Boiler

troubles
 Boiler Feed Water
“The water mainly used in boilers for steam generation is known as boiler
feed water”.
For such water we need some specification:
• Hardness should be below 0.2 ppm
• Its caustic alkalinity (due to OH-) should be in the range of 0.15 – 0.45
ppm.
• Its soda alkalinity (due to CO32-, HCO3-) should be in the range of 0.45 –
1.0 ppm.
Excess of above impurities cause the following problems-
Caustic
Scale and
Sludge embitterm
ent
Problems

Boiler Priming and

corrosion Foaming
 Boiler problems

1. Scale Hard adherent coating on

inner walls of boiler

water

Boiler wall

• Scales are hard deposits firmly sticking to the inner surface of the
boiler. Scale may be formed inside the boiler due to decomposition
of calcium-bicarbonate [Ca(HCO3)2].

Ca( HCO3 ) 2 
 CaCO3   H 2O  CO2 

3
 Slimy loose precipitate
1. Sludge called sludge suspended
in water

water

Boiler wall

Sludge is a soft, loose and slimy precipitate formed within the boiler.
It can be easily scrapped off with a wire brush.
II. Priming and foaming

Foaming- It is the production of continuous

foam or hard bubbles in boilers. Foaming is
due to the presence of substance like oil in
boiling water.
Foaming
Priming- It is the process in which some
particles in water are carried along with the
steam. The resulting process is called as wet
steam or carry over. The process of formation
of wet steam in boilers is called as priming.

Causes of Priming,
Priming
1. Presence of dissolved salts
2. High velocity steam due to sudden boiling
3. Improper boiler design
III. Caustic embitterment

Boiler corrosion which takes place due to presence of highly

alkaline water in boiler is known as caustic embrittlement
Na2CO3 + H2O NaOH + H 2O

Na2CO3 + H2O 2NaOH + H 2O

2NaOH + Fe Na 2FeO2 + H2O
3Na2FeO2 + 4 H2O 6 NaOH + Fe 3O4 + H2

IV. Boiler corrosion

Degradation or destruction of boiler materials (Fe) due to the

electrochemical attack is called boiler corrosion
Prevention of scale formation
Internal conditioning methods - of boiler water to prevent
scale formation
1. Colloidal conditioning – spreading of organic compounds like tannin,
agar gel
2. Carbonate conditioning – addition of carbonate compound
3. Phosphate conditioning – addition of phosphate compound
4. Calgon conditioning – addition of sodium hexa meta phosphate

1. Colloidal conditioning

Scale formation can be avoided by adding organic

substances like kerosene, tannin, agar-agar etc. These
substances get coated over the scale forming precipitates,
thereby yielding non-sticky and loose deposits similar to
sludge which can be removed by blow down operation.
 2. Carbonate conditioning
CaSO4 (Boiler water) + Na2CO3 CaCO3 + Na2SO4
Calcium sulfate Sodium calcium carbonate
carbonate
(non adherent loose sludge and can be
removed by blow down method)

Caution: Excess Na2CO3 can result in caustic embrittlement

3. Phosphate conditioning

3CaCl2 (Boiler water) + 2 Na3PO4 Ca3(PO4)2 + 6 NaCl

Calcium Sodium calcium phosphate
chloride phosphate (non adherent and can be
removed by blow down
method)

Scale formation can be prevented by adding sodium

phosphate to the boiler water which reacts with the hardness
producing ions and forms easily removable phosphate salts of
respective ions
 4. Calgon conditioning

• Calgon conditioning is a most useful method to remove

hardness products (i.e. scale & sludge) from boiler.

• In this process the Graham’s salt is used. Graham’s Salt is

also known as Calgon (sodium hexa metaphosphate).

• Calgon (sodium hexa metaphosphate) is soluble in water

and it converts the impurity like CaCO3, CaSO4 into soluble
complex compound, which will remain in dissolved form in
water. This property helps to remove the scale and sludge.
 4. Calgon conditioning continue….

Na2[Na4(PO3)6 2Na++ [Na4P6O18]2-

sodium hexa meta phosphate

2CaSO4 (Boiler water) + [Na4P6O18]2- [Ca2P6O18]2- + 2Na2SO4

Soluble complex ion of calcium -

Calcium Sulfate can be removed easily

Calgon tablets are used in the cleaning of washing machine

drums
 Quiz
• What is boiler feed water?
• What are the requirements for Boiler feed
water?
• What is priming and foaming?
• Boiler corrosion due to use of highly alkaline
water is called_______
• What is scale and sludge?
 FAQ

• What do you mean by boiler feed

water? Explain the calgon conditioning
method of descaling?
• Define the following terms:
– Priming and Foaming
– Caustic embrittlement
– Sludge and Scales.