The Challenge
The coconut processing plant in the Riau Islands operates a high-capacity (80–100 tons/hr) turbine boiler system as the central power source for continuous 24/7 production. Prior to implementing a new treatment strategy, the plant confronted recurring issues: unstable residual phosphate levels, accelerated mineral scale buildup leading to frequent and costly boiler cleaning, and inefficiently high use of alkalinity boosters. These technical and operational challenges resulted in unpredictable system reliability, excessive maintenance intervals, and increased operational expenditures, threatening both production continuity and compliance with industry best practices for boiler operation.
The Solution
Seeking a robust and sustainable solution, the plant’s technical team evaluated comprehensive water treatment strategies and selected Hydro suite of boiler treatment chemicals—Hydro 1020, Hydro 590, and Hydro 310—for integrated scale control, alkalinity management, and corrosion prevention. The decision was grounded in Hydro proven compatibility with high-volume industrial boilers and its ability to deliver consistent performance under rigorous operational demands. The implementation focused on recalibrating phosphate dosing for precise scale inhibition, introducing dispersants to minimize deposit accumulation, and optimizing alkalinity booster dosing to maintain target P/M ratios, all supported by ongoing technical monitoring and fine-tuning.
The Results
Within several weeks of adopting the Hydro treatment protocol, the plant realized significant operational improvements. Residual phosphate was stabilized within the targeted technical range, providing robust protection against both scale formation and corrosion. Cleaning frequency was drastically reduced, leading to extended boiler uptime and reduced maintenance-related downtime. Moreover, the optimized dosing strategy led to a notable reduction in alkalinity booster usage, directly lowering chemical procurement costs and minimizing environmental impact. Key performance indicators include a stable boiler capacity of 80–100 tons/hr, residual phosphate maintained within target range, significantly reduced cleaning intervals, and decreased chemical consumption—collectively ensuring long-term reliability and cost-efficient operation of the plant’s critical boiler infrastructure.
