Water Treatment and Boiler Problems in Engineering Sciences
Water treatment: Boiler
Problems
Dr.Smita Kavalgikar
Engineering Sciences
International Institute of Information Technology, I²IT
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
BOILER
A
boiler
is
a
device
for
generating
steam
T
he
furnace,
which
provides
heat,
usually
by
burning
a
fuel,
and
the
boiler
proper,
a
device
in
which
the
heat
changes
water
into
steam.
The
steam
Applications :
water
heating,
central
heating,
boiler-based
power
generation,
cooking,
and
sanitation.
Proper
treatment
of
boiler
feed
water
is
an
important
part
of
operating
and
maintaining
a
boiler
system.
As
steam
is
produced,
dissolved
solids
become
concentrated
and
form
deposits inside
the
boiler.
This
leads
to
poor heat
transfer
and
reduces
the
efficiency
of the
boiler.
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
BOILER
FEED
WATER
Feedwater
is
water
that
undergoes
purification
or
preheating
and
is
then
supplied
to
boilers
for
hot
water and
steam
production,
or
it
can
remain
still.
It
is
typically
found
in thermal
power
plants
where
it
is
stored
and
conditioned
in
tanks,
known
as
boiler
feed water
It
should
have
the
following
composition:
1.
Its
hardness
should
be
below
0.2
ppm.
2.
Its
caustic
alkalinity(due
to
OH
-
)
3.
Its
soda
alkalinity(due
to
Na
2
CO
3
)
should
be
0.45-1ppm.
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Scale & sludge formation
Water in boiler is continuously heated causes the increase in the concentration of
dissolved and suspended solids.
•
The precipitation in the form of
soft loose
and
slimy
deposits
(sludge)
•
The precipitation in the form of
hard deposits
, which are
sticky
on the walls
of boilers
(scale)
sludge & Scale formation process
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Disadvantages of sludge
Sludges are
bad conductors of heat
and results in wastage of heat and fuel
Sludges entrapped in the scale get
deposited as scale
causes more loss of
efficiency of boiler
Excessive sludge formation leads to setting of sludge in slow circulation.
Areas such as pipe connections leading to
chocking
(or) blockage of the
pipes
an
disturb the working of boilers
Prevention
By using
soft water
which is free from dissolved salts like
MgCO
3,
MgCl
2
, CaCl
2
& MgSO
4.
Blow down operation
can prevent sludge formation
Sludge
:
The muddy solid at the bottom of the boiler (or) the loose, slimy and
soft deposits in the boiler are called sludge.
Occurs in colder areas ,collected in area where flow rate is slow or at
bends of pipes
Causes of the sludge:-
The
sludge is caused by MgCO
3
, MgCl
2
,CaCl
2
which have more
solubility in hot water
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Scale:
-
Scales are hard sticky deposits on the inner walls of boiler.
The scales are very difficult to remove
Main boiler trouble
Causes of the sludge
:
Due to the decomposition of Ca(HCO
3
)
2
at high temperature & pressure
present in boiler, It forms caco
3
insoluble salt settles as ppt in the boiler.
Ca(HCO
3
)
2
→
CaCO
3↓
+ CO
2↑
+
H
2
O
CaSO
4
highly soluble in cold water and less soluble in hot water. So the
CaSO
4
in boiler water is precipitates out as hard scale if the temp of boiler
increases.
The dissolved Mgcl
2
present in water is precipitates as Mg (OH)
2
at high
temperature, deposits as scale.
MgCl
2
+2H
2
O→ Mg (OH)
2↓
+ 2HCl
Sio
2
present in water deposits as calcium silicate or magnesium Silicate. The
deposits are very hard.
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Disadvantages of Scale: -
Wastage of Fuel:
As the scale is hardly sticky on the walls of the boiler and it is very bad conductor
of heat
or have low thermal conductivity
. Heat transfer from wall of boiler to water
is decreased.
To
get a steady supply of heat over heating is done. So
there is loss of heat and
fuel.
Depends upon thickness of scale
Lowering of boiler safety:
Due to the scale formation we have to heat the boiler to high temperatures this
causes the weakening of boiler material.
Distortion of boiler tubes makes boiler unsafe to bear pressure of the steam
(especially in high pressure boiler)
Decease in efficiency
:
Due to scale deposits the chocking of boiler is observed.
Danger of explosion:
Due to uneven heat there may be developing of cracks in Scale.
Due to uneven expansion crack in scale may increases.
Whenever the water passes through this crack comes to contact with boiler plate
and generates sudden steam and high pressure results explosion of boiler.
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Removal of Scales
:
•
If the scale is
soft.
It can be removed by scrapping,
by piec
e of wood or wire.
•
If the scale is
brittle.
By giving thermal shocks done by heating to higher
temperature and suddenly cooling.
•
If scale is
hard and adherent.
The CaCO
3
scale is removed by the washing with 5-
10% HCl Solution and CaSO
4
scale in removed washing with EDTA solution.
•
If the scale is
loosely bound.
Blow down operation also removes Scale
Prevention of scale formation:
Internal treatment :
1} Precipitate out scale forming impurities form of sludge which will be blown
down.
2} Impurities can be converted into compounds which are dissolved form in water
so wont harm.
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Important Internal treatment methods
1}Colloidal conditioning:
•
In low pressure boilers, by adding organic substances e.g. kerosene, tanin
,agar-agar
•
These will coat on the scale and yield non-sticky and loose deposits as like
sludge
which will be removed by blown down operation
2}Phosphate conditioning:
In high pressure boilers, by adding sodium phosphate
3CaCl
2
+ 2Na
3
Po
4
→
Ca
3
(PO
4
)
2
↓ + 6NaCl
↑
Non-adherent, easy to remove
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
3} Carbonate conditioning
:
By adding Na
2
CO
3
to boiler
CaSO
4
+ Na
2
CO
3
→CaCO
3
↓ + Na
2
SO
4
↑
removed by blow down operations
4} Treatment with sodium aluminate(
NaAlO
2
)
By addition of
NaAlO
2
hydrolysis occur gives gelatinous ppt
NaOH reacts with the magnesium salt to form sludge
entraps the colloidal impurity (oil,
silica)
removed by blow down operation
5} Calogen conditioning
Sodium hexametaphosphate
Na
2
[Na
4
(PO
3
)
6
] is forming soluble complex.
N
a
A
l
O
2
+
H
2
O
N
a
O
H
+
A
l
(
O
H
)
3
NaOH + MgCl
2
Mg(OH)
2
↓+2NaCl
N
a
2
[
N
a
4
(
P
O
3
)
6
]
2
N
a
+
+
[
N
a
4
P
6
O
1
8
]
2
-
N
a
2
[
N
a
4
P
6
O
1
8
]
+
2
C
a
S
O
4
N
a
2
[
C
a
2
P
6
O
1
8
]
+
2
N
a
2
S
O
4
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057
Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-
+912022933441/2/3 | Email-info@isquareit.edu.in
Dr. Smita Kavalgikar
Mob. No: 9011079483
Email ID: smitan@isquareit.edu.in
Water treatment is crucial for boiler systems to prevent scale and sludge formation, ensuring efficient steam generation. Proper treatment of boiler feedwater, control of dissolved solids, and maintaining ideal water composition are key aspects discussed in detail. Scale and sludge formation are common issues in boilers, impacting heat transfer efficiency. Learn about the causes of sludge and how to address them effectively in engineering practices.
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Water treatment: Boiler Problems Dr.Smita Kavalgikar Engineering Sciences International Institute of Information Technology, I IT www.isquareit.edu.in
International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
BOILER Aboilerisadeviceforgeneratingsteam The furnace, which provides heat, usually by burning a fuel, and the boiler proper,adeviceinwhichtheheatchanges waterintosteam. The steam Applications :water heating, central heating, boiler-based power generation,cooking,and sanitation. Proper treatment of boiler feed water is an important part of operating and maintaining a boiler system. As steam is produced, dissolved solids become concentratedandform depositsinsidetheboiler. Thisleadsto poorheattransferand reducestheefficiencyofthe boiler. International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
BOILER FEEDWATER Feedwateriswaterthat undergoespurificationorpreheating and isthen supplied to boilers for hot water and steam production, or it can remain still. It is typicallyfound in thermal power plants where it is stored and conditioned in tanks, known as boiler feed water It should have the followingcomposition: 1. Its hardness should be below 0.2 ppm. 2. Its caustic alkalinity(due to OH-) 3. Its soda alkalinity(due to Na2CO3) should be 0.45-1ppm. Types of boiler Permitted hardness in feed water Low Pressure 40-80 ppm Medium Pressure 10-40 ppm High Pressure 0-3 ppm International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Scale & sludge formation Water in boiler is continuously heated causes the increase in the concentration of dissolved and suspended solids. The precipitation in the form of soft loose and slimy deposits (sludge) The precipitation in the form of hard deposits, which are sticky on the walls of boilers (scale) sludge & Scale formation process International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Sludge: The muddy solid at the bottom of the boiler (or) the loose, slimy and soft deposits in the boiler are called sludge. Occurs in colder areas ,collected in area where flow rate is slow or at bends of pipes Causes of the sludge:- The sludge is caused by MgCO3, MgCl2,CaCl2 which have more solubility in hot water Disadvantages of sludge Sludges are bad conductors of heat and results in wastage of heat and fuel Sludges entrapped in the scale get deposited as scale causes more loss of efficiency of boiler Excessive sludge formation leads to setting of sludge in slow circulation. Areas such as pipe connections leading to chocking (or) blockage of the pipes an disturb the working of boilers Prevention By using soft water which is free from dissolved salts like MgCO3, MgCl2, CaCl2 & MgSO4. Blow down operation can prevent sludge formation International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Scale: - Scales are hard sticky deposits on the inner walls of boiler. The scales are very difficult to remove Main boiler trouble Causes of the sludge: Due to the decomposition of Ca(HCO3)2 at high temperature & pressure present in boiler, It forms caco3 insoluble salt settles as ppt in the boiler. Ca(HCO3)2 CaCO3 + CO2 +H2O CaSO4 highly soluble in cold water and less soluble in hot water. So the CaSO4 in boiler water is precipitates out as hard scale if the temp of boiler increases. The dissolved Mgcl2 present in water is precipitates as Mg (OH) 2 at high temperature, deposits as scale. MgCl2 +2H2O Mg (OH)2 + 2HCl Sio2 present in water deposits as calcium silicate or magnesium Silicate. The deposits are very hard. International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Disadvantages of Scale: - Wastage of Fuel: As the scale is hardly sticky on the walls of the boiler and it is very bad conductor of heat or have low thermal conductivity. Heat transfer from wall of boiler to water is decreased. To get a steady supply of heat over heating is done. So there is loss of heat and fuel. Depends upon thickness of scale Lowering of boiler safety: Due to the scale formation we have to heat the boiler to high temperatures this causes the weakening of boiler material. Distortion of boiler tubes makes boiler unsafe to bear pressure of the steam (especially in high pressure boiler) Decease in efficiency: Due to scale deposits the chocking of boiler is observed. Danger of explosion: Due to uneven heat there may be developing of cracks in Scale. Due to uneven expansion crack in scale may increases. Whenever the water passes through this crack comes to contact with boiler plate and generates sudden steam and high pressure results explosion of boiler. International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Removal of Scales: If the scale is soft. It can be removed by scrapping, by piece of wood or wire. If the scale is brittle. By giving thermal shocks done by heating to higher temperature and suddenly cooling. If scale is hard and adherent. The CaCO3 scale is removed by the washing with 5- 10% HCl Solution and CaSO4 scale in removed washing with EDTA solution. If the scale is loosely bound. Blow down operation also removes Scale Prevention of scale formation: Internal treatment : 1} Precipitate out scale forming impurities form of sludge which will be blown down. 2} Impurities can be converted into compounds which are dissolved form in water so wont harm. International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Important Internal treatment methods 1}Colloidal conditioning: In low pressure boilers, by adding organic substances e.g. kerosene, tanin ,agar-agar These will coat on the scale and yield non-sticky and loose deposits as like sludge which will be removed by blown down operation 2}Phosphate conditioning: In high pressure boilers, by adding sodium phosphate 3CaCl2 + 2Na3Po4 Ca3(PO4)2 + 6NaCl Non-adherent, easy to remove NaH2PO4 Acidic Alkalinity of water is too high Alkalinity of water is adequate Slightly alkaline Na2HPO4 Alkalinity of water is low Na3PO4 International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in Alkaline
3} Carbonate conditioning: By adding Na2CO3 to boiler CaSO4 + Na2CO3 CaCO3 + Na2SO4 removed by blow down operations 4} Treatment with sodium aluminate(NaAlO2) By addition of NaAlO2 hydrolysis occur gives gelatinous ppt NaAlO2 + H2O NaOH + Al(OH)3 NaOH reacts with the magnesium salt to form sludge NaOH + MgCl2 Mg(OH)2 +2NaCl entraps the colloidal impurity (oil, silica) removed by blow down operation 5} Calogen conditioning Sodium hexametaphosphate Na2[Na4(PO3)6] is forming soluble complex. Na2[Na4(PO3)6] 2Na+ + [Na4P6O18]2 - Na2[Na4P6O18] + 2CaSO4 Na2[Ca2P6O18] + 2Na2SO4 International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone-+912022933441/2/3 | Email-info@isquareit.edu.in
Dr. Smita Kavalgikar Mob. No: 9011079483 Email ID: smitan@isquareit.edu.in International Institute of Information Technology,I2IT,P-14,Rajiv Gandhi infotech Park,Hinjawadi Phase1,Pune-411057 Phone- +912022933441/2/3 | Email-info@isquareit.edu.in
