Regular boiler cleaning is essential after prolonged operation, as scale and corrosion are almost inevitable. The primary cause of scale formation is the presence of hardness components in water. Under high temperature and pressure, these minerals evaporate and concentrate within the boiler, leading to a series of physical and chemical reactions that ultimately result in hard, dense deposits on the heated surfaces. These scales are a major contributor to boiler failures and can lead to serious accidents. Their negative effects include:
Significant fuel waste: The thermal conductivity of scale is only a fraction of that of steel. When the heating surfaces become fouled, heat transfer is significantly reduced. To maintain the boiler’s output, the temperature on the fire side must be increased, which leads to greater heat loss through radiation and flue gas emissions. The amount of fuel wasted depends on the type and thickness of the scale, which varies with the boiler's working pressure. According to tests and calculations, the relationship between scale thickness and fuel loss is as follows: when the scale thickness (S) is ≥ 1 mm, fuel loss ranges from 5% to 13%; at ≥ 2 mm, it increases to 13% to 18%; and at ≥ 3 mm, it reaches 18% to 26%.
Increased risk of overheating and damage to metal components: After scaling, the boiler must maintain its operating pressure and evaporation rate, but the fire-side temperature has to rise. The thicker the scale, the lower the thermal conductivity, causing the fire-side temperature to increase further. Typically, the fire-side temperature is around 900°C, while the water-side temperature is about 190°C. Without scale, the steel plate temperature is roughly 230°C. However, when there is a 1 mm layer of scale, the steel plate temperature rises by approximately 140°C. At 315°C, the metal begins to lose its plasticity, and at 450°C, it may creep or deform due to excessive heat. Therefore, scale buildup greatly increases the risk of metal damage and failure.
Higher maintenance costs and shorter service life: A significant portion of boiler accidents—often one-third or more—are caused by scale-related issues. These incidents not only damage equipment but also pose risks to personnel safety. Even with good water quality, strict adherence to national standards during boiler operation is crucial. Preventing scale formation during operation and addressing it promptly when it occurs is essential. Regular cleaning and descaling should be carried out to ensure safe and efficient performance. The most effective modern approach involves using high-quality chemicals for maintenance and implementing routine cleaning procedures to control water quality and prevent scale accumulation.
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