BOILER WATER OPERATOR TRAINING Notes

Cold Lime Softening

WHAT IS IT?
Cold lime softening is the addition of lime (and sometimes soda
ash) primarily to reduce the level of alkalinity or hardness in
water. It can also reduce the level of silica and dissolved solids.

Cold lime softening is most often used in very large plants to

partially soften process water, cooling tower make-up, or boiler
water make-up.

Additionally, some municipalities utilize the cold lime softening

process in order to partially soften domestic (drinking) water.

©2006 Nalco Company 1 SECTION 1 – Cold Lime Softening, Book 316 (9-06)
 BOILER WATER OPERATOR TRAINING Notes

HOW DOES IT WORK?

In cold lime softening, lime is added to raise the pH.

Lime raises the pH by contributing hydroxide alkalinity. By

raising the pH, calcium and magnesium compounds are made less
soluble.

Calcium precipitates as calcium carbonate, and magnesium

precipitates as magnesium hydroxide. Maximum calcium
removal occurs at a pH of 9.2; but combined removal of calcium
and magnesium is optimized at a pH of 10.2.

Equilibrium concentration of calcium and magnesium ions

plotted against pH

©2006 Nalco Company 2 SECTION 1 – Cold Lime Softening, Book 316 (9-06)
 BOILER WATER OPERATOR TRAINING Notes

Although cold lime softening is a complex process,

the basic steps are:

1. pH of the water is raised.

Lime is added to raise the pH, making calcium and
magnesium compounds less soluble.
2. Sometimes soda ash (Na2CO3) is added to increase hardness
removal.
3. Sometimes gypsum (CaSO4) is added as a source of calcium
to remove excess alkalinity.
When raw water magnesium is low, MgO is added with the
lime to help remove additional silica.
4. Sometimes other chemicals are added such as sodium
aluminate and polymers.
5. Hardness (Ca and Mg) precipitates as CaCO 3 and Mg(OH) 2
sludge. Some silica precipitates with the Mg(OH) 2 sludge.
6. The sludge is either used as a reaction blanket or recirculated
to the incoming water to increase the reaction rate.
The sludge level is controlled by blowdown.
7. Clean water with lower hardness, alkalinity, silica, and TDS
leaves the softener.

Silica removal:
Silica is removed as it precipitates on magnesium sludge
(Mg(OH)2).
At the temperature involved in cold lime softening, silica removal
is not highly effective. Typically, only small amounts of silica are
removed in this manner. Additional silica removal can be
achieved with the use of sodium aluminate.

Suspended Solids Removal:

In some instances, suspended solids removal is accomplished as
the sludge agglomerates (combines) with incoming suspended
solid particles.

©2006 Nalco Company 3 SECTION 1 – Cold Lime Softening, Book 316 (9-06)
 BOILER WATER OPERATOR TRAINING Notes

HOW DOES IT WORK?

Calcium and Magnesium reduction lowers scale potential.
Alkalinity removal lowers corrosion potential of the condensate
and reduces alkalinity in the boiler water or cooling water.
Dissolved solids reduction reduces blowdown energy losses.
Silica reduction reduces potential for turbine deposits and scale.

Other effects:

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Cold lime softeners are subject to carryover if flow rates fluctuate

or if lime or aluminate is overfed. The carryover of suspended
solids leads to problems of scale or fouling.

©2006 Nalco Company 4 SECTION 1 – Cold Lime Softening, Book 316 (9-06)
 BOILER WATER OPERATOR TRAINING Notes

WHAT DO I NEED TO DO TO OPERATE IT?

1. Operate at a steady rate.
Changing the flow through the unit will upset the sludge bed
and will increase the amount of solids carryover.
2. Test the P and M alkalinities.
Calculate the OH alkalinity (2P-M). Alkalinity tests are used
to control lime feed, as well as soda ash or gypsum, if used.
Plant range ___________________________________
___________________________________
3. Test for soluble and acid hardness levels.
Hardness reduction indicates overall proper operation. High
difference between soluble and acid hardness readings
indicates possible bed upset and carryover.
Plant range ___________________________________
___________________________________
4. Determine the sludge solids concentration.
The blowdown sludge density should have a 90-98%
concentration on a five-minute settling test. The center cone
solids in a sludge recirculation clarifier should be 10-20%.
The center cone solids in a sludge blanket clarifier should be
5-20%.
Plant range ___________________________________
___________________________________
5. Check the sludge bed level.
If the sludge level is too high, carryover may occur. If the
sludge level is too low, improper mixing may occur and
impurity reduction may suffer.
Plant range ___________________________________
___________________________________
6. Check the pH.
pH is a secondary check to confirm the alkalinity
measurements.
Plant range ___________________________________
___________________________________

©2006 Nalco Company 5 SECTION 1 – Cold Lime Softening, Book 316 (9-06)
 BOILER WATER OPERATOR TRAINING Notes

7. Check the turbidity.

Turbidity is a secondary check for carryover.
Plant range ___________________________________
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8. Check the chemical feeder.
Proper and continuous chemical feed is important for the cold
lime softening process.

9. Other controls:
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©2006 Nalco Company 6 SECTION 1 – Cold Lime Softening, Book 316 (9-06)