Since I have written my experience visiting a boiler manufacturing company recently, I think it is good if I follow up with another article related to boiler. This time, it is about the importance of boiler water treatment chemicals. I remembered monitoring the boiler man blended and poured some chemicals (from Nalco) to be injected into the boilers.
Do you know that like cooling tower, a boiler also requires chemical treatment for various reasons. When I was a process engineer, I got the opportunity to learn about the chemical water treatments for utility boiler and cooling tower. There are various chemicals with specific functions. The chemicals, which I will explain below will imperatively preserve the life of a utility boiler (in this case a low pressure boiler). A low pressure boiler in this case is one which is less then 200 psi. We shall look upon several chemical parameters, namelu the amines, alkalinity, sulfites and phosphates or polymers of the boiler water.
Amines are used to increase the condensate pH to a range of 7.8 to 8.7. When generating steam, carbonic acid forms and as a result your steam pH is low. Amines are volatile and when introduced into the steam header or boiler water, amines will increase the condensate pH. A low pH will lead to excessive condensate pipe corrosion.
Alkalinity is used to increase the boiler water pH to above 10.5. This serves three purposes. pH above 10.5 will decrease your overall corrosion rates, it will keep a 3:1 ratio of total alkalinity to silica, and it allows the polymer to react with calcium. A 3:1 ratio keeps silica from plating in the boiler. A low pH will result in an over general corrosion appearance on your boiler tubes.
Sulfites are used to remove any dissolved oxygen from the water. Dissolved oxygen enters the boiler in make up water or as air is sucked into the system. Dissolved oxygen is extremely corrosive to your tubes and localized pits will form, ultimately resulting in premature tube failure. Maintain a 20 to 40 ppm residual of sulfite in your boiler water.
Phosphates and polymers are used to react with any calcium in the water. The polymer attaches itself to the calcium. The polymer and calcium then is able to exit the boiler through the surface or bottom blowdown. Phosphate reacts with the calcium and sinks the calcium to the bottom of the boiler. When using phosphates you must perform boiler blowdown daily to release the phosphate and calcium. Failure to use a polymer or phosphate will result in calcium build up on the tubes or as some call it boiler scale. This will decrease the over boiler efficiency and will drastically increase your fuel cost.
It is vital to note that water expands 100,000 times when it change from a liquid to vapor phase. A typical home water boiler 30 gallon system has enough energy to throw a 2,000 pound car over 100 feet in the air if catastrophically failed.
First Image credited to: www.johnstonboiler.com. Second Image credited to http://www.indiamart.com (Example of Nalco Chemical for boiler water treatment).
HIGHLY Recommended GREEN Info Product
"Don't buy solar panels. Instead, Build them - like they did!" Watch the FREE video presentation NOWand discover…
Why you should run like hell from $10,000 and $20,000 retail solar panel systems
A little known way to slash your electric bill by 80% or more (or even get off the grid entirely)
How a “technologically retarded” guy stumbled on a way to generate free energy with homemade solar panels
A simple, 5-step process for building your own low-cost solar panels
And how to say “goodbye” to the electric company… and “hello” to clean, FREE electricity!
------------------------------------------------------------------- FREE Recommended magazines to get you updated with current engineering news
Have you downloaded my free "Choosing Alternative Fuel" Ebook? If not, then please download it here. It's Free and on top of getting the free ebook, you'll get eCourse on Alternative Fuel. It's a good and easy way to add more valuable information to yourself.
Last November I joined a group of Institution Engineers Malaysia (IEM) members for a technical visit trip to Mechmar Boiler in Pasir Gudang, Johor, Malaysia. This was the first time I visited a boiler manufacturer company. Honestly I was thrilled to learn and explore how a boiler is made and what the factory looks like. I mean the production plant site. In total there were about 20-30 engineers from IEM. The program started at 9.30 am up to 12.30 pm.
Some information about Mechmar Corporation (Malaysia) Berhad
Mechmar Boiler was established over 30 years ago. Currently, Mechmar Boiler is the leading industrial boiler and pressure vessel manufacturer within the Asian Pacific region.
With a core emphasis on superior engineering and strict manufacturing quality standards, Mechmar continually strives and meets the ever increasing expectations of today’s customers for reliable heat, power or steam generation at an economical investment cost.
Mechmar wide product range serves to meet the heat, steam or power needs of our customers regardless of their industry and location. Their products are the result of years of continuous and rigorous detailed engineering and dedication to providing quality in our manufacture and in our service to our customers.
The headquartered of Mechmar is in Kuala Lumpur, Malaysia. Mechmar’s engineering team reinforces their commitment to their customers by providing sound engineering input with attention to detail. With two world class manufacturing and fabrication facilities in South East Asia both of which are ISO9001 certified by Lloyds, we meet this commitment with speed and at competitive prices. (Information taken from Mechmar official website).
Products manufactured by Mechmar
Here are the list of products manufactured by Mechmar Corporation (Malaysia) Berhad:
Oil/Gas-Fired Boiler
Titan HT
Titan AS
Titan MB
Solid Fuel-Fired Boilers
Titan MCC
Titan MCH
Titan BD
Titan MTH
-Heat Recovery Boiler -Various Custom Made Boilers -Reconditioned boilers
For more comprehensive list of products, please click here.
The factory administrator of Mechmar Boiler gave us some explanation on the history and business of the company.
A nice pen as souvenir for the IEM delegates. Luckily they provided a free pen because I forgot to bring my own pen.
This is the view in the production facility of Mechmar Boiler One of the oil/gas fired boiler nearly completed
That's me with some nice background in the Mechmar Boiler facility
Taking a group photo together in the boiler manufacturing plant
HIGHLY Recommended GREEN Info Product
"Don't buy solar panels. Instead, Build them - like they did!" Watch the FREE video presentation NOWand discover…
Why you should run like hell from $10,000 and $20,000 retail solar panel systems
A little known way to slash your electric bill by 80% or more (or even get off the grid entirely)
How a “technologically retarded” guy stumbled on a way to generate free energy with homemade solar panels
A simple, 5-step process for building your own low-cost solar panels
And how to say “goodbye” to the electric company… and “hello” to clean, FREE electricity!
Have you downloaded my free "Choosing Alternative Fuel" Ebook? If not, then please download it here. It's Free and on top of getting the free ebook, you'll get eCourse on Alternative Fuel. It's a good and easy way to add more valuable information to yourself.
I’m Zaki. I used to be a project, process and chemical engineer. Few years ago I successfully became a Chartered Engineer (IChemE) and Professional Engineer (BEM). I'm now employed as a chemical engineering educator/researcher/consultant. Hope you like reading my blog. I welcome any feedback from you. My email: zaki.yz[alias]gmail.com. TQ!
Get this powerful 80-page ebook on various alternative energy that can save our environment and save your money. On top of that, you'll get a FREE eCourse on alternative energy from me.
boiler in make up water or as air is sucked into the system. Dissolved oxygen is extremely corrosive to your tubes and localized pits will form, ultimately resulting in premature tube failure. Maintain a 20 to 40 ppm residual of sulfite in your boiler water.
Have you downloaded my free "Choosing Alternative Fuel" Ebook? If not, then please download it here. It's Free and on top of getting the free ebook, you'll get eCourse on Alternative Fuel. It's a good and easy way to add more valuable information to yourself.
