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LECTURE PLAN
1.2) Boiler troubles – (sludge and scale, priming and foaming, caustic
embrittlement, boiler corrosion)
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CY8151 – ENGINEERING CHEMISTRY
1. Definition of Desalination:
Removal of common salt (NaCl) from water is called ‘Desalination’. The various
desalination methods are Electrodialysis, Reverse osmosis, Distillation and Freezing.
3. Reverse osmosis is used to convert sea and brackish water to fresh water.
4. Osmosis:
When two different concentrated solutions are separated by a semi permeable membrane,
due to osmotic pressure, low concentrated solvent flows to higher one. This is known as
osmosis.
5. Reverse Osmosis:
6. During this RO process , only the water flows across the membrane and it prevents the
salt migration. So, this method is also called as ‘Super filtration’.
2. Removes ionic, non-ionic and colloidal silica impurities , which cannot be removed by
demineralization method.
5. The membrane can be replaced within a few minutes, thereby providing uninterrupted
water supply.
Disadvantages:
Diagram:
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1.2) Boiler Troubles
3. Boiler troubles:
If the untreated water is fed directly to the boiler, it may cause sludge, scale, priming,
foaming, caustic embrittlement and boiler corrosion which are collectively known as
boiler troubles.
Definition:
If the water contains hardness causing salts like MgSO4, MgCl2 ,CaSO4 , Ca (HCO3)2 . on
evaporation, the salts are precipitated .
If they form loose, slim , non-adherent precipitate, It is known as sludge.
If they form hard, thick , adherent precipitate, it is known as scale.
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Reasons for sludge and scale:
a) Wastage of fuel
b) Decrease in efficiency
c) Boiler explosion
a) Wastage of fuel:
Scales have low thermal conductivity. So, the heat transfer from boiler to inside water
may not be sufficient. In order to provide steady supply of heat to water, over heating is
to be done which causes wastage of fuel. The wastage of fuel depends on the thickness
and nature of the scale which is shown in the table.
b) Decrease in efficiency:
Scales sometimes deposit in the valves and condensers of the boilers and heat exchangers
and cause choking. This results in decrease in efficiency of the boiler and heat
exchangers.
c) Boiler explosion:
Sometimes due to overheating the thick scales may crack which causes the sudden
contact of high heated boiler material with water. This causes formation of a large
amount of steam and it develops high pressure. This leads to explosion.
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Prevention of Scales:
1. At earlier stage, scraper, wire brush, mechanical scrubber can be used to remove scales.
5. By acid treatment
N Sludge Scale
o
1 Loose, slim , non-adherent deposit on the Hard, thick , adherent precipitate
inner walls of boiler.
2 Due to salts like MgSO4 , MgCl2 Due to salts like CaSO4 , Ca(HCO3)2
3 Due to poor conductance, they decrease Due to poor conductance, they decrease
the boiler efficiency to lesser extent and the boiler efficiency to maximum extent,
causing chocking in the pipelines. cause reduced fuel economy , improper
boiling, boiler explosion etc.,
5 Diagram:
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1.2 – B) Priming and Foaming:
Priming:
Due to rapid boiling, the steam may carry some water droplets along with it. This is
called wet steam .The process of wet steam production is called Priming. It can reduce
the heat of the steam and cause corrosion in the pipelines.
S.No Reasons for Priming Control measures of priming
1 Improper design of boiler Proper boiler design
2 High water level Maintaining proper water level
3 High velocity of steam Regulating the velocity of steam
4 Uneven boiling Proper boiling
Foaming:
If oils and greases are present, they produce stable bubbles on the water surface.This will
increase the wet steam production. This is known as “Foaming”.
Prevention of foaming:
Foaming is prevented by adding
i) Anti foaming agents (e.g.) synthetic poly amides , castor oil, cotton seed oil
ii) Coagulants (e.g.) Aluminium hydroxide, sodium aluminate
iii) Oil can be removed by cataphoresis ( separation of colloidal charged particle by
electrical plates)
This NaOH occupies the hair line cracks of boiler metal and converts the insoluble Fe
into soluble Sodium Ferroate. Thus it makes the cracks bigger in bents, joints and
crevices.
Fe + 2 NaOH Na2FeO2 + H2 ↑
( Insoluble) (Soluble) 7
Prevention of caustic embrittlement:
1. As softening agent, we can use sodium phosphate instead of sodium carbonate.
2. The hair line cracks can be sealed by waxy materials like Tannin and Lignin.
3. By adjusting the pH of the water around 6.5 – 8.5
1. This is based on the Henry and Dalton’s law principle that at high temperature , low
pressure and high exposed area, the solubility of gases in water is decreased. So, the
gases can be expelled easily.
2. Here, the water is fed into the mechanical deaerator which is provided with vacuum
pump, heaters and perforated plates.
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.
Corrosion due to Carbon – di – oxide:
Salts like Calcium bicarbonate on heating produces CO2 . CO2 dissolves in water to
form carbonic acid which corrodes the boiler metal.
Dissolved salts like MgCl2 cause acid formation. This will be prevented by alkali
neutralisation.
MgCl2 + 2 H2O Mg(OH)2 + 2 HCl (Corrosive acid)
Neutralisation:
Excess acidic nature is neutralized by adding alkalis and vice versa.
HCl + NaOH NaCl + H2O
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1.3) EXTERNAL TREATMENT
Removal of impurities, salts from boiler feed water before feeding it to the boiler is
known as external treatment. (e.g) Zeolite process, ion exchange demineralisation
1.3) - A) ZEOLITE (PERMUTIT) SOFTENING PROCESS
ii) These natural zeolites are green sand . They are non porous in nature.
iii) Zeolites are having the general formula Na2O . Al2O3. xSiO2 . yH2O
(x = 2 to 10; y = 2 to 6)
iv) The porous and gel structured synthetic zeolites are known as permutit.
Principle
i) The sodium ions are loosely held in these zeolites. They are easily replaced by Calcium
ii) When hard water is passed through a bed of sodium zeolite kept in a cylinder, it
exchanges its sodium ion with Ca2+ and Mg2+ ions present in the water to from Calcium
Reactions:
The outcoming water is enriched with large amount of sodium salts which do not cause
any hardness. But in cannot be used in boiler.
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Regeneration:
i) On prolonged use, all the zeolite sodium ions are exhausted.
ii) There will be no sodium ions to exchange the Calcium and magnesium ions. So, they
have to be regenerated.
iii) The exhausted zeolite is regenerated by treating with 10% solution of NaCl.
Regeneration reaction:
The regeneration step comprises of a) back washing b) salting c) rinsing before reuse
1. The outlet water will have least hardness around 1 – 2 ppm only.
2. As the zeolite can be regenerated, the method is cheap.
3. Operation is easy.
4. The space requirement for this setup is minimum .
5. No sludge is formed during this process.
1. Turbid water cannot be treated as it blocks the pores of the zeolite bed.
2. Acidic water cannot be treated as it decomposes the structure of zeolite.
3. Water containing Fe, Mn cannot be treated as the regeneration is difficult.
4. Brackish water cannot be treated because it contains Na+ ions. So, the ion exchange
reaction will not occur.
5. When the softened water contains more dissolved sodium salts, it may result in boiler
corrosion and caustic embrittlement. 11
1.3) - B).Ion exchange method - ( Demineralisation)
Working:
1. Here all the cations and anions are completely removed. It uses two cylinders of cation
exchange cylinder and anion exchange cylinder filled with resins.
2. Resins are long chain, insoluble, cross linked, organic polymers. There are 2 types.
The resultant polymer is treated with acid, it forms cation exchange resin. If the polymer
is treated with bases and ammonium chloride, it forms anion exchange resin.
4. The water is fed into cylinder –I where all the cations are replaced by RH2 Resins.
RH2 + CaCl2 R Ca + 2 HCl
RH2 + MgCl2 R Mg + 2 HCl
5. The cation free water is fed to cylinder II, where all the anions are replaced.
R’(OH)2 + 2 HCl R’Cl2 + 2H2O
On prolonged use, as all the resins are exhausted, there will be no H+ orOH – ions
to exchange the unwanted ions. So, they have to be regenerated. Cation resins are
regenerated by HCl and anion resins are regenerated by NaOH.
Diagram:
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Differences between soft water and demineralized water.
5 The treated water contains relatively The treated water does not contain any
large amount of dissolved Na salts dissolved salts. They may not cause any
which causes caustic embrittlement in boiler troubles.
boilers.
6. The setup and operating cost is The setup and operating cost high.
relatively low.
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1.4) INTERNAL TREATMENT METHODS
i) The residual salts that are not removed by external methods can be removed by adding
some chemicals directly into the boiler water.
ii) These chemicals are known as ‘Boiler compounds’. This method is known as
‘Internal treatment’ (or) sequesterisation.
iii)E.g) Carbonate conditioning, Phosphate conditioning , Calgon conditioning,
colloidal conditioning, Sodium aluminate conditioning
iv) In general, internal treatment methods are followed by blow down operation.
a) Carbonate conditioning:
ii) Here the salts like CaSO4 are converted to easlity removable CaCO3.
iii) But in high pressure boilers, the excess Na2CO3 undergoes hydrolysis and is converted
to NaOH.
b)Phosphate conditioning:
i) Phosphate conditioning is used for high pressure boiler.
ii) It is superior than carbonate conditioning as there is no risk of CO2 liberation, caustic
c) Colloidal conditioning:
i) Colloidal conditioning is used for low pressure boilers.
ii) Here, scale formation is avoided by adding organic substances like kerosene, tannin,
agar-agar etc., which get coated over the scale forming precipitates.
iii) This converts the scale into sludge and they are removed by blow down operation
methods.
3. Types of Hardness:
a) Temporary Carbonate hardness : The hardness due to carbonates and
bicarbonates can be removed by simple boiling. So, they are known as temporary or
carbonate or alkaline hardness.
Ca(HCO3)2 (On heating) CaCO3 + H2O + CO2
4. Units of hardness:
i) ppm ii) mg/L iii) degree Clarkes iv) Degree French
S.No Unit Parts of CaCO3 equivalence Parts of water
1 Ppm (parts per million) 1 106
2 Degree French (0F) 1 105
3 degree Clarkes (0Cl) 1 70,000
4 mg/L 1 mg 1 litre
0 0
Therefore , 1ppm = 1mg/L = 0.07 Cl = 0.1 F
5.CaCO3 equivalence:
Hardness is expressed in CaCO3 equivalence. Because,
i) It is the most insoluble and easily precipitatable salt.
ii) Its molecular weight is 100 and equivalent weight is 50. As these are whole numbers, it
is very easy to use them in calculations. 17
1.6) ESTIMATION OF HARDNESS OF WATER BY EDTA METHOD
The tendency of water not to lather with soap is known as hardness. The hardness
due to carbonates and bicarbonates can be removed by simple boiling. So, they are known
as temporary or carbonate or alkaline hardness. The hardness due to chlorides and sulphates
cannot be removed by simple boiling. They need special methods like lime soda process
and zeolite process. This hardness is called as Permanent hardness or Non-carbonate or
non alkaline hardness.
1. Aim:
To estimate the amount of hardness present in the given water sample.
2. Chemicals required:
a) Standard hard water – 1g CaCO3 + dil. HCl – made up to 1 Lr.
b) EDTA solution – 4 gms of EDTA sodium salt / 1 Lr of water
c) EBT Indicator – 0.5g EBT / 100 ml alcohol
d) Ammonia buffer - 67.5g Ammoniumchloride +570ml Ammonia-- made up to 1Lr
3. Principle:
EDTA stands for Ethylene Diamine Tetra Aceticacid. As it is insoluble in water, we use
its disodium salt.
Structure of EDTA:
Ca2+ / Mg2+ in water + EBT [Ca / Mg –EBT] unstable wine red complex
When EDTA is titrated against the complex, EDTA replaces all the EBT and forms a
stable Ca / Mg –EDTA complex. The liberated EBT indicates the end point as steel
blue.
[Ca / Mg –EBT] + EDTA [Ca / Mg –EDTA] + EBT
(Wine red/unstable) Stable) (Steel blue)
So, the end point is the colour change from wine red to steel blue. 18
4. Short Procedure:
S.No Content Titration-I Titration-II Titration-III
Standardisation Total Hardness permanent
of EDTA Hardness
1 Burette EDTA StandardEDTA StandardEDTA
5. Calculation:
= V2 X 20 mg of CaCO3
V1
= V3 X 20 mg of CaCO3
V1
Total hardness:
100ml of sample requires = 20 ml of 0.01M EDTA
= 20 x 1 mg = 20mg of CaCO3
Therefore, 1000 ml of sample requires = 20 x 1000 / 100 = 200mgs of CaCO3
i.e., Total hardness = 200 mg / L = 200 ppm
5. 0.28 g of CaCO3 was dissolved in HCl and the solution was made upto one litre with
distilled water. 100 ml of the above solution required 28 ml of EDTA solution on titration.
100 ml of a hard water sample required 33 ml of same EDTAsolution on titration. Another
100 ml of the same water, after boiling, cooling and filtering required 10 ml of EDTA
solution on titration. Calculate the temporary and permanent hardness of water. (June 10)
Given :
1000 ml of std. hard water contains = 0.28 gm of CaCO3 = 280 mgs of CaCO3
Therefore, 1 ml of std. hard water = 0.28 mg of CaCO3
28 ml of EDTA = 100 ml of the std hard water = 100 x 0.28 mgs of CaCO3
Hence, 1 ml of EDTA = 100 x 0.28 x 1 / 28 = 1 mg of CaCO3
Total hardness:
100ml of sample requires = 33 ml of 0.01M EDTA
= 33 x 1 mg = 33mg of CaCO3
Therefore, 1000 ml of sample requires = 33 x 1000 / 100 = 330mgs of CaCO3
i.e., Total hardness = 330 mg / L = 330 ppm
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