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Pre-Treatment
Boiler
Process
Process
Process
Blowdown Flash
Low
flash tank tank
pressure
steam Condensate
Receiver
Corrosion
Scale
Solubilities
Compound ppm as CaCO3
o o o o
32 F (0 C) 212 F (100 C)
Calcium
Bicarbonate 1620 decomposes
Carbonate 15 13
Sulfate 1290 1250
Magnesium
Bicarbonate 37,100 decomposes
Carbonate 101 75
Sulfate 170,000 356,000
Sodium
Bicarbonate 38,700 decomposes
Carbonate 61,400 290,000
Chloride 225,000 243,000
Hydroxide 370,000 970,000
Sulfate 33,600 210,000
Scale Formation Mechanisms
Hematite Fe2O3
Magnetite Fe3O4
Effect of Scale on Heat Transfer
Effect of Scale on Tube Temperature
Effect of Scale - Example
Effect of Scale - Example
Temp Drop Across Water Film = 76o F. Max. Tube Temp (1004o F.) is above allowable
Temp Drop Across Internal Scale = 362oF. Oxidation Temp limit of SA-210 Carbon Steel
Temp Drop Across Tube Wall = 66o F.
Assume CaSO4 scale (0.024”)
Thermal Conductivity = 10 BTU/ft2-hr-o F/in
Scale Problems
Boiler tube failure
Caused by reduced heat transfer and tube
overheating
Under-deposit corrosion
Caused by high concentration of corrosive
agents (usually NaOH)
Scale Prevention
Disadvantages
Low cycles
Scale formation
Treatment With Makeup Softening
Phosphate residual
Chelants
All-polymer treatment
Phosphate Residual
Chemistry
Poly Phosphates
Sodium hexa meta phosphate
Poly phosphate
Detailed Chemistry
Synthetic polymers
Tannins
Lignins
Starches
Use of Sludge Conditioners
Deaerator storage
Disadvantage
Requires much stricter control of feedwater
hardness and chemical program
Chelants
NTA
(Nitrilo triacetic acid)
No precipitates formed
Oxygen corrosion
Alkalinity concentration
Caustic corrosion
Acid corrosion
Chelant corrosion
Erosion/Corrosion
Oxygen Corrosion
Can be found throughout the system
– pH
Boiler Metal Passivation
Caustic corrosion
Caustic embrittlement
Caustic Corrosion
Usually found only in high pressure boilers
Localized in boiler
No embrittlement of metal
Requirements for Caustic Corrosion
Two conditions are necessary for caustic corrosion to occur:
Organic materials
Chelant corrosion