Beruflich Dokumente
Kultur Dokumente
Rockville, MD 20850
Phone: 301-740-1421
Fax: 301-990-9771
E-Mail: awt@awt.org
Part of the recertification process is to obtain Continuing Education Units (CEUs). One way to do that is to
review a technical article and complete a short quiz. Scoring an 80% or better will grant you 0.5 CEUs.
You need 25 CEUs over a 5-year period to be recertified.
The quiz and article are posted below. Completed tests can be faxed (301-990-9771) or mailed (9707 Key West
Avenue, Suite 130, Rockville, MD 20850) to AWT. Quizzes will be scored within 2 weeks of their
receipt and you will be notified of the results.
Name: ______________________________________________
Company: ___________________________________________
Address: ____________________________________________
E-mail: _____________________________________________
QUIZ
Analyst Fall 2004
Chemical Cleaning of an Industrial Boiler, an Overview
A. 1 foot long
B. 2 feet long
C. 3 feet long
D. 4 feet long
A. 2%
B. 5%
C. 8%
D. 10%
6. Which chemical is effective with high- content copper scale, and is also compatible with
steel alloy?
A. Hydrochloric Acid
B. Sulfuric Acid
C. Citric Acid
D. EDTA
A. Citric Acid
B. EDTA
C. Hydrochloric Acid
D. Sulfuric Acid
8. Which chemical is considered more dangerous to handle than the others in the list?
A. Hydrochloric Acid
B. Sulfuric Acid
C. EDTA
D. Citric Acid
9. At what stage is pressure-water jetting most effective in removing loosened
deposits?
Abstract
The internal surfaces of a boiler in contact with water and steam must be kept clean
and free of deposits to assure efficient heat transfer in the generation of steam. This
article discusses when and how to chemically clean a boiler. Several methods can be
used to determine the need to chemically clean a boiler. The high heat flux boiler
tube surfaces mainly consist of magnetite and copper. The article outlines cost
effective cleansing solvents for chemically cleaning boilers with magnetite and
copper deposits. The chemical cleaning must be thoroughly planned. Criterion for
determining the success of a chemical procedure and the effectiveness of the solvent
in dissolving the deposit is covered in detail.
Introduction
Water-side scale build-up in boilers is a progressive, inevitable process. Even with
stringent control of feedwater and condensate chemistry, scale and deposition will
occur. The main problems caused by boiler scales are:
The increase in tube wall temperature is a result of the low thermal conductivity of
scales as compared to metal. The reduction in heat-transfer can lead to the design
temperature of the tube wall being exceeded, which in turn may lead to failure of the
tube by creep rupture.
Overall efficiency can be defined as the ratio of steam output to the fuel
consumption ratio. Again, since scaling impedes heat transfer, more fuel is required
to produce a given amount of steam, thus reducing overall efficiency and loss of
energy.
Eventually, removal of scale from the boiler becomes essential if damage to the
boiler is to be prevented. One way of removing scale is to chemically clean the
boiler. Chemical cleaning is a multiple stage process that seeks to remove all the
existing scale from the boiler internals, leaving a clean, passivated waterside system.
One step in the process involves the use of inhibited acid to dissolve the scales. This
acid stage is potentially damaging to the boiler and therefore, it requires careful
monitoring to prevent serious metal loss.
This article reviews the criteria for chemically cleaning industrial water-tube boilers
of operating pressures up to 900 psi that are used for steam generation in plant
operation. The article covers the major cleaning steps, as well as the choice of
particular chemicals to use in some steps, with a focus on the removal of iron and
copper scales.
Aragonite CaCO3
Brucite Mg(OH)2
Copper Cu
Calcite CaCO3
Hematite Fe2 O3
Magnetite Fe3 O4
Quartz SiO2
Thenardite Na2 SO 4
Wollastonite CaSiO3
Chemical cleaning proposals must take into consideration the different compounds
present in the scale in order to formulate the optimum cleaning solutions. This
recommendation should effectively remove scale without damaging the underlying
metal.
Other factors influencing the decision of whether or not to chemically clean include:
overall efficiency
hot spots - as evidenced by infrared inspection
tube failure during normal operation
If the data gathered during the normal inspection process indicates a possible need to
chemically clean a boiler, obtaining tube samples is the most reliable and effective
means. Tube samples should be removed from locations where heavy scaling is
suspected. The tube sample should be at least three feet long so the method of
removal (cut-off wheels and cutting torches) does not contaminate the scale at the
center of the sample with slag or filings.
The scale is then analyzed using several different techniques in order to determine
its composition. The scale density is determined gravimetrically after dissolution of
scale in inhibited HCl. Loss of weight on firing in a furnace will measure the
percentage of hydrocarbons present, which then determines the need for alkaline
degreasing. The need to clean is based on the scale density. Table 2 shows the range
of scale density encountered, along with the appropriate action required.
mechanical cleaning
water flushing
alkaline treatment
solvent cleaning
neutralization and passivation
Mechanical cleaning and water flushing can remove loose scale and other debris
from the boiler. Alkaline treatment removes oils and hydrocarbons that might
interfere with the dissolution of the scale by acid solvents. The solvent cleaning
stage is the process in which inhibited acid is used to remove scale form the boiler.
Once the scale is removed in the solvent stage, fresh active metal is exposed. The
neutralization and passivation stages are designed to remove any last traces of iron
oxides and to replace the active metal with a well-passivated surface layer.
Fouling composition, quantity and distribution will vary considerably between
one boiler to another and even within the same boiler at various times during its life
span. It is therefore essential in each case to select a specific treatment or series of
treatments that will be most effective in achieving thorough and safe cleaning to the
desired standards. This segment provides a guide to the selection of treatments.
The treatment must be safe to use and compatible with the materials of
construction of the equipment to be cleaned.
The foulant must show sufficient solubility in the treatment selected so when
it is considered together with any insoluble matter that may reasonably be
expected to detach fully during the process, it will achieve the desired degree
of cleaning.
With these criteria satisfied, make the final selection with due reference to other
constraints including cost, disposal problems and cleaning time available.
Chemical cleaning will normally involve one or more of the following steps:
Laboratory evaluation of tube samples will determine the above sequence. High-
pressure water jetting may follow to remove loosened scale. If high pressure water
jetting is used, it must be followed by flash rust removal and passivation. Remote
fiberscope inspection recorded on a videotape and tube removal for scale density
analysis, before and after the chemical cleaning, will provide visual evidence on
cleaning effectiveness.
Caustic degreasing (NaOH) treatment is used for all new boilers, where mill scale is
present or where organic contamination is 5 to 30 percent. Table 4 shows the control
parameters for caustic degreasing.
Citric Acid - Citric acid is compatible with alloy steels, requires low chloride
solvents and presents good handling, safety and corrosion characteristics in
comparison to hydrochloric acid. It is less aggressive in its attack of some iron oxide
scales and therefore usually requires higher temperatures or longer contacts times. It
has a very limited effect on calcium salts present in boiler scales. In general, it is
more expensive than hydrochloric acid treatment.
The citric acid cleaning stage control parameters are shown in Table 9.
Sulfuric Acid - Sulfuric acid is an effective solvent for iron oxides and iron sulfides
and is generally lower in cost than hydrochloric acid. It is also compatible with
stainless steels. However, it is considerably more dangerous to handle. Sulfuric acid
in its concentrated form is aggressive to organic material and contact with the skin
or eyes is extremely dangerous. Sulfuric acid is not recommended where scales
contain significant calcium due to the formation of insoluble calcium sulfate. Table
11 shows the control parameters of sulfuric acid cleaning stage.
Sulfamic Acid - Sulfamic acid has the advantage of being a crystalline solid, which
is easy to store, handle and mix. It is frequently sold with an inhibitor and a color
indicator of effective acid strength added. It is compatible with stainless steels and is
a moderately aggressive solvent for iron oxide and calcium carbonate. Due to its
relatively high cost, it is mainly used on low volume equipment. The control
parameters of the sulfamic acid cleaning is shown Table 12.
Conclusion
It is essential to clean a boiler periodically for efficient operation, corrosion control,
reliability and prevention of tube failures. Cleaning is accomplished by a
combination of steps. For some boilers it may not be necessary to use all the
cleaning steps, since the degree of contamination will vary from one boiler to
another. The exact procedure to be used depends upon the scale density and its
analysis, tube bulging or failure, water treatment analysis, inspection and history or
the unit itself. The formulations recommended do not override the boiler
manufacturer's chemical cleaning recommendations especially where warranty rights
are involved.
References
This paper was presented at the 64th Annual Water International Conference in
Pittsburgh, Oct. 19 to 23, 2003.
Sam Harvey and Philip Battaglia, "Pressure Pulse Chemical Cleaning of the
Sequoyah 1 Steam Generators," International Water Conference, paper no. IWC-96-
01, Pittsburgh, 1996.
Wayne W. Frenier and Stephen P. Donner, "Field Application of a New Solvent for
Cleaning Once-Through Boilers"
J. Katzel, "Focus on Boilers", Plant Engineering, May 24, 1990, p. 68. "Guidelines
for Chemical Cleaning of Fossil-Fueled Steam Generating Equipment", EPRI, Palo
Alto, CA, TR-102401, June 199