CASE STUDY: BOILER SYSTEM RESOLVING CHEMICAL AND OPERATIONAL ISSUES

A major industrial facility operating multiple high-pressure boilers was facing frequent operational challenges that affected steam quality and system efficiency. 

Despite using treatment chemicals from another supplier, the plant experienced recurring issues that led to unplanned downtime and higher fuel consumption. 

• Foaming and carryover in boilers, leading to poor steam purity.
   
• High blowdown frequency, increasing water and energy loss.
   
• Corrosion in condensate lines, due to inefficient oxygen scavenging.
   
• Scaling in boiler tubes results in reduced heat transfer and high fuel usage.
   
• Inconsistent chemical performance, causing constant adjustments and monitoring.

HNJ Hydro Chem’s technical team conducted a comprehensive system evaluation, identifying the root causes of instability and inefficiency.

A new optimized boiler treatment program was implemented, featuring:

• HNJ’s advanced multifunctional boiler chemistry combines oxygen scavenger, scale inhibitor, and alkalinity builder in one formulation.
   
• pH control optimization for both feedwater and condensate systems.
   
• Improved blowdown management strategy, based on real-time TDS monitoring.
   
• Operator training on correct dosing and chemical control procedures.

• The old multi-chemical program was replaced with HNJ’s integrated boiler treatment solution.
   
• The condensate system was flushed and conditioned to remove old deposits.
   
• Dosing control systems were recalibrated to ensure precise and stable chemical feed.
   
• Continuous monitoring of pH, TDS, and dissolved oxygen was introduced.

Under the previous supplier’s program, the client’s boiler system suffered from frequent tube scaling, visible rust, and condensate line pitting, and required 8–10 blowdowns per day, resulting in high water and energy loss. The buildup of scale also led to declining fuel efficiency, increasing operational costs over time. After implementing HNJ Hydro Chem’s multifunctional boiler chemical, all these issues were resolved. 

Scaling was eliminated, and no corrosion was observed in the condensate system. The frequency of boiler blowdown was reduced to 3–4 times per day, significantly conserving both water and fuel. Additionally, fuel efficiency improved by 5–8%, while the use of a single multifunctional product simplified dosing operations and lowered overall chemical costs, delivering measurable savings and stable boiler performance. 

By introducing its optimized boiler treatment program, HNJ Hydro Chem helped the client achieve:

• Zero scaling and corrosion incidents.
   
• Reduced chemical usage and operational costs.
   
• Improved boiler efficiency and steam quality.
   
• Extended equipment lifespan and reduced downtime.

The plant now operates reliably and efficiently, with consistent boiler performance and lower operational expenses — powered by HNJ Hydro Chem’s expertise.