Solutions for Steam Boiler Systems

• Introduction
  • Mineral Scale
  • Pitting Corrosion
• Benefits
• Case Studies

Steam is widely used in industrial and commercial processes for heating, cleaning and disinfection etc... and it is commonly generated by gas fueled, diesel fueled or electrical boiler. Boiler water is treated or not treated depends on applications.

Water fed to boiler is normally treated to prevent scale formation and corrosion. Water softener (ion exchanger or demineralizer) is used to keep the total hardness of boiler water below 5ppm. Oxygen scavenger and deareator is used to remove dissolved oxygen for anti-corrosion purpose. Anti-corrosion agent is also added to coat on the boiler tube surface for additional anti-corrosion effect. No matter how hard we do to prevent the problem of scale formation and corrosion, it appears inevitably but in a controllable way.

For disinfection purpose and production of food & beverage, the water might not be treated to avoid contamination. Under such circumstances, the problem is the worst.

As steam is generated and consumed, minerals are left behind in boiler water. Preheated fresh water together with minerals and sometimes condensate returned is added to the system. The concentration of minerals accumulates and finally deposited on the boiler tubes or heating filament of boilers.

The mineral scale not only lowers the efficiency of the device but also promotes the corrosion due to uneven heat distribution. For electrical boiler, the heating filament is vulnerable when it is coated by mineral scale because excessive heat energy cannot be transfered to the water. It is eventually burnt out.

Click here to see how we solve the mineral scale problem.

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Often termed "under deposit corrosion," this is a localized, deep penetration of the metal surface with little general corrosion in the surrounding area. Due to surface deposits, electrical imbalance or some other initiating mechanism, all existing corrosion potential attacks a select number of individual sites.

In most cases, pitting is extended throughout the entire metal surface, creating an irregular or very rough surface profile. In other instances, pits are concentrated in specific areas, leaving the majority of the metal surface in like new condition.

When deposition of mineral scale can be reduced or eliminated, this kind of corrosion can be diminished. Click here to see how we solve the mineral scale problem.

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Benefits

HydroFLOW C Range helps to solve the mineral scale problem existed in steam boilers in an innovative, reliable, cost effective and environmental friendly way. The benefits that an HydroFLOW C Range can bring to you is numerous and summarised as below:

- Energy Efficiency of Boiler Optimized

Mineral scale has a poor thermal conductivity which reduces system performance and at worst leads to system shut down. The heat transfer coefficent is now brought to its designed value. Thus no more energy is lost due to the deposition of mineral sclae on heating elements.

- Equipment Down Time and Maintenance Cost Reduced

The cleaning of heating elements demands manpower, parts, material and time. The duration of cleaning is dramatically reduced. In our experience, the heating element can be cleaned simply by water jet.

- Equipment Life Extended

The attack to heating element by acid cleaning can be reduced when mineral scale problem is solved. Moreover the rate of pitting corrosion is lowered which extends the tube life. In case of electrical boiler, the burnt out of filament due to mineral scale is eliminated. All these results not only reduce the maintenance cost but also extends the equipment life.

- Low Power Comsumption

It consumes 15W - 65W (depends on the model used) for its operation. The electricity cost of it is negligible for continuous operation.

- Ease of Installation

It is a non intrusive method and installation can be completed within an hour provided that a single phase power point is available. There is no change in the pipework and the original equipment.

- Minimal Attention Required

It builts on latest low power solid state technology and its typical power consumption is less than 45W. There is no problem of fatigue, wear out, over-heating and fast aging. It is maintenance free and the only attention to it is to make sure the two LEDs on the control unit are lit up.

- Environmental Friendly

Less chemical is used for tube cleaning and less energy is consumed due to the minimized mineral scale coating by the use of HydroFLOW C Range.

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