Boiler Water Treatment

Producing quality steam on demand depends on properly managed water treatment to control steam
purity, deposits and corrosion. A boiler is the sump of the boiler system. It ultimately receives all of the
pre-boiler contaminants. Boiler performance, efficiency, and service life are direct products of selecting and
controlling feed water used in the boiler.
When feed water enters the boiler, the elevated temperatures and pressures cause the components of
water to behave differently. Most of the components in the feed water are soluble. However, under heat
and pressure most of the soluble components come out of solution as particulate solids, sometimes in
crystallized forms and other times as amorphous particles. When solubility of a specific component in
water is exceeded, scale or deposits develop. The boiler water must be sufficiently free of deposit forming
solids to allow rapid and efficient heat transfer and it must not be corrosive to the boiler metal.
Deposit Control
Deposits in boilers may result from hardness contamination of feed water and corrosion products from the
condensate and feed water system. Hardness contamination of the feed water may arise due to deficient
softener system.
Deposits and corrosion result in efficiency losses and may result in boiler tube failures and inability to
produce steam. Deposits act as insulators and slow heat transfer. Large amounts of deposits throughout
the boiler could reduce the heat transfer enough to reduce the boiler efficiency significantly. Different type
of deposits affects the boiler efficiency differently. Thus it may be useful to analyse the deposits for its
characteristics. The insulating effect of deposits causes the boiler metal temperature to rise and may lead
to tube-failure by overheating.
Impurities causing deposits
The most important chemicals contained in water that influences the formation of deposits in the boilers
are the salts of calcium and magnesium, which are known as hardness salts.
Calcium and magnesium bicarbonate dissolve in water to form an alkaline solution and these salts are
known as alkaline hardness. They decompose upon heating, releasing carbon dioxide and forming a soft
sludge, which settles out. These are called temporary hardness-hardness that can be removed by boiling.
Calcium and magnesium sulphates, chlorides and nitrates, etc. when dissolved in water are chemically
neutral and are known as non-alkaline hardness. These are called permanent hardness and form hard
scales on boiler surfaces, which are difficult to remove. Non-alkalinity hardness chemicals fall out the
solution due to reduction in solubility as the temperature rises, by concentration due to evaporation which
takes place within the boiler, or by chemical change to a less soluble compound.
Silica
The presence of silica in boiler water can rise to formation of hard silicate scales. It can also associate with
calcium and magnesium salts, forming calcium and magnesium silicates of very low thermal conductivity.
Silica can give rise to deposits on steam turbine blades, after been carried over either in droplets of water
in steam, or in volatile form in steam at higher pressures.
Two major types of boiler water treatment are: Internal water treatment and External water treatment.
Internal Water Treatment
Internal treatment is carried out by adding chemicals to boiler to prevent the formation of scale by
converting the scale-forming compounds to free-flowing sludges, which can be removed by blowdown. This
method is limited to boilers, where feed water is low in hardness salts, to low pressures- high TDS content
in boiler water is tolerated, and when only small quantity of water is required to be treated. If these
conditions are not applied, then high rates of blowdown are required to dispose off the sludge. They
become uneconomical from heat and water loss consideration.
Different waters require different chemicals. Sodium carbonate, sodium aluminate, sodium phosphate,
sodium sulphite and compounds of vegetable or inorganic origin are all used for this purpose. Proprietary
chemicals are available to suit various water conditions. The specialist must be consulted to determine the
most suitable chemicals to use in each case. Internal treatment alone is not recommended.
External Water Treatment
External treatment is used to remove suspended solids, dissolved solids (particularly the calcium and
magnesium ions which is a major cause of scale formation) and dissolved gases (oxygen and carbon
dioxide).

The external treatment processes available are: ion exchange; demineralization; reverse osmosis and deaeration. Before any of these are used, it is necessary to remove suspended solids and colour from the raw
water, because these may foul the resins used in the subsequent treatment sections.
Methods of pre-treatment include simple sedimentation in settling tanks or settling in clarifiers with aid of
coagulants and flocculants. Pressure sand filters, with spray aeration to remove carbon dioxide and iron,
may be used to remove metal salts from bore well water.
The first stage of treatment is to remove hardness salt and possibly non-hardness salts. Removal of only
hardness salts is called softening, while total removal of salts from solution is called demineralization.
The processes are:
Ion-exchange process (Softener Plant)
In ion-exchange process, the hardness is removed as the water passes through bed of natural zeolite or
synthetic resin and without the formation of any precipitate. The simplest type is base exchange in which
calcium and magnesium ions are exchanged for sodium ions. After saturation regeneration is done with
sodium chloride. The sodium salts being soluble, do not form scales in boilers. Since base exchanger only
replaces the calcium and magnesium with sodium, it does not reduce the TDS content, and blowdown
quantity. It also does not reduce the alkalinity.
Demineralization is the complete removal of all salts. This is achieved by using a cation resin, which
exchanges the cations in the raw water with hydrogen ions, producing hydrochloric, sulphuric and carbonic
acid. Carbonic acid is removed in degassing tower in which air is blown through the acid water. Following
this, the water passes through an anion resin which exchanges anions with the mineral acid (e.g.
sulphuric acid) and forms water. Regeneration of cations and anions is necessary at intervals using,
typically, mineral acid and caustic soda respectively. The complete removal of silica can be achieved by
correct choice of anion resin.
Ion exchange processes can be used for almost total demineralization if required, as is the case in large
electric power plant boilers
Softening reaction:

Na2R + Ca(HCO3)2 CaR + 2 Na(HCO3)

Regeneration reaction:

CaR + 2 NaCl Na2R + CaCl2

De-aeration In de-aeration, dissolved gases, such as oxygen and carbon dioxide, are expelled by
preheating the feed water before it enters the boiler. All natural waters contain dissolved gases in solution.
Certain gases, such as carbon dioxide and oxygen, greatly increase corrosion. When heated in boiler
systems, carbon dioxide (CO2) and oxygen (O2) are released as gases and combine with water (H 2O) to
form carbonic acid, (H2CO3). Removal of oxygen, carbon dioxide and other non-condensable gases from
boiler feedwater is vital to boiler equipment longevity as well as safety of operation. Carbonic acid corrodes
metal reducing the life of equipment and piping. It also dissolves iron (Fe) which when returned to the
boiler precipitates and causes scaling on the boiler and tubes. This scale not only contributes to reducing
the life of the equipment but also increases the amount of energy needed to achieve heat transfer.
De-aeration can be done by mechanical de-aeration, by chemical de-deration or by both together.

Mechanical de-aeration

Mechanical de-aeration for the removal of these dissolved gases is typically utilized prior to the addition of
chemical oxygen scavengers. Mechanical de-aeration is based on Charles' and Henry's laws of physics.
Simplified, these laws state that removal of oxygen and carbon dioxide can be accomplished by heating
the boiler feed water, which reduces the concentration of oxygen and carbon dioxide in the atmosphere
surrounding the feed water. Mechanical de-aeration can be the most economical. They operate at the
boiling point of water at the pressure in the de-aerator. They can be of vacuum or pressure type.
The vacuum type of de-aerator operates below atmospheric pressure, at about 82 oC, can reduce the
oxygen content in water to less than 0.02 mg/litre. Vacuum pumps or steam ejectors are required to
maintain the vacuum. The pressure-type de-aerators operates by allowing steam into the feed water
through a pressure control valve to maintain the desired operating pressure, and hence temperature at a
minimum of 105oC. The steam raises the water temperature causing the release of O 2 and CO2 gases that
are then vented from the system. This type can reduce the oxygen content to 0.005 mg/litre. Where
excess low-pressure steam is available, the operating pressure can be selected to make use of this steam
and hence improve fuel economy. In boiler systems, steam is preferred for de-aeration because:
Steam is essentially free from O2 and CO2, readily available & adds heat required to complete the reaction.
Chemical de-aeration: While the most efficient mechanical deaerators reduce oxygen to very low levels
(0.005 mg/litre), even trace amounts of oxygen may cause corrosion damage to a system. Consequently,
good operating practice requires removal of that trace oxygen with a chemical oxygen scavenger such as
sodium sulfite or hydrazine. Sodium sulphite reacts with oxygen to form sodium sulphate, which increases
the TDS in the boiler water and hence increases the blowdown requirements and make-up water quality.
Hydrazine reacts with oxygen to form nitrogen and water. It is invariably used in high pressures boilers
when low boiler water solids are necessary, as it does not increase the TDS of the boiler water.
Reverse Osmosis : Reverse osmosis uses the fact that when solutions of differing concentrations are
separated by a semi-permeable membrane, water from less concentrated solution passes through the
membrane to dilute the liquid of high concentration. If the solution of high concentration is pressurized,
the process is reversed and the water from the solution of high concentration flows to the weaker solution.
This is known as reverse osmosis.

Recommended boiler and feed water quality

The impurities found in boiler water depend on the untreated feed water quality, the treatment process
used and the boiler operating procedures. As a general rule, the higher the boiler operating pressure, the
greater will be the sensitivity to impurities. Recommended feed water and boiler water limits are shown in
Table 1 and Table 2.

TABLE 1 RECOMMENDED BOILER WATER LIMITS

Upto 20 kg/cm2

21 - 39 kg/cm2

40 - 59 kg/cm2

TDS, ppm

3000-3500

1500-2500

500-1500

Total
iron
solids ppm

dissolved

500

200

150

Specific
conductivity
(mho)

electrical
at
250C

1000

400

300

Phosphate residual ppm

20-40

20-40

15-25

pH at 250C

10-10.5

10-10.5

9.8-10.2

Silica (max) ppm

25

15

10

TABLE 2 RECOMMENDED FEED WATER LIMITS

Upto 20 kg/cm2

21 - 39 kg/cm2

40- 59 kg/cm2

Total iron (max) ppm

0.05

0.02

0.01

Total copper (max) ppm

0.01

0.01

0.01

Total silica (max) ppm

1.0

0.3

0.1

Oxygen (max) ppm

0.02

0.02

0.01

Hydrazine residual ppm

-0.02-0.04

pH at 250C

8.8-9.2

8.8-9.2

8.2-9.2

Hardness, ppm

1.0

0.5

BOILER WATER QUALITY REQUIREMENTS

It must be understood that every Steam Boiler system requires a proper Boiler Water Treatment Program
with regular water analyses, adequate regulated blow downs, correct maintenance, periodic safety checks
and periodic inspection follow-up. All of these are necessary for long life and efficient boiler service. These
are some of the basic essentials in your boiler program:
1. Soft water should be used at all times to prevent scale build-up and tube stoppage. Test daily and
regenerate water softener when hardness exceeds 17 parts per million (or 1.0 Grain per Gallon).
2. Boiler water compound should be selected and regulated on the basis of actual water analysis. This
compound should have the proper chemicals to treat for: (1) hardness up to 5.0 GPG, (2) maintain a pH
level of 10.0 to 11.5 in the boiler water, (3) excessive oxygen by maintaining the Sodium Sulfite level
between 40 to 100 ppm in the boiler water, (4) a protective metal coating material, and (5) other
conditions found in the water analysis. A Boiler compound comparable to PB677 is standardly
recommended. When steam may come in contact with potable water or food products for human
consumption, a USDA approved compound, such as PB633, is required.
3. The compound must be added in adequate quantities uniformly throughout the shift. An automatic
chemical feed system should be purchased or provided by your chemical supplier so these chemicals are
induced into the condensate holding tank or feedwater line as recommended by your chemical supplier.
We recommend these chemicals be introduced as far before the boiler as possible to also protect the feed
tank and feed lines.
4. Regular Water Analysis should be made as often as possible but at least every 30 days to assure water
treatment is properly regulated. If there are indications of scale, corrosion, or any other unfavorable
condition, water analysis may need to be performed more often until condition is corrected
5. Partial blowdowns should be made in accordance with the Blowdown Instructions. The Boiler blowdowns
must be made sufficiently so that total dissolved solids in the Boiler water between 2600-3200 PPM (36004200 micromhos/cm) and mud and sediment are removed from the boiler. The type of blowdown and
period between blowdowns can be extended only when the total dissolved solids in the boiler are
maintained below between 2600-3200 PPM (3600-4200 micromhos/cm).
6. Regular Internal Tube Inspections should be made every 60 days until the Water Treatment Program is
properly regulated. Thereafter, every 6-12 months or more often if an unsatisfactory condition is found.
This is done by removing at least two (2) of the plugs on the bottom and top of each Tube Header Section.
Internal Drum Inspection is made by removing the Inspection Plugs on the heads of the Steam Drum.
Water feed inlet should be Inspected every 6 months by removing the plug on the inlet fitting to Boiler
Drum. Clean as necessary. Note: always use a high temperature teflon based anti-seize compound when
re-installing plugs.
7. The Return Tank and pump suction strainer should be inspected and flushed clean every 90 days or as
needed. This is important to prevent any sediment accumulation from causing stoppage, or damage to
Pump or Boiler.
8. Proper Grounding of the boiler is necessary if there is a possibility of electrolysis (a form of corrosion)
and to help maintain normal tube life. Periodic internal inspections are necessary to determine if the thin
protective coating has developed in the tubes. Proper grounding of the boiler requires driving a copper rod
of 6 or more into the ground. Readings in excess of 35MV on ungrounded installations require grounding
to prevent the onset of a corrosion problem.