SCALE REDUCTION SYSTEM FOR BOILERS

Read the story below.

The Biocon® feedwater treatment unit (BO-9) was approximately 6" in diameter and 12" long, housing Filter Foam Technology's patented filter technology. This is an oxidation-reduction potential (ORP) technology to treat the water for scale prevention and removal.

THE TEST

Almag initiated a one month trial with a Biocon® BO-9 on each boiler. The units were installed between the feedwater tank and the boiler. A water softener continued to treat the make-up water, but all chemical treatment was discontinued.

During the month-long test the Almag engineers continued to watch the same parameters as previously. No changes from normal were seen except for a drop in TDS in the 100 hp blowdown. Under normal operation with chemical treatment the TDS was generally found to be between 3,000 - 5,000. With the Biocon® product it dropped to below the 2,500 recommended by the manufacturer. They also carefully watched the other chemical analysis, including alkalinity, ph, dissolved CO2 and oxygen. All the other parameters were well within range.

THE RESULTS

After one month of operation both boilers were opened. The 80 hp, which was cleaned at the start of the test, showed approximately 5-10 gallons of scale at the bottom of the boiler. It was apparent that the scale which remained on the tubes after cleaning was now sloughing off the tubes. Pieces of scale as large as 8 inches long and 1/3 diameter of the tube had fallen off the tubes and it was clear that the scale still remaining on the tubes was easily knocked off leaving a bare tube. No corrosion of the metal parts was seen.

The 100 hp boiler showed similar results, but more dramatic. Approximately 2/3 of the boiler tubes are now completely clear of scale. In addition to the mud/sludge which was already on the bottom of the boiler, newly sloughed off scale was obvious.

Both boilers were closed up and returned to operation. After an additional 6 weeks of running they were again opened and inspected. As expected, additional scale was removed from the tubes, tube sheet and the inside of the drum. No new scale was formed and no deterioration of the boiler surfaces was observed.

Tate cleaned out both the boilers and returned the boilers to operation. Since Almag was very pleased with the results of the Biocon® product they continued using it and avoided the use of the chemicals. At this point, in addition to the savings from not using the feedwater treatment chemicals, Almag has seen a direct reduction of approximately 18% to 20% in energy costs. Finally, they have avoided the cost and complications relating to acid washing the boilers.