Prevention of scales
a.) Internal treatment
(Sequestration)
Conditioning methods
Sequestration:
The process where suitable chemicals are added to the boiler containing
hard water with which scales are either precipitated or converted in to
soluble complexes. The chemical used is called Sequestrating agent.
1. Colloidal Conditioning
Certain organic substance like tannin is added to the boiler water they get
absorbed over scale forming substances thus preventing scale Deposition.
2. Phosphate conditioning
In high pressure boilers, scale formation is prevented by adding sodium
phosphate to boiler feed water. This reacts with Ca 2+ and Mg2+ ions in water
forming non adherent and easily removable soft sludge of Ca and Mg
phosphate. The commonly used phosphate are NaH2PO4, Na2HPO4 and Na3PO4.
3. Carbonate Conditioning
In low pressure boilers, scale formation can be prevented by
adding Na2CO3 to boiler feed water. Ca salts are precipitated as
loose sludge of CaCO3 which can be removed by blow down operation.
CaCl2 + Na2CO3
CaCO3 + 2NaCl
4. Calgon Conditioning
Addition of sodium hexameta phosphate called calgon prevents
scale formation by converting Ca2+ and Mg2+ ions in to soluble
Complexes.
Na2[Na4(PO3)6]
2Ca2+ + [Na4(PO3)6]2-
5. Aluminium conditioning
Boiler water is treated with sodium meta aluminate when NaOH
and Al(OH)3 are formed. NaOH precipitates Mg salt as Mg(OH)2.
Both Al(OH)3 and Mg(OH)2 ppts formed entraps all the scale
forming materials. These loose ppt formed can be removed by
blow down operation.
NaAlO2 + 2H2O NaOH + Al(OH)3
2NaOH + MgCl2 Mg(OH)2 + 2NaCl
Boiler corrosion
2Fe2O3.xH2O
Mg(OH) 2 + 2HCl
FeCl 2 + H2
Fe(OH) 2 + 2 Hcl
Here HCl is formed again and again in a chain like process and
silicic acid catalyse the reaction, if silica is present in water rate
of the reaction increases
Prevention
1. By mechanical deaerator
Dissolved gases like CO2 and O2 can
be removed by this method
Water undergo deaeration at high
temperature and low pressure because
Solubility of gases in water P /T
3. By addition of alkali
N2 + 2H2O
Na2SO4
2 Na2SO4
Foaming
Foaming is the production of froth or bubbles which canot break easily
on the surface of boiler water. It may occur when the pH of the solution
is between 7 and 9.
Causes
1. Presence of dissolved impurities and suspended oil content which will reduce
the surface tension of water resulting in bubble formation.
2. Presence of finely divided sludge particles
Prevention
1) By removing oil or sludge by addition of coagulants .e.g FeSO 4, NaAlO2 etc
2) By addition of antifoaming chemicals e.g. Caster oil
Disadvantages of Priming and Foaming
1. Water hammer which disrupts operation of the equipment. Uneven heating of
water
2. Actual height of water column in the boiler can not be judged properly, thereby
maintenance of boiler pressure becomes difficult.
3. Dissolved solids in boiler water are carried by the wet steam to super heater
and turbine blades where they get deposited as water evaporates. This deposit
reduces the efficiency of the machine.
4. Erosion of turbine blades
Caustic Embrittlement
The formation of irregular intergranular cracks on boiler metal
particularly at the point of high local stress by the use of highly
alkaline water in the boiler is called Caustic Embrittlement
Causes:
Na2CO3 + H2O
2NaOH + O 2
This caustic water flows in to the minute hair cracks usually present
on boiler material through capillary action
Here water evaporates and the concentration of NaOH increases progressively
which attacks the surrounding area, thereby dissolving iron of the boiler as
sodium ferroate
3Na2FeO2 + 4 H2O
6NaOH + Fe 3O4 + H2
Prevention:
1. By phosphate conditioning of water
2. By addition of certain chemicals like lignin, tannin etc. These prevent
the infiltration of NaOH through air cracks and thus help in preventing it
3. By addition of Na2SO4 to boiler water. Ratio of Na2SO4 : NaOH(present
in boiler water should be
1:1 For up to 10 atm boiler pressure
2:1 For up to 20 atm boiler pressure
3:1 For more than 20 atm boiler pressure
4. Neutralization of excess alkali by suitable technique
External treatment
Ion Exchange
Ion exchange softening, also known as zeolite
softening, passes water through a filter containing
resin granules. In the filter, known as a softener,
calcium and magnesium in the water are
exchanged for sodium from the resin granules.
Ion exchange softening does not require the flash
mixer, flocculation basin, and sedimentation basin
required for lime-soda ash softening. In addition,
the process does not require as much operator
time. Ion exchange softening is effective at
removing both carbonate and non carbonate
hardness and is often used for waters high in
noncarbonate hardness and with a total hardness
less than 350 mg/L.
However, ion exchange softening has its disadvantages as well. The
calcium and magnesium in the hard water are replaced by sodium ions,
which may cause problems for people with health problems (High salt).
Softeners have to be backwashed in a manner similar to a filter, and the
recharge water, known as brine, can cause disposal problems.
Desalination....
(c) Electrodialysis
Electrodialysis(ED) is
used to
transportsaltionsfrom
onesolutionthroughion
exchangemembranest
o another solution
under the influence of
an applieddifference.