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Water Circulation Ratio OR clean condensate

Friday, November 24, 2017   By: Mohamed Kamal [2205] 0 Stars
Hey Gents,

I have an issue for package water tube boilers fed with condensate water coming from the process side. the process condensate is contaminated with slurry which lead to performing a scale in the boiler tubes and tube failure is occurred subsequently. in the other hand we have performed a circulation study which showed that the Circulation ratio is 5.5 : 1.

The question here where to start: is the water circulation ratio is OK so we can start and give the preference and efforts to clean the condensate ?

appreciating your help

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Sunday, November 26, 2017   By: Jim Watts [764] 5 Stars
It is fundamental to operate the boiler with water which will not scale.
A boiler designed by experienced manufacturer will work reasonably well.
Any study of a boiler with tubes fouled to the point of failure will likely show circulation problems.
You must stop looking for miracles and clean up the boiler tubes and its feed water.

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Monday, November 27, 2017   By: Ross Burns [390] 5 Stars
I agree with Mr. Watts, so if your condensate is fouled then dump the condensate. Also, I want to add that your circulation ratio is dependent on the design and its firing rate, and that is to say the circulation ratio varies or has a range with how the boiler is fired. Your circulation ratio is not the issue, but the heat transfer is the issue, so dump the condensate, for the condensate cannot possibly be worth scaling up the watersides. Maybe you have more information that is not foreseen right now.


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Monday, November 27, 2017   By: cmolanes@itba.edu.ar [50] 4 Stars
Mr. Kamal:

Making any further comment after Mr. Watts and Mr Burns seems daring and too bold on my part, but if scaling occurred in your watertube boiler, which I imagine it to be of the D-type, for you say package, I suppose you must have been suffering of an increased fuel consumption due to the isolating effect of the scaling affecting heat transfer to the water side, and possibly an increased flue gas temperature.

Adding the cost of having the boiler repaired and the working time lost, it seems you must consider either replacing all the feed water as it has been suggested by Mr. Burns, or seeing that the process will not contaminate the water side in the heat exchangers if they be of the surface type, perhaps repairing some pieces of equipment. I do not know if the possibility of incorporating a treatment plant to get rid of the slurry is possible, but you will certainly know this much better.

Good luck, and I hope you will soon find a solution.

Claudio Molanes

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VWO, BMCR, TMCR, Full Load and Base Load
By: Jim Watts [764]

MCR is maximum continuous rating.

BMCR is the Boiler MCR, TMCR is the turbine MCR

VWO is valves wide open and at normal pressure allows the turbine to exceed TMCR by 5-10 percent

Full load is not fixed but means the turbine has reached it intended maximum

Base Load is also a flexible number and means the turbine will not be operated below that figure. It is mostly used in power system scheduling where the cheapest plants run fully loaded and are referred to as base load plants. O....   Read All
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