The efficiency of boilers can be increased to 90% with maintaining the system properly.

A few of the most common issues can hinder the boiler’s ability create output to its full capacity.

1. Priming:

When steam is generated in the boiler, drops of water are transported away by steam, leading to the formation of “wet steam’. This is referred to as priming.

Problem:

1. The valves are prone to deposits that could cause overheating and rust
2. The quality of the product has decreased, which impacts the rates of heat transfer
3. More steam consumption to similar power production
4. The boiler’s life and its components are exposed to risk

Cause:

There are two primary reasons for the process of priming to happen within a boiler

Mechanical Causes:

1. Design of boiler shells that are not correct
2. Too high of a level of water
3. Incorrect firing rate
4. Boiler running at a pressure that is below the pressure of design.

Chemical Causes:

1. The presence of organic matter present in boiler water.
2. Suspended solids in boiling hot water.
3. Very alkalinity
4. Soap-like structures that are present in boiler water

Solution:

1. Maintain low levels of sodium in the water
2. Water filtration that is efficient in the boiler.
3. Inflate the sludge from now to time.
4. The control of rapid changes in flow speed

2. Foaming

The development of a layer foam or froth that is stable over the entire surface is referred to as foaming.

Problem:

1. The formation of soap-like structures decreases the water’s surface tension substantially, which reduces the efficiency of boilers.
2. Variation in the water levels.
3. Water hammer problem.
4. It can cause the possibility of contamination and even scaling.

Cause:

1. The presence of various chemical (especially the presence of alkalis and oil) and solid components in boiling water. The alkali and oil components react to form soaps. This in turn reduces the surface tension and thus raising the probability of foaming.
2. The lubrication in boilers is a source of oil which is the main cause of foaming.
3. The formation of tiny bubbles on the surface of the water. They don’t break easily.

Solution:

1. The use of anti-foaming substances like castor oil. (Anti-foaming substances neutralize surface tension)
2. Water that is properly treated prior to entering the boiler is essential to eliminate foaming substances (such as alkali, oil)
3. The use of sodium aluminates has proved to be a reliable method to eliminate oil residues by entrapping oil droplets.