Chemical supply for the conditioning of boiler feed water

1. The Challenge

At the Vynova Wilhelmshaven site, steam boilers used in PVC production must operate around the clock under high pressure and at high temperatures. This requires stable and precise treatment of the feedwater, as deviations can quickly lead to corrosion, scale buildup, and equipment damage. However, the ammonium hydroxide solution used is volatile, safety-critical, and delivered in IBCs, which made reliable, complete, and safe emptying, as well as explosion-proof handling, a challenge. The goal was a solution that simultaneously ensures process safety, occupational safety, and supply reliability.

2. The sera Solution

A custom-designed IBC emptying and supply station for ammonium hydroxide was implemented for Vynova. The station enables the complete emptying of the IBCs via an intermediate tank with continuous radar level measurement. A sera diaphragm pump with a pulsation damper and flow monitoring ensures a stable flow rate to the downstream system. Due to the properties of the media and their concentrations, a comprehensive explosion protection concept was implemented: All electrical components are zone-compliant, and all components in contact with the media are made of conductive plastic. The entire system is gas-tight; any vapors generated are neutralized via a chemical vapor lock and vented through a deflagration vent.

3. Customer Benefits

• Safe, complete, and uninterrupted supply for boiler water treatment
• Significantly improved plant and operational safety thanks to a comprehensive explosion protection concept
• No loss of residual quantities during IBC changes
• Stable and controlled dosing process during continuous operation

4. Summary

The project demonstrates that chemical handling in safety-critical processes is not a secondary process—but rather a key factor for plant availability and operational safety.