Boiler systems are an integral part of countless industrial facilities across the world, from power plants and refineries to food & beverage operations and chemical processing facilities. Whether generating electricity for communities or supporting critical manufacturing processes, these steam generation systems require ultrapure water free of organic contaminants to operate safely and efficiently. However, maintaining equipment uptime and preventing unplanned costs are critical to preserving profitability and operational control in these competitive industries.
Water chemistry and boiler system performance
Proper boiler water chemistry is essential for preventing scale formation and corrosion, which can lead to costly equipment failure and unplanned shutdowns. With the elevated temperatures and pressures inherent in water-steam cycles, even trace amounts of organic compounds can degrade to organic acids and accelerate damage. Contaminants such as sugars, cleaning agents, cooling fluids, or organic acids are often present at low levels and remain undetected by traditional monitoring methods, creating hidden risks that can result in catastrophic failures.
Contamination: Sources and real-world incidents
These contaminants can originate from various sources - CO2 corrosion typically stems from issues within the boiler feedwater system itself, while glycol contamination often results from external leaks in associated heat exchangers or chiller systems. For example, CO2 entering through feedwater leads to generalized metal loss, while glycol leaks from cooling systems can contaminate steam condensate and cause severe fouling.
Recent incidents at major facilities underscore these risks. Glycol leaks forced power plant shutdowns at multiple facilities, while a major Texas refinery experienced steam condensate contamination and boiler fouling that resulted in unplanned shutdowns and significant financial losses. For plant managers across these industries, implementing robust contamination detection systems isn't just about maintenance - it's about protecting profits, preventing shutdowns, and ensuring reliable operations.
Traditional monitoring techniques including pH and conductivity often fail to detect many common contaminants. Glycol leaks, for instance, remain undetected due to their nonionic state at room temperature and pressure. Unfortunately, these methods don't alert operators to organic acid degradation until damage has already occurred.
Monitoring total organic carbon (TOC) in boiler water provides a proactive solution for detecting contamination and optimizing processes. TOC serves as a leading measurement to indicate potential corrosion and system integrity issues before detrimental consequences occur - something traditional monitoring methods often fail to achieve. TOC monitoring successfully identified glycol contamination at power plants, enabling proactive maintenance that prevented costly shutdowns. Similarly, continuous TOC monitoring at industrial facilities enables real-time detection of contamination events, protecting capital equipment and enhancing production uptime.
Maximizing condensate reuse through effective monitoring
Reusing condensate from industrial processes carries inherent contamination risks, but these risks and their financial implications can be effectively mitigated with online organics monitoring. Accurate assessment of condensate quality not only provides opportunities to detect leaks and prevent fouling, but also impacts operational decisions - enabling maximum reuse while reducing costs associated with producing additional make-up water and wastewater treatment.
The Sievers InnovOx TOC Analyzer addresses these critical monitoring needs with reliable online organics detection using advanced supercritical water oxidation technology. This proven oxidation method achieves over 99% oxidation efficiency, delivering superior accuracy and precision in TOC measurement across the full range of potential contaminants. By providing real-time visibility into boiler water quality, the InnovOx helps optimize performance, minimize unplanned maintenance, and increase profitability. To learn more about how the Sievers InnovOx TOC Analyzer can help your boiler water system needs, read our application note.