Boiler Water Treatment
Why treat industrial boiler water?
Scale
Scale formation is a significant issue in boiler systems, primarily caused by the precipitation of salts (calcium, magnesium, silica). This buildup can lead to several problems:
- Reduced Heat Transfer Efficiency: Scale acts as an insulating layer on heat transfer surfaces, making it harder for heat to be transferred from the combustion gases to the water. This inefficiency can cause the boiler to consume more energy, increasing operational costs.
- Increased Pressure and Temperature: As scale accumulates, it can restrict water flow, leading to increased pressure and temperature within the boiler. This not only stresses the system but can also lead to equipment failures.
- Frequent Maintenance and Downtime: The presence of scale often requires more frequent maintenance interventions, resulting in increased downtime and associated costs.
Corrosion
Corrosion is another critical concern for boiler systems, occurring when metal components are exposed to water and oxygen. The consequences of corrosion include:
- Material Degradation: Corrosion leads to the disintegration of metal components, which can result in leaks or even failures if not addressed promptly. Pitting corrosion, in particular, creates localized weak points that can deepen over time.
- Increased Repair Costs: Corroded components require replacement or repair, which can be costly and time-consuming. This not only affects the budget but also disrupts operations.
- Reduced System Efficiency: As corrosion products accumulate, they can contribute to further scaling, creating a vicious cycle that diminishes overall efficiency.
Solutions
To combat the issues of scale and corrosion in industrial boilers (low, medium and high pressure) , KontrolKem offers a range of chemical treatments and equipment solutions:
Chemicals
- Oxygen Scavengers: By removing dissolved oxygen from the water, these agents help prevent oxidative corrosion.
- Scale Inhibitors and Dispersants: Specially formulated chemicals prevent scale formation by modifying the crystallization process of minerals in the water and dispersing minerals preventing accumulation.
- Corrosion Inhibitors: These chemicals protect metal surfaces from corrosive elements by forming a protective film that minimizes direct contact with harmful substances.
- Neutralizing Amines: These volatile compounds are essential for controlling corrosion in condensate systems by neutralizing carbonic acid formed from dissolved carbon dioxide.
- Antifoamers: Reduce the tendency of water to foam, when high in salt content, thus decreasing the need for blowdown and provides excellent energy savings.
- Acidic cleaning chemicals: Used to dissolve and remove metal deposits and hard scale from industrial boilers, restoring heat transfer efficiency. Include corrosion inhibitors to minimize damage to metal surfaces during cleaning.
Equipment
- Water Filtration Systems (sand, mechanical, special media): Effective filtration removes impurities that contribute to scaling and corrosion.
- Micro/Ultra/Nano Filtration: These advanced membrane filtration processes utilize semipermeable membranes with varying pore sizes to separate particles and solutes from liquids
- Water Softeners: These systems reduce hardness in feedwater, significantly minimizing scale buildup.
- Reverse Osmosis (RO) : RO systems effectively remove dissolved solids and contaminants from water, reducing both scaling and corrosion risks.
- Electrodeionization (EDI) Systems: EDI provides high-purity water by removing ions from feedwater, further protecting boiler components.
- Mixed Bed : Use a combination of cation and anion exchange resins to achieve extremely low conductivity water.
- Chemical Dosing Pumps: Accurately inject treatment chemicals to maintain optimal boiler water conditions.
- Automated Blowdown Systems: Control and manage boiler blowdown based on real-time conductivity measurements, optimizing water usage and reducing energy loss.
- Dissolved Oxygen (DO) Sensors: Continuous monitoring of oxygen levels helps detect and prevent corrosion risks.
Optimize your industrial process with our expert water treatment solutions, designed to improve efficiency and protect the environment. Contact us today to schedule a meeting and discover how we can help you achieve your goals!
