1.

24
ngineerng Chemistry
BOILER FEED WATER
(1.6)
The fed into the boiler for the production of ctoeam
water
water. Boiler feed water should be fr
is called boiler feed
alkali and hardness causina
from turbidity, oil, dissolved gases,
substances. If hard water
obtained trom natural sources is fed
the following troubles may arise,
directly into the boilers,
Boiler troubles (or) disadvantages of using hardwater in boilers
Formation of Scales and sludges in boilers.

Priming and foaming (carry over).

3. Caustic embrittlement.

4. Boiler corrosion.

1.6.1 Formation of Scales and Sludges in boilers

When water is continuously converted into steam in
boilers (or) heat exchangers, the concentration of dissolved salts
in water increases progressively. When the concentration of the
salts reaches their saturation point, they are thrown out in the
form of precipitates on the inner walls of the boilers (or) heat
exchangers. The least soluble one gets precipitated first
Loose precipitate
Hard adhering precipitate on
suspended in water inner walls of boiler (scale)
(sludge) Boiler
wall

Water

Heat
Heat
(a) (b)
Fig. 1.1 (a) Sludge in boiler (b) Scale in boiler
.Sludge (Loose deposit)
If the precipitate is loose and slimy it is called sludge.
Sludges are formed by the substances like MgCl, MgCO
MgSO4 and CaCl2. They have greater solubilities in hot water
than cold water.

2. Scale (Hard deposit)

On the other hand, if the precipitate forms hard and
adherent coating on the inner walls of the boiler, it is called
scale. Scales are formed by substances like Ca(HCO3)2
CaSO4 and Mg(OH)2

Table 1.1 Comparison of Scales and Sludges

S.No. Sludge Scale

1. Sludge is a loose, slimy|Scale is a hard, adherent
and non-adherent coating
precipitate.
2. The main sludge formingThe main scale forming
substances are MgCO3. substances are Ca(HCO3)2»
and CaS04, Mg(OH)2.
MgCl2. MgSO4
CaCl etc
Disadvantages: Sludges Disadvantages: Scales act
are poor conductors of as thermal insulators. It
heat.
heat. Excess of sludge decreases the efticiency of
formation decreases the boiler. Any crack

efficiency of boiler. the scale

| developed on

leads to explosion.
4.Prevention |Prevention
(i) Sludge formation can |(i) Scale formation can
be prevented by be prevented by
using softened water. dissolving using acids
like HC1, HSO4.
 Engineering C
1.26
Chemist
Sludge Scale
S.No. ii) Sludges can also be|(ii) Scale formation can
removed by be removed by
blow-down (a) Extemal
operation.
treatment.
(b) Intermal
treatment.

(ii) Blow-down operation |(iii) They

They can also
also be
is a processof removed by applying
removing a portion thermal shocks
of concentrated water Scrapers, wire brush
by fresh water etc.,
frequentlyy from the
boiler during steam
production.

Disadvantages of Scale Formation

1. Wastage of fuels
Scales have low thermal conductivity, so the heat transi
from boiler to inside water is not efficient. In order to rovide

pl
steady supply of heat to water, overheating is done and this
causes wastage of fuel. The
wastage of fuel depends
thickness and nature of the scale. which is shown in n ahe
ou
Thickness of scale (mm) 0.325 0.625 | 1.25 2.5 12
Wastage of fuel 150
10% 15% 50% 80%
2. Decrease in efficiency
Scales sometimes c o n d e n s e

of the boiler deposit

and choke. This
in the valves
and

fficien
the boiler. results in decrea
3. Boiler explosion
Calesm
Sometimes due to over thick
sca
Crack and
causes
heating the th
ng the
h e a t e d b o i l e rI n a t e

sudden contact of
high healc
 Water arnd its Treatnent 1.27

with This causes tormation of a large amount of steam

water.
and high pressure is developed which may lead to explosion.

Prevention of scale formation

At the initial stage, scales can be removed using
brush etc.
scraper, wire
If scales are brittle, they can be removed by
thermal shocks.
suitable chemicals like dil. acids (for
3 By using with
CaCO scale). EDTA (for CasO4 scale)
which they form suitable complexes.
be
4 If the scales are loosely adhering. they can

removed by frequent blow down operation.

1.6.2 Priming and Foaming (carry over)

the production of steam in the boiler, due to rapid
During with
droplets of liquid water are carried along
boiling. some
of liquid water is called
wet
steam. Steam containing droplets
water carry with
them somne
steam. These droplets of liquid
This phenomenon is
dissolved salts and suspended impurities.
and foaming.
called carry over. It occurs due to priming

1. Priming
steam.
Priming is the process of production of wet

Priming is caused by

(i) High steam velocity.

(ii) Very high water level in the boiler.
ii) Sudden boiling of water.
(iv) Very poor boiler design.
Prevention
Priming ean be controlled by
0) Controlling the velocity of steam.
(1)) Keeping the water level lower
 Good boiler design.
(ii)
treated water.
(iv) Using

2. Foaming
The formation
of stable bubbles above the
the surface
These bubbles are care ed over
is called foaming.
water
to excessive priming. by
steam leading
caused by the
Foaming is
presence of oil, and grease,
i)
presence of finely divided particles.
(ii)

Prevention

Foaming can be prevented by

(i) adding coagulants like sodium aluminate,
aluminium hydroxide,
agents like synthetic
(i) adding anti-foaming
polyamides.

1.6.3 Caustic Embrittlement (lntercrystaline

Cracking)
Caustic embrittlement means intercrystalline cracking o
boiler metal.
of
Boiler water usually contains a small proporti
3 undergoes
NaCO. In high pressure boilers this Na,CO3 Un
decomposition to give NaOH.

NaCO + H,0- 2NaOH +CO2 hair cracks and

This NaOH flows into the minute na

crevices, usually present on the boiler material, by a s s o d i n

a
action and dissolves the surrounding area of iron
ferroate.

Fe + 2NaOH->NafFe0, + H2
Water and its Treatment 1.29

This
This causes brittlement of boiler parts, particularly
stressed parts like bends, joints, rivets, etc., causing even failure
of the boiler.

Prevention
Caustic embrittlement can be prevented by

(i) using sodium phosphate as softening agent instead

of sodium carbonate.
to the boiler water, which
(ii) by adding tannin, lignin
blocks the hair cracks.

1.6.4 Boiler corrosion

Corrosion in boilers is due to the presence of

1. dissolved oxygen.
2. dissolved carbon dioxide.
3. dissolved salts.

1. Dissolved oxygen
Dissolved oxygen in water is mainly responsible for the
corrosion of boiler. The dissolved oxygen in water attacks the
boiler material at higher temperature.

4Fe+6H,0+30>4Fe(OH)3
Removal of dissolved oxygen
Dissolved oxygen can be removed by chemical (or)
mechanical methods.

(a) Chemical method

Sodium sulphite, hydrazine are some of the chemicals
used for removing dissolved oxygen.

2NaSO3+O2 2Na,SO4
NH +O>N^ +2H,0
1.30 Engineerng Chemist
Hydrazineis found to be an ideal compound
removing dissolved oxygen in the water, since the productfo
are water and inert N2 gas.

(b) Mechanical de-aeration

Dissolved oxygen can also be removed from
by
mechanical deaeration (Fig. 1.2).
Water

- Vacuum pump

ip
Perforated plate
Heater

-Tower

Deaerated water

Fig. 1.2 Mechanical deaeration of water

In this process, water is allowed to fall slowly on te
perforated pBates fitted inside the tower. The sides of the towe
are heated, and a vacuum pump is also attached to it. E

hagh temperature and low pressure produced inside the towe

reduce the dissolved oxygen content of the water.

2. Dissolved carbon dioxide

onic
Dissolved carton dioxide in water produces carbon
accid, wiuch is acidic and corrosive in nature

CO+H0>H,CO3
Water and its Treatment 1.31
Carbon dioxide gas is alsoproduced from the
of bicarbonate salts present in water.
decomposition
A

Ca(HCO3)2-CaCO3 J + H,0 +CO, 1

dioxide
Removal of dissolved Carbon
(a) Carbon dioxide can be removed from water by
(a)
calculated amount of NH,OH into water.
adding a

2NH,OH+ CO%>(NH,),CO3 +H,O

be
(b) Carbon dioxide along with oxygen can also
removed mechanically by de-aeration method.

3. Dissolved MgCl2
are alsoD
Acids, produced from salts dissolved in water,
of boilers. Salts like
mainly responsible for the corrosion
MgClh, CaCl2. etc, undergo hydrolysis at higher temperature

to give HCI, which corrodes the boiler.

2HCI
MgClh +2H,0>Mg(OH) +

Fe+2HC1>FeCl +H

FeCl,+2H,0>Fe(OH), + 2HCI
Removal of acids by neutralisation
Corrosion by acids can be avoided by the addition of
alkali to the boiler water.

HCI+NaOH>NaCl + H,O

1.6.5 Requirements of Boiler Feed Water

Any natural source of water does not supply a pertectiy
Suitable boiler feed water. The boiler feed water must have
the following requirements.
1.32 Engineering Chemist
Type Amount
< 0.2 ppm
Hardness
Soda alkalinity 0.15-1.0 ppm
Caustic alkalinity 0.15-0.45 ppm
Excess soda ash 0.3-0.55 ppm
Dissolved gases like O2, CO 0 ppm

S.No. Specifications Disadvantages

1. Boiler feed water should Scales and sludges will be
have zero hardness. produced, which prevents
efficient heat transfer.

to boiler
2 It must be free from |It leads
dissolved gases like |corrosion.
02, CO
3. It should be free from|Produces wet steam.
suspended impurities.
4. It should be free from Produces caustic

which
dissolved salts and causes
embrittlement,
brittlement of
| alkalinity.
(OH, CO& HCO). boiler parts.
5. It should be free from oil | Produces priming and
and turbidity. foaming.
and
6. It should be free from Produces priming a
total dissolved solids. foaming, caustic

embrittlement etc.,