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Boiler Water
Water Treatment
Treatment
Corrosion Boiler
Scale
Boiler
Boiler Scale
Scale
• One of the most common deposit problems is
boiler scale
• This happens when calcium, magnesium and
silica, common in most water supplies, react
with tube metal found in boilers to form a hard
scale on the interior of the boiler tubes,
reducing heat transfer and lowering the
boiler’s efficiency
Boiler
Boiler Scale
Scale
Boiler
Boiler Scale
Scale Formation
Formation
• Scale is formed on boiler tube heating
surfaces by the depositing of impurities in
the feed water in the form of a more or less
hard adherent crust. Such deposits are due
to the fact the water loses its soluble power
at high temperatures or because the
concentrations become so high, due to
evaporation, that the impurities crystallize
and adhere to the boiler surfaces
Solubility
Solubility of
of Mineral
Mineral Salts
Salts in
in
Water
Water
Effect
Effect of
of Boiler
Boiler Scale
Scale
• 1/8-inch (3mm) of scale can cause a
2.0-3.0% loss in fire-tube boilers and
water tube boilers.
• A second but more serious effect from
scale is the overheating of boiler tube
metal, causing eventual tube failure. In
modern boilers with high heat-transfer
rates, even extremely thin layers of
scale will cause a serious elevation in
the temperature of tube material
Corrosion Related Problems
Corrosion is due to the acidity/or oxidizing
properties of the feed water
Pitting Corrosion
Which consists of isolated spots of active corrosion
caused by Oxygen attack
General Corrosion
Produced by an acid attack mainly due to the
presence of CO2 which dissolve in water forming
carbonic acid (H2CO3)
Pitting Corrosion
• Dissolved oxygen interacts with boiler component
surfaces, forming “pits” on the metal surface.
• These pits may eventually grow large enough to
penetrate the metal forcing a boiler shutdown.
Pitting
Pitting Corrosion
Corrosion
• Dissolved oxygen in boiler feedwater
intensifies the corrosion of boiler tubing, by
acting as a depolarizer agent, and accepting
free electrons liberated from the surface of the
boiler tubing, and is instrumental in
determining the intensity of waterside
corrosion of boiler tubing.
• Fe - 2e---->Fe2+
• O2 + 2H2O + 4e -------->4OH-
• Fe2+ + 2OH- --------> Fe(OH)2
Pitting
Pitting Corrosion
Corrosion
• The presence of oxygen in condensate can be
caused by poorly operating deaerators, leakage
of air into vacuum condensers, and leakage of
cooling water.
• Oxygen in the boiler feed water becomes
extremely aggressive when heated.
• In addition to tube corrosion, further damage
may occur to steam and mud drums.
Pitting
Pitting Corrosion
Corrosion
General Corrosion
• The most common cause of general
corrosion is the presence of carbon
dioxide (CO2) in the boiler feed water and
the condensate.
• Carbon dioxide form carbonic acid and
reduce the pH of the condensate and
acid attack while oxygen directly attack
metal.
General Corrosion
CO2+H2O <=====>H2CO3
H2CO3 <======> HCO-3 + H+
General
General Acidic
Acidic Corrosion
Corrosion
Treatment Processes
• External treatment
• Internal treatment
• Condensate treatment
Softening
Softening
HARDNESS
MAGNESIUM CALCIUM
HARDNESS HARDNESS
Caused by magnesium Caused by calcium ions
ions (Mg2+) (Ca2+)
TOTAL HARDNESS
It is the sum of the hardness caused by both
calcium and magnesium ion.
Softening
Softening
Cause a coating
to form inside
Food
water heater
processing
Difficulties in doing
the laundry and
dishwashing.
SOLUBLE FORM
HARDNESS INSOLUBLE
FORM
HARDNESS
Chemical Reaction
Softening
Softening
T h e e q u a tio n s b e lo w d e s c rib e th e re m o v a l o f c a rb o n a te h a rd n e s s .
C a (H C O 3 ) 2 + C a (O H ) 2 2 C a C O 3 + 2 H 2 O
M g (H C O 3 ) 2 + C a (O H ) 2 C a C O 3 + M g C O 3 + 2 H 2O
M g (H C O 3 ) 2 + C a (O H ) 2 C a C O 3 + M g (O H ) 2 + 2 H 2 O
Ion Exchange
(Softening)
Cations Anions
Calcium Bicarbonate
Magnesium Chloride
Sodium Sulfate
Iron Nitrate
Manganese Carbonate
Demineralisation
Demineralisation
In the demineralizer, water is treated in two
steps. First, it is passed through the cation ex-
change bed, where the cations (calcium,
magnesium and sodium) are exchanged for
hydrogen ions. The treated water is now free of
cations but is too acidic and cannot yet be used
in the boiler.
In the second step the water passes through the
anion exchange bed where the anions (sulfate,
chloride, carbonate and silica) are ex-changed
for hydroxide ions. The hydrogen and hydroxide
ions react to form water, now suitable for use in
the boiler.
Cation
Cation Exchange
Exchange
Anion
Anion Exchange
Exchange
Mixed
Mixed Bed
Bed Ion
Ion Exchange
Exchange (Polishing)
(Polishing)
Softener
Softener Regeneration
Regeneration
Cation
Cation &
& Anion
Anion exchangers
exchangers regeneration
regeneration
Cation
Cation &
& Anion
Anion exchangers
exchangers regeneration
regeneration
• Oxygen Scavengers
Hydrazine N2H4
Hydrazine sulphate N2H4.H2S4
N2H4+O2----->N2+2H2O
2Na2SO3+02---->2Na2SO4
COMMON BOILER FEEDWATER
CONTAMINANTS
IMPURITY RESULTING IN GOT RID OF BY COMMENTS
Soluble Gasses
Water smells like rotten eggs: Tastes bad, Found mainly in groundwater, and polluted
Hydrogen Sulphide (H2S) and is corrosive to most metals.
Aeration, Filtration, and Chlorination.
streams.
Deaeration & chemical treatment with Pitting of boiler tubes, and turbine blades,
Oxygen (O2) Corrosion and pitting of boiler tubes.
(Sodium Sulphite or Hydrazine) failure of steam lines, and fittings etc.
Internal
Internal Treatment
Treatment
1-Sodium Phosphate