Preventing Scale Formation in Boilers with Scale Inhibitors

Boiler is one of the vital equipment in industry that functions to produce steam for various processes. In its operation, the boiler faces various technical challenges, one of which is the formation of scale or scale formation on the tube. This problem often occurs due to the use of water with non-standard quality, causing mineral deposits on metal surfaces in the boiler.

1. What is Scale Formation?

Scale is a deposit of inorganic solids such as calcium carbonate (CaCO₃), magnesium silicate, and silica, which forms due to the chemical reaction of boiler feed water containing minerals. When water is heated, these minerals precipitate and stick to the surface of tubes (pipes) that carry steam or hot water.

2. Negative Impact of Scale on Boiler Tubes

1. Decrease in Heat Efficiency
   The scale that forms acts as an insulator, thus inhibiting heat transfer from the combustion gases to the water. This causes the boiler to require more fuel to produce the same amount of steam.

2. Overheating and Tube Damage
   Since heat transfer is impaired, the metal temperature increases excessively and can lead to deformation, even tube rupture.

3. Increased Energy Consumption
   The efficiency of the boiler decreases resulting in more wasteful and costly operations.

4. Production Downtime
   Boilers that are heavily scaled need to be stopped for chemical cleaning, which results in disruption of the production process.

3. Solution: Use of Scale Inhibitors

One of the most effective solutions to prevent scale formation is the use of scale inhibitors. This product is a chemical added to boiler water with the main function of preventing mineral deposition on metal surfaces.

Scale Inhibitor Function:

• Binds scale-causing ions such as Ca²⁺ and Mg²⁺ to remain soluble in water.

• Disperses small particles, so they do not have time to settle and form scale.

• Changes the crystal structure of the precipitate so that it does not stick strongly to the tube surface.

Advantages of Using Scale Inhibitor:

• Maintain boiler thermal efficiency.

• Extends equipment life.

• Reduces frequency and maintenance costs.

• Improves operational safety.

4. Application in Boiler Systems

To obtain optimum results, scale inhibitors should be used with supervision of boiler water parameters such as:

• pH

• Total Dissolved Solids (TDS)

• Level of hardness

• Working temperature and pressure

It is also important to conduct regular laboratory testing and adjust the chemical dosage appropriately according to boiler capacity and feed water conditions.

5. Conclusion

Scale formation on tubes is a serious problem that can reduce efficiency and damage boiler systems. The use of scale inhibitors is a practical and effective solution that has been proven to prevent scale formation, maintain system performance, and save operational costs.

For industries that rely on boilers, investing in a good water treatment program and the use of high-quality chemical products such as scale inhibitors are important steps to maintaining production continuity and efficiency.

Whether you need help determining which scale inhibitor is right for your system or want to integrate a comprehensive water treatment program, we're here to provide the right solution.