Phosphate Hideout
Phosphate Hideout
Phosphate Hideout
What is Hideout?
Sodium salts of sulfate, phosphate and silicate are less soluble than most other dissolved substances
present in boiler water. These are the first salts to precipitate out of the bulk boiler water when
concentrating film conditions develop on tube surfaces.
During steam generation a small amount of dissolved solids are left on the tube surface as the water is
evaporated to steam. Boiler water then fills the void left by the steam bubble and re-dissolves the salt
residue. When operating conditions are severe (high loads & High Pressure > 900 psig) the normal
rinsing/re-dissolving process may be disrupted. The salts may remain on the tube surface. The loss of
dissolved species under these operating conditions is termed chemical hideout.
OR
Defined as the disappearance of ionic PO4 by precipitation or absorption, from boiler water under
conditions of high heat transfer. It is primarily the result of interaction of Sodium Phosphate salts with
compounds of iron oxide to produce low solubility reaction products. More definitively, it is a localized
“interaction” of phosphate with iron oxides at the heat transfer surface under high load/temperature
conditions, which results in a gradual loss of phosphate that “returns” suddenly when the load is
reduced. It is MORE frequent in higher pressure boiler water operations, at higher heat flux (typically
localized) and dirty boilers. Most importantly it ONLY occurs where the internal boiler water chemistry is
PO4 based to provide buffering capacity or a “sponge” should there be slight contamination issues
during boiler operation. PO4 hideout cannot happen with non PO4 based internal boiler water
treatment programs.
How is it caused?
Hideout usually first occurs in boiler tubes with the highest heat flux and low mass flow, where
departure from nucleate boiling (DNB) or under deposit concentration occur. Surprisingly, hideout and
boiler tube corrosion can also occur in Heat Recovery Steam Generators (HRSGs) where the heat flux is
much lower than in coal- or oil-fired units. This is because there may be accumulation of corrosion
products or inadequate mass flow through some generating tubes; particularly during duct burner firing.
Because the solubility of phosphate decreases as boiler pressure increases, hideout is typically only
noticed during load changes. Phosphate hideout usually results in an increase of PO4 concentration and
a decrease of pH during load reduction and in an increase of pH and decrease of PO4 concentration
during the load increases. The severity of phosphate hideout is boiler, heat flux, temperature, pressure,
and boiler cleanliness specific. In clean, conservatively designed and operated boilers, these swings do
not result in any boiler tube corrosion problems.
Many historical “caustic gouging” failures were likely caused by acid phosphate
corrosion
4. Do NOT use Mono Sodium Phosphate to compensate for high boiler water pH.
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