Unit I

Water Technology

PART III
Boiler
Trouble

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 Unit I
Water Technology
1) Explain scale and sludge. How these can be removed from boiler?

ANS:-

Scale and sludge formation

Scale

Scales are hard substances which sticks very firmly to the inner surfaces
of the boiler wall. Scales are difficult to remove even with the help of a
hammer and chisel.Examples: CaSO4, CaCO3, Mg (OH)2 etc.

Removal of scale

1.Using scrapper, wire brush often.

2.By thermal shock- heating and cooling suddenly with cold water.

3.Using chemicals – 5-10% HCl and by adding EDTA

Formation of scales may be due to

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(1) Decomposition of Calcium Bicarbonate

Ca (HCO3)2 -----→ CaCO3 ↑ +H2O + CO₂ ↑

(Scale)

But in high-pressure boilers, calcium carbonate is soluble due to formation

of Ca (OH)2

CaCO3 + H₂O -----→ Ca (OH) 2 ↓+ CO₂↑

(Soluble)

(2) Deposition of Calcium Sulphate

The solubility of calcium sulphate in water decreases with rise of

temperature. In other words, CaSO4 is soluble in cold water but almost
completely insoluble in superheated water.

(3) Hydrolysis of Magnesium Salts

Dissolved magnesium salts get hydrolysed forming magnesium hydroxide

precipitate, which forms a soft type of scale i.e.

MgCl2 + 2H2O -----→ Mg (OH)2 ↓+ 2HCI ↑ (Scale)

(4) Presence of Silica

Even if a small quantity of SiO2 is present, it may deposit as calcium silica

(CaSiO3) and magnesium silicate (MgSiO3). These deposits adhere very

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firmly on the inner side of the boiler surface and are very difficult to
remove. One important source of silica in water is the sand filter.

Sludge

Sludge is a soft, loose and slimy precipitate formed within the boiler. It can
be easily scrapped off with a wire brush.

It is formed at comparatively colder portions of the boiler and collects in

areas of the system, where the flow rate is slow or at bends.

It is formed by substances which have greater solubility's in hot water than

in cold water, e.g. MgCO3, MgCl2, CaCl2, MgSO4 etc.,

Removal of sludge

Sludges can be removed using wire brush or mild acid.

2) What are prevention and disadvantages of scale and sludge

formation?

ANS: -

Prevention of scale formation

Scale formation can be prevented by two methods.

1.Internal conditioning or Internal Treatment

It includes efficient softening of water (i.e. removing hardness producing

constituents of water) and then it is fed to boiler.

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Water Technology
2.External conditioning or External treatment

a) By precipitating the scale forming impurities in the form of sludge which

can be removed by blow-down-operation.

b) By converting them into compounds, which will remain in dissolved

form in water and thus, do not cause any harm.

Important internal conditioning treatment methods are

(i) Phosphate Conditioning

In high pressure boilers.

3CaCl2 + 2Na3PO4 -----→ Ca3 (PO4)2 +6NaCl

3MgCl2 + 2Na3PO4 -----→ Mg3 (PO4)2 + 6NaCl

Following phosphates are mainly used

1. NaH2PO4, Sodium Dihydrogen Phosphate (Acidic).

2.Na2HPO4, Disodium Hydrogen Phosphate (Weakly Alkaline).

3.Na3PO4, Trisodium Phosphate (Alkaline).

The choice of salt (sodium phosphate) depends upon the alkalinity of the
boiler-feed water.

1)Sodium dihydrogen phosphate, NaH2PO4 (acidic) is preferred when the

alkalinity of boiler water is too high.

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Water Technology
2)Disodium hydrogen phosphate, Na2HPO4 (weakly alkaline) is more
preferred when the alkalinity of boiler water is sufficient.

3) Trisodium phosphate, Na3PO4 (alkaline) is most suitable for treatment

when the alkalinity of boiler water is low.

(ii) Carbonate Conditioning

In low-pressure boilers, scale formation can be avoided by adding sodium

carbonate to boiler water. The scale CaSO4 is converted into CaCO3.

CaSO4 +Na2CO3 ------→ CaCO3+Na2SO4

Hence deposition of CaSO4 as a scale does not take place and loose
sludge of CaCO3, can be removed by blow-down operation.

Scales are removed by mechanical (1-3) and by chemical (4) methods.

(1) If the scales are loosely adhering, it can be removed with the help of
scraper or piece of wood or wire brush.

(2) If the scales are brittle, it can be removed by giving thermal shocks
(i,e. heating the boiler and then suddenly cooling with cold water).

(3) If the scales are loosely adhering, they can be removed by frequent
'blow-down operation.

(4) If scales are adherent and hard, they can be removed by dissolving
them in chemicals e.g. CaCO3 scales can be dissolved by using 5-10%
HCl. CaSO4 scales can be removed by adding EDTA, since Ca-EDTA
complex is highly soluble in water.

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Water Technology
Disadvantages of scale formation

1) Wastage of Fuel-

➢ Scale have low thermal conductivity, so the rate of heat

transfer from boiler to inside water is greatly decreased.

➢ In order to provide a steady supply of heat to water, excessive

or over heating is done and this causes increase fuel
consumption.

➢ The wastage of fuel depends upon the thickness and the

nature of scale.

2) Lowering of Boiler Safety –

➢ Due to scale formation, over heating of boil done in order to

maintain the constant supply of steam.

➢ This overheating of the be tube makes the boiler material

softer and weaker.

➢ This causes distortion of boiler and also makes the boiler

unsafe to bear the pressure of the steam, especially in
pressure boilers.

3) Decrease in Efficiency –

➢ Deposition of scales in the valves and condensers of the

boiler, choke them partially. This results in decrease in
efficiency of the boiler.

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4) Danger of Explosion –

➢ When thick scales crack due to uneven expansion, the water

comes suddenly in contact with overheated iron plates.

➢ This causes in the formation of a large amount of steam

suddenly. So sudden high pressure is developed which may
even cause explosion of the boiler.

Prevention of sludges formation

➢ By using well softened water.

➢ By frequently 'blow-down operation' (i.e. partial removal of

concentrated water through a tap at the bottom of boiler, when the
extent of hardness in the boiler becomes alarmingly high).

Disadvantages of sludge formation

➢ Sludges are poor conductor of heat, so they tend to waste a portion

of heat generated and thus decreases the efficiency of boiler.

➢ Excessive sludge formation disturbs the working of boiler. It settles

in the regions of poor water circulation such as pipe connection, plug
opening, bends, etc. thereby causing even choking of the pipes.

16) Distinguish between scale and sludge formation.

ANS: -

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Water Technology
Sludge Scale

Soft, loose & slimy precipitates. hard deposits.

Non-adherent deposits & can be Stick very firmly to the inner

easily removed. surface of boiler and are very
difficult to remove.

Formed by substances like CaCl2, Formed by substances like CaSO4,

MgCl2, MgSO4 & MgCO3. Mg(OH)2, CaCO3 & CaSiO3.

Formed generally at colder Formed generally at heated

portions of the boiler. portions of the boiler.

Decrease the efficiency of boiler Decrease the efficiency of boiler &

but are less dangerous. chances of explosions are also
there.

17) Discuss in details of priming and Foaming.

ANS: -

Priming and Foaming

Priming

When steam is produced rapidly in the boilers, some droplets of the liquid
water are carried along with the steam. This process of 'wet-steam'
formation, is called priming.

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Water Technology
Causes of Priming

1) The presence of considerable quantities of dissolved solids (mainly

due to suspended impurities and due to dissolved impurities in
water).

2) Steam velocities high enough to carry droplets of water into the

steam pipe.

3) Sudden boiling.

4) Improper design of boiler.

5) Sudden increase in steam-production rate.

Prevention of Priming

(6) By improving boiler design.

(7) By fitting mechanical steam purifiers.

(8) By maintaining low water level in boilers.

(9) By using soft water.

(10) By decreasing the number of dissolved salts.

Disadvantages of Priming

(1) Dissolved salt in boiler water are carried out by the wet steam to
turbine blades - which reduces their efficiency.

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(2) Dissolved salts may enter the parts of other machinery may
decrease the life of the machinery.

(3) Actual height of the water column cannot be judge properly, thereby
making the maintenance of the boiler pressure becomes difficult.

Foaming

It is the production of continuous foam or hard bubblers in boilers Foaming

is due to the presence of substance like oil in boiling water. It is the
production of foam or bubbles in boiler which do not break easily.

Causes of Foaming

It is due to the presence of oily substances in water.

(1) Low level of water in boiler.

(2) The presence of dissolved salts in water.

(3) Sudden increase in steam production rate.

Prevention of foaming

(1) By the addition of anti-foaming chemicals like castor oil, Gallic acid,
tannic acid etc.

(2) removing oil from boiler water by adding compounds like sodium
aluminate.

Disadvantages of foaming

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Water Technology
(1) Actual height of the water column cannot be judge.

(2) Dissolved salts in water carried by the wet steam may damage
turbine blades or machinery parts.

(3) Boiler pressure cannot be maintained.

19) Explain caustic embrittlement?

ANS:-

CAUSTIC EMBRITTLEMENT

➢ It is a type of boiler corrosion.

➢ It is caused due to use of highly alkaline Water in boiler container.

➢ In high pressure boilers, Na2CO3 decomposes to give sodium

hydroxide and carbon dioxide,

2NaCO3 + H2O → 2NaOH + CO2 ↑

➢ Boiler water becomes ‘Caustic’

➢ Water evaporates caustic soda concentration increase which

attacks surrounding area of boiler machine, thereby dissolving iron
of boiler as sodium ferrate. Iron converted in to sodium ferrate.

➢ Causes embrittlement of boiler parts, stressed parts( bends, joints,

etc causing even failure of the boiler.

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➢ Cracking of boiler can be explained as Iron in dilute NaOH cathodic
side. Iron in concentrated NaOH anodic side ..(which get dissolved
or corroded)

PREVENTION FROM CAUSTIC EMBRITTLEMENTS

➢ By using Sodium phosphate as softening reagent, instead of sodium

Carbonates.

➢ Adding lignin to boiler water, since these blocks the hair cracks,
thereby preventing infiltration of caustic soda solution.

➢ By adding Sodium sulphate to boiler water:Na2SO4 concentration.

Kept 1:1, 2:1 &3:1,

Pressure: 10,20 & above20.

20) Explain Boiler corrosion.

Boiler Corrosion

Boiler corrosion is decay or destruction of boiler material by chemical

electrochemical attack by environment.

Following are the main reason of boiler corrosion.

(1) Dissolved gases

(2) Dissolved Salts

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Water Technology

(3) Acidity and alkalinity of water.

(1) Dissolved Gases

a) Dissolved Oxygen (O2)

Among the dissolved gases, oxygen is the most corroding impurity

in water. Dissolved oxygen about 8 mg/lit in water under high
temperature attacks the material of boiler and forms ferric oxide
(rust- coating formed on iron by the action of water and air)

4 Fe + 4H2O + 202 -----→ 4 Fe (OH)2

(Dissolved) (Ferrous hydroxide)

4Fe (OH)2 + 02 -----→ 2 (Fe2O3.2H₂O)

(Ferric oxide, rust)

Removal of Dissolved Oxygen

(i) By chemical method

Dissolved oxygen can be removed from water by adding calculated
quantity of sodium sulphide (Na2S) or sodium sulphite (Na2SO3) or
hydrazine (N2H4).

Na2S + 2 02 ----→ Na2SO4

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(Sodium Sulfide)

2Na2SO3 + 02 ----→ 2Na2SO4

(Sodium Sulfite)

N2H4 + 02 -----→ N₂↑ +2H2O

(Hydrazine)

(ii) By Mechanical De-aeration

Dissolved oxygen can also be removed by mechanical de-aeration i.e.

spraying water in a tower fitted with perforated plates. This tower is heated
from sides and connected to vacuum pump. The high temperature, low
pressure and large exposed area reduces the quantity of dissolved
oxygen, from water, it is as shown in the following figure.

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Prof. P. G. Rajas