Condensate Polisher Saves Hospital Thousands in Maintenance and Operational Costs

GoalImprove boiler reliability and efficiency by eliminating scale formation and reducing maintenance costs.

<p><!-- wp:acf/two-cols-text {"name":"acf/two-cols-text","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-to-60","_padding_options":"field_6629e0d2860af","background_colour":"blue","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a1b96b768f","block_title":"Overview","_block_title":"field_6629f36ac5d6b","block_content_clone":"","_block_content_clone":"field_662a1b96b76fb","text_list_0_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eIndustry: \u003c/b\u003eHealthcare\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_0_text_item":"field_662a1bf77d245","text_list_1_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eApplication: \u003c/b\u003eBoiler System\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_1_text_item":"field_662a1bf77d245","text_list_2_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eProblem: \u003c/b\u003eThree 800 HP boilers were experiencing leaks and tube failures due to excessive scale formation.\u003c/li\u003e\r\n\u003c/ul\u003e\r\n\u0026nbsp;","_text_list_2_text_item":"field_662a1bf77d245","text_list_3_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eSolution\u003c/b\u003e: Chem-Aqua recommended feedwater pretreatment improvements, a condensate polisher, and boiler chemical cleanings.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_3_text_item":"field_662a1bf77d245","text_list_4_text_item":"\u003cul class=\u0022list-check-mark\u0022\u003e\r\n \t\u003cli\u003e\u003cb\u003eResult: \u003c/b\u003eImproved feedwater/condensate quality and clean boiler surfaces resulted in $250,000 cost avoidance in addition to significant energy and water savings.\u003c/li\u003e\r\n\u003c/ul\u003e","_text_list_4_text_item":"field_662a1bf77d245","text_list":5,"_text_list":"field_662a1bb97d244"},"mode":"edit"} /--><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Customer Challenge</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>A large hospital in the southern United States was experiencing constant leaks and tube failures on three 800 HP boilers. Chem-Aqua found there was excessive scale formation due to water softener problems, contaminated condensate, and other mechanical and operational issues. The hospital was anticipating approximately $200,000 in boiler tube repairs in addition to $50,000&nbsp; annually to chemically clean the boilers.</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Recommended Solution</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>Chem-Aqua surveyed the boiler systems to determine the scope and cause of the problems. We recommended repair and optimization of the water softener, installation of a condensate polisher, and operational improvements to protect the boilers from the negative impacts of hardness contamination and scale deposits.</p> <p><!-- /wp:paragraph --><!-- wp:heading {"level":5} --></p> <h5 class="wp-block-heading">Results Achieved</h5> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>Addressing the water softener problems removed one source of the boiler scale. However, a condensate polisher was also required to eliminate hardness contamination coming from the condensate return system.</p> <p><!-- /wp:paragraph --><!-- wp:paragraph --></p> <p>With good quality feedwater now going to the boilers:</p> <p><!-- /wp:paragraph --><!-- wp:list --></p> <ul class="wp-block-list"><!-- wp:list-item --> <li>Chemical cleanings were avoided at a cost of $50,000/year</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Boiler tube repairs due to scale formation were eliminated ($200,000)</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Boiler efficiency was increased which reduces energy usage</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Blowdown rates were decreased which reduces both water and energy usage</li> <!-- /wp:list-item --></ul> <p><!-- /wp:list --><!-- wp:image {"id":7321,"sizeSlug":"full","linkDestination":"none","align":"center"} --><!-- /wp:image --></p> <p><img style="display: block; margin-left: auto; margin-right: auto;" src="/link/619c67ed543b42f6bf8ac30bf71faa12.aspx" alt="" width="300" height="310" /></p> <p><!-- wp:heading {"level":5} --></p> <h6 class="wp-block-heading">Scaled Boilers Are More Likely to Fail</h6> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>Since scale deposits are insulating, they reduce how efficiently heat is transferred through the metal boiler tubes to the water. The reduced heat transfer efficiency in a dirty boiler means more of the heat goes out the stack instead of being converted into steam. This also means more fuel must be burned to produce the required amount of steam accompanied by more greenhouse gas emissions (GHG).</p> <figure class="image"><img src="/link/470f7c8ad9434133b0b05247025c9014.aspx" alt="" width="250" height="277" /> <figcaption>800 HP Cleaver Brooks Boiler</figcaption> </figure> <p><!-- /wp:paragraph --><!-- wp:gallery {"linkTo":"none"} --><!-- /wp:gallery --><!-- wp:heading {"level":5} --></p> <figure class="image"><img src="/link/c6e8a5c4d7f14808ab0c7ae4e3c1ac75.aspx" alt="" width="300" height="281" /> <figcaption>Scale deposits inside Boiler #2</figcaption> </figure> <figure class="image"><img src="/link/62e19972b50a4d1bbb6f2a94b3d1c37c.aspx" alt="" width="300" height="193" /> <figcaption>Scale deposits removed from Boiler #2</figcaption> </figure> <h6 class="wp-block-heading">Benefits of Polishing Contaminated Condensate</h6> <p><!-- /wp:heading --><!-- wp:paragraph --></p> <p>Removing scale and deposit forming contaminants from returned boiler condensate can result in:</p> <p><!-- /wp:paragraph --><!-- wp:list --></p> <ul class="wp-block-list"><!-- wp:list-item --> <li>Increased heat transfer</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Reduced tube failure</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Reduced fuel costs</li> <!-- /wp:list-item --><!-- wp:list-item --> <li>Reduced water costs Reduced downtime</li> <!-- /wp:list-item --></ul> <p><!-- /wp:list --><!-- wp:paragraph --></p> <p><em>CS4-010</em></p> <p><!-- /wp:paragraph --><!-- wp:acf/two-cols-text-ctas {"name":"acf/two-cols-text-ctas","data":{"option_change_padding_block":"1","_option_change_padding_block":"field_6629e1de35327","padding_options":"py-none","_padding_options":"field_6629e0d2860af","background_colour":"white","_background_colour":"field_6629e20935328","block_options_clone":"","_block_options_clone":"field_662a2539a7d03","block_text_list_0_block_title":"","_block_text_list_0_block_title":"field_662a2573bc047_field_6629f36ac5d6b","block_text_list_0_block_excerpt":"","_block_text_list_0_block_excerpt":"field_662a2573bc047_field_6629f37dc5d6c","block_text_list_0_show_cta_button":"1","_block_text_list_0_show_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f386c5d6d","block_text_list_0_block_cta_button":{"title":"Download PDF","url":"https://www.chemaqua.com/en-us/wp-content/uploads/sites/6/2024/07/CS4-010.pdf","target":""},"_block_text_list_0_block_cta_button":"field_662a2573bc047_field_662b4b6278ee7_field_6629f39cc5d6e","block_text_list_0_use_special_button":"0","_block_text_list_0_use_special_button":"field_662a2573bc047_field_663af6cb5a467","block_text_list":1,"_block_text_list":"field_662a2550bc046"},"mode":"edit"} /--></p>