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Boiler water chemical treatment is necessary to prevent or control scale and deposit formation. The formation of scale and sludge can cause tube failures, restrict circulation, reduce system efficiency, and compromise your boiler system’s reliability.
Boiler scale is a deposit that forms directly on heat transfer surfaces when constituent solubility limits are exceeded and the resulting compounds precipitate onto the tube surfaces. Such deposits may contain calcium, magnesium, phosphate, iron, and silica. A tenacious form of boiler scale results when calcium precipitates in the form of calcium carbonate.
Boiler sludge is a deposit that forms when suspended materials present in the boiler water settle on, or adhere to, hot boiler tubes or other surfaces. Sludge typically consists primarily of compounds such as hydroxyapatite (also known as calcium hydroxyl phosphate) or serpentine (magnesium silicate). Metal oxides are normally the result of condensate corrosion, but may also come from the makeup water or feedwater system corrosion. Metal oxides can form a hard tenacious deposit on tube surfaces, which restricts heat transfer. Metal oxides can also be absorbed onto sludge particles and become part of the sludge. Metal oxides are typically iron oxide, but may include copper or other metallic components.
ChemTreat’s boiler scale and deposition control treatment programs are designed to prevent and control crystallization resulting in deposit formation, as well as provide deposit dispersion and sludge conditioning.
Discover More | Our customized scale and deposition control programs may include:
Polymeric dispersants or sludge conditioners are added with the phosphate to condition the sludge for improved removal from the boiler. ChemTreat’s phosphates for the chemical treatment of water always include polymers either blended in the solution or as supplements to prevent scale formation and deposits on heat transfer surfaces. Phosphate treatment programs are recommended in the following conditions:
- Infrequent operator attention and testing
- Poor or nonexistent feedwater deaeration
- Water softeners are in use, but control is less than ideal
- Low treatment costs are desirable
- Boiler design, operating pressure, and steam production rates are compatible with precipitating chemistries
Care should be taken whenever phosphate treatment is used under the following set of operating conditions:
- High iron levels (>0.5 ppm) in the feedwater
- Feedwater hardness greater than ASME guidelines (>1 ppm)
- Feedwater economizers are present
- Exceptional boiler internal cleanliness is required
Boiler water polymers function as dispersants and weak sequestrants. Phosphate chemistry works by precipitating calcium as any of several insoluble calcium phosphate compounds. This material can deposit on tube and drum surfaces. Buildup of this material can impede heat transfer on generating tubes and cause tube failures. Polymers are used in conjunction with phosphate programs to condition the precipitated compounds, prevent their accumulation and aid in removal from the boiler. Unfortunately, it is not possible to purge all the insoluble material from the boiler via the limited amount of blowdown. Thus, varying degrees of deposition are generally found in phosphate treated boilers where hardness incursion has occurred. Many plant sites find the insoluble material generated with phosphate treatment programs undesirable. Chelants form soluble compounds with calcium and magnesium during hardness excursions provided there is sufficient free chelant present. Problems arise with chelating chemistries because of the poor thermal hydrolytic stability of free EDTA, the most commonly used boiler water chelant. The inability to maintain a free residual can result in hardness scale formation during upsets. Chelants can be very aggressive to boiler metal if fed in the wrong location or if overfed.
All-polymer chemistry can overcome the drawbacks of both phosphate and chelant programs. Polymers sequester hardness forming soluble compounds. Some commercially available polymers become insoluble when exposed to high calcium hardness conditions. Polymers also disperse insoluble materials. (Weak sequestrants are not aggressive to boiler metallurgies; and free residuals can be maintained and tested for).
The ChemTreat boiler water product line includes phosphate/polymer, chelant/polymer, phosphate traced/polymer, and true all-polymer products. The polymers utilized in these products are optimized for regulatory requirements, molecular weight, thermal hydrolytic stability, and functionality specific for dispersion and sequestration. Most products contain a blend of two polymers. This allows us to incorporate the best polymer functionalities into a specific product. Polymer applications are limited to boiler operating pressures below 900 psig. Dosage requirements are dictated by operating pressure/temperature, feedwater quality, and boiler cleanliness.
- Dissolved oxygen levels below 25 ppb.
- Removal of calcium and magnesium to below 0.5 ppm as calcium carbonate.
- Removal of silica and/or alkalinity from the makeup water.
- Plant steam production and operating requirements preclude the use of a precipitating program.
- Boiler design prevents the use of phosphate treatment.
Because complete chelation is theoretically never attained, ChemTreat incorporates polymeric dispersants in all chelant-based programs to assist in preventing iron and mineral deposition. Since the predominant chelation reactions take place in the boiler feedwater and not in the boiler water, considerable care must be given to selecting the proper chemical feed points. ChemTreat field engineers are experts at applying chelant technologies to all types of boiler systems.