• Open Country Dairy – 13 MW, ~ 20 m 3/hr steam flow at ~10-11 bar – commissioned
2020
• Example Committed Projects (others around or in pipeline)– both replacing current
coal boilers
– Woolworks – 8 MW, 10 bar boiler under construction – commissioning early 2023
– Mataura Valley Milk – 20 MW, 40 bar boiler, 28 m 3/hr, – project underway,
commissioning later 2023
Synlait 12 MW Electrode Boiler and Feedwater System
Open Country Dairy 13 MW Electrode Boiler
University of Auckland (Medical School) 300 kW and 75 kW
eBlrs
University of Auckland (Medical School) 300 kW and 75 kW
eBlrs – major corrosion issues – under investigation
Ørsted (Dennmark) 40 MW Hot Water District Heating Electrode
Boiler(s)
 Electrode Boiler Problems Observed Internationally
• Conflict between electrolyte chemistry requirements and corrosion and steam process chemistry (observed)
• Chemical concentration/pH/conductivity have fixed relationship
• Steam host, steam purity requirements drive chemistry choices
• Vendor requirements impossible to meet

• Solubility contamination of incorrect materials (observed)

• Glass Reenforced Plastic (GRP) and aluminum silicate used in some boilers – silica and organics contamination

• Electrical arcing and side reactions – (observed)

• Steam boilers – uncontrolled electrolysis/high energy breakdown of water reactions – formation of hydrogen/oxygen
radicals, hydrogen peroxide and hydrogen gas
• Hot water boilers – similar to steam boiler reactions plus now nitrogen breakdown reactions and formation of nitrogen
radicals and nitric acid leading to low boiler pH’s and increased corrosion
• Degradation and failure of electrodes

• Risk of stray current reactions – out of control anodic and cathodic electrochemical reactions and elevated corrosion
(hypothesized at this stage based on some observations and in progress investigations)

• High corrosion rates/corrosion production generation

• Unusual water chemistry behavior – loss of alkalizing agent, unstable pH control

Electrode and Plant Damage Due to Arcing Examples (multiple
projects)
Bottom PTFE plate bolt
damage/destruction due
to arcing

Electrode
Damage

Arc burn
marks
 eBlr standards
• Very limited information/standards – some
info in old (1997) British Standard. Vendor
application is very ad hoc

• NZ Chemical vendor support/experience is

limited (but growing)

• Europe experience reports limited vendor

water/steam support also

• Strong need for robust international

standards (such as a IAPWS TGD)
Incorrect Materials Uses and Leaching/Contamination
Overflow pipes - GRP

Electrodes and top of

overflow pipe - GRP
Possible Arcing Reactions/Uncontrolled Electrolysis in
Water/Steam (many questions still remain here)
(Same as what happens in a Nuclear Reactor….)
Steam Oxygen and Hydrogen Online Monitoring
 Steam Hydrogen and Oxygen and Hydrogen and Steam Flow
Relationships
Hydrogen (H2) vs Steam Flow filtered
80 second offset + steam flow > 0.99 + boiler pressure > 4.99
120
24hrs (5:30pm
31/1/20 to
100 5:30pm
1/2/20)
Hydrogen (H2) vs Oxygen (O2)
80

Hydrogen (ppb)
120
24hrs Overnight
(5:30pm 60 (2:00am to
100 31/1/20 to 4:00am
5:30pm 40 1/2/20)

80 1/2/20)
Hydrogen (ppb)

20
Overnight
60 (2:00am to 0
4:00am 0 1 2 3 4 5 6
40 1/2/20)
Steam Flow (m3/hr)
y = 0.1103x + 4.3362
20

0
0 200 400 600 800 1000
Oxygen (ppb)
 Hydrogen and Load relationship
(pre and post arc reduction internal eBlr modifications)

31
 Key Lessons for new eBlr Projects
1. Expect the unexcepted and be ready for new learnings

2. Need well performing, full demineralized water plant – highest purity make up water boosts
efficiency, lowers chemical complexity and lessens corrosion risks

3. Need to clearly understand the water/steam chemistry needs of both the steam host and the
eBlr – not normal boiler chemistry, “electrolyte” chemistry is most important - need to
carefully consider steam/condensate chemistry as well

4. Plant needs right chemical dosing (chemicals/concentration/dosing logic)

5. Plant needs right sampling and analysis systems – safe and proper sampling stations +
correct online analysis including steam hydrogen analysis for early detection of arc damage

6. OEMs and users have limited water/steam chemistry knowledge – steep learning curve
 Summary and Solutions
1. Very different plants to conventional fossil/biomass hotwater/steam
boilers but science “rules” always apply. No current guidelines and
very little technical information out there

2. Continued up take in NZ as part of decarbonization of industry –

likely coming to industrial sites in Aus in future. Major advantages
over conventional boilers – fast response, remote operation no
fuel/waste handling etc

3. Potential for issues around water chemistry control and

arcing/hydrogen formation – able to be resolved via good
chemistry monitoring and the use of steam hydrogen testing

4. Water/steam chemistry needs to take into account steam use,

feedwater and boiler corrosion control and electrolyte chemistry
– IAPWS guideline likely to be developed to provide industry
guidance