OPTIMIZING BOILER WATER CHEMISTRY AND CORROSION CONTROL SYSTEMS FOR ENHANCED EFFICIENCY AND RELIABILITY
Keywords:
Boiler water chemistry, corrosion control, scale formation, high-pressure boilers, chemical treatment.Abstract
Background: Industrial boilers are vital in power generation, petrochemical processing, and large-scale heating applications. Maintaining proper water chemistry is essential to prevent scale formation, corrosion, and operational inefficiencies, as deviations can reduce heat transfer, increase fuel consumption, and shorten equipment lifespan.
Objectives: The study aimed to: (1) assess the impact of water chemistry on scale formation, corrosion, and overall boiler performance; (2) evaluate conventional and advanced chemical treatment methods; (3) investigate corrosion behavior under varying operating conditions; and (4) develop a comprehensive boiler water management and corrosion control framework to enhance system reliability and longevity.
Methods: A hybrid approach combined long-term field monitoring, laboratory analysis, and corrosion-coupon testing. Samples were collected from feedwater, deaerator outlets, boiler drums, and condensate return lines. Parameters measured included pH, alkalinity, hardness, TDS, conductivity, dissolved oxygen (DO), and silica. Scale deposition was assessed via suspended solids and microscopic examination, while corrosion rates were determined using weight-loss coupons and electrochemical techniques. Controlled laboratory tests were used to supplement field observations.
Results: Maintaining alkaline pH, moderate TDS, and low DO effectively minimized corrosion and scale deposition. Chemical treatments including oxygen scavengers, phosphate conditioning, dispersants, and controlled blowdown reduced corrosion rates in treated boiler water to 1.0–1.4 mpy, compared to 8–12 mpy in untreated water. Silica accumulation in the boiler drum and minor DO variations in condensate return lines indicated areas needing ongoing monitoring. Hardness and alkalinity levels confirmed effective softening and internal phosphate reactions.
Conclusions: Coordinated water-management strategies combining chemical treatment, mechanical pretreatment, and continuous monitoring improve boiler reliability, energy efficiency, and lifespan. Regular evaluation of water chemistry is essential to prevent scaling, corrosion, and operational disruptions.
