to calculate the boiler blowdown rate, multiply the steam consumption by the

total dissolved solids in the water, then divide by the difference between the
dissolved solids in water and the maximum allowable solids.

Blowdown in Boiler Definition

Blowdown in Boiler, Usually, water that is fed to the boiler contains high Total Dissolved Solids
(TDS) content as well as other dissolved and undissolved solids in it. On heating water or converting
water to steam, these dissolved solids do not evaporate and get separated from water or steam and
settled at the bottom of the shell.
These undissolved solids are also responsible for the scaling, corrosion, and carryover of solids with
the steam and other specific problems. This will further prevent the transfer of heat between the gases
and the water and will eventually overheat the boiler tubes or shells.
Boiler in Blowdown Diagram

Source: C
ampbell
So some part of the water from the shell bottom is drained either intermittently or continuously to
keep the TDS level of water under allowable operating limits. Therefore removing of TDS or
impure water from the boiler shell is termed as blowdown.
Blowdown type in Steam Boilers
There are two ways of blowdown depending upon the type of design, a capacity of a boiler as well
as the characteristics of a boiler feed water:-
 Intermittent or Manual blowdown – When a blowdown is done manually by the boiler
operator without keeping at regular intervals is termed a Manual blowdown. This type of
blowdown is useful to remove sludge formation or suspended solids from the boiler. In this
blowdown valve is opened manually at regular intervals according to the set operating
schedule. Although to reduce the heat losses in terms of hot blowdown water, the valve is
opened frequently and slightly to allow only a small quantity of blowdown to occur but this
kind of blowdown is responsible for high heat and pressure losses.
 Continuous blowdown – When blowdown is done continuously and automatically to keep
the dissolved and suspended solids under boiler operating limits known as continuous
blowdown. An automatic blowdown continuously monitors the quality of feed water as well
as the quality of water inside a boiler shell and automatically opens as soon as the boiler
water TDS exceeds the permissible operating limit. This type of blowdown helps remove a
maximum amount of dissolved solids with only minimal loss of water and heat from the
boiler. Also in continuous blowdown heat in terms of hot water from the boiler can be
utilized to preheat the feed water by installing a heat exchanger or heat recovery
equipment in the path.
Depending on the type of operation either manual or continuous and automatic, a blowdown valve is
provided along with suitable accessories.

Pros:-
  Blowdown of water keeps the water TDS level under permissible limits.
 It prevents the corrosion and scaling of boiler tubes.
 It prevents the carryover of contaminants from the steam thereby providing pure steam.
Cons:-
 Blowdown of water increases the heat and pressure losses if not taken care of or proper
scheduling is not done.
 Eventually, these heat and pressure losses reduce the boiler’s efficiency.
Also Read: High-Pressure Boiler
Boiler Blow Down Calculation Formula
The blowdown rate can be calculated with Following Formula

BBR = SC * TDSW / (TDSM-TDSW)

Where:

BBR = Boiler blowdown rate (kg/h)

SC = Steam consumption (kg/h)

FC is Total Dissolved Solid

TDSM = Maximum allowable dissolved solids (ppm)

s – TDS – in the feed water is ppm

For example, if the steam consumption is 100 kg/h, the total dissolved solids in the water is 1,000
ppm, and the maximum allowable dissolved solids is 500 ppm, then the boiler blowdown rate would
be:

bc is the maximum allowable Total Dissolved Solids – TDS – in the boiler water in ppm

A blowdown of the boiler is a routine operation necessary due to the increased

concentration of Total Dissolved Solids - TDS - in the boiler water when producing
steam.

The blow down rate of a boiler depends on

 steam consumption (steam used in the process and not returned as condensate to
the boiler)
 concentration of impurities in the feed water
 maximum allowable TDS in the boiler

The blowdown rate can be calculated as

qBD = qS fc / (bc - fc) (1)

where

qBD = blowdown rate (kg/h)

qS = steam consumption (kg/h)

fc = Total Dissolved Solids - TDS - in the feed water (ppm)

bc = maximum allowable Total Dissolved Solids - TDS - in the boiler water (ppm)

Cooling tower must be made up because the water level decrease by the time during operation.
There are aspect that contribute to calculation of cooling tower makeup water. Those are:

 Evaporation loss
 Drift loss
 Blow down
Total cooling water makeup water requirement = evaporation loss + drift loss + blow down.
Let’s take a look one by one how to calculate each component.

Evaporation Loss
Evaporation loss is loss of water due to evaporation. It is calculated by this equation:
Evaporation loss = 0.00085 Wc (T -T )1 2

Where:
T – T = inlet water temperature minus outlet water temperature ( F)
1 2
o

0.00085 is evaporation constant (rule of thumb). The actual evaporation rate is a function of
season and climate.

Drift Loss
Drift is entrained water in the tower discharge vapor. Drift loss in cooling tower is a function of
drift eliminator design.
Drift loss = 0.02% water supply [for new development in eliminator design]

Blowdown
Blowdown is a portion of circulating water that is discharged in order to lower solids
concentration due to evaporative cooling. The requirement of blowdown is related with cycle of
concentration (COC). COC is best described as ratio of chloride content in circulation water
and in makeup water.
Blowdown = [ Evaporative loss – (COC – 1) x Drift loss] /(COC – 1)
Cycle of concentration is normally 3-4 cycles. When cycle of concentration below 3 cycles,
quantity of water to be discharged will be large.

EXAMPLE
Let say we have cooling tower with the following data:
Inlet water flow rate = 10 000 gpm
Inlet water temperature = 100 Fo

Outlet water temperature = 85 Fo

Drift loss = 0.02%

Cycles of concentration = 5
Recall again, cooling tower makeup water = evaporation loss + drift loss + blowdown. Let’s
calculate each component.
 Evaporation loss = 0.00085 x 10 000 x (100-85) = 127.5 gpm
 Drift loss = 0.02% x 10 000 = 2 gpm
 Blowdown = [127.5 – (5-1) x 2]/(5-1) = 29.87 gpm
 Cooling tower makeup water = 127.5 + 2 +29.87 = 159.37 gpm