Excess phosphate (PO4) injection in boiler water systems can lead to the phosphate

compounds deposits on boiler tubes through a series of chemical reactions and

physical processes. This is how its occurs: 1. Phosphate Treatment in Boilers:
Phosphate compounds such as trisodium phosphate [Na₃PO₄] is added to the boiler
water to control water PH, to precipitate hardness ions (calcium and magnesium)
and maintain alkalinity to prevent corrosion. In the boiler water, phosphate ions
(PO₄³⁻) react with calcium ions (Ca²⁺) and magnesium ions (Mg²⁺) present in the
water to form insoluble phosphate salts: When the concentration of phosphate ions
in the boiler water exceeds the solubility product, the solution becomes over
saturated with respect to the phosphate salts which lead to deposits on boiler
tubes. In addition to high temperature there will form a hard scale of mainly consist
of calcium phosphate (Ca₃(PO₄)₂) and magnesium phosphate (Mg₃(PO₄)₂). The
phosphate scale reduces heat transfer efficiency, causing the boiler to consume
more fuel and the insulating effect can lead to localized overheating, potentially
causing tube failure due to thermal stress or creep. Finally, there is a potential risk
that Phosphate deposits will obstruct water flow, leading to uneven water
distribution and further operational issues.
TSP isn't a good choice because of caustic (cationic conductivity) it will lead to
caustic embrittlement.
TSP is effective in between of 270°C to 340°C temperature, otherwise it cause
Phosphate hide out . Below or above mention temp TSP disappear from the water
while boiler water steaming. When Boiler load is frequently variation then
phospahte hide out in the boiler water is happening.
a. High pH: Excessive TSP dosage can significantly raise boiler water pH,
potentially causing issues with foaming and carryover of solids into the
steam.
b. b. Sodium build-up: Frequent use of TSP can lead to increased sodium
concentration in the boiler water, requiring more frequent blowdown to
maintain proper water chemistry.
c. c. Precipitate formation: Under certain conditions, high phosphate
concentrations can lead to the formation of phosphate precipitates within the
boiler, potentially impacting heat transfer. Important considerations for TSP
dosing during boiler start-up: i. Water quality analysis: Analyze feedwater
chemistry to determine the appropriate dosage of TSP needed to achieve the
desired pH level. ii. Gradual addition: Add TSP slowly to the boiler during
start-up to avoid sudden pH fluctuations.
Proper dosing of TSP is crucial to avoid excessive alkalinity and pH levels.
Overdosing can lead to high pH conditions, which may result in scale formation,
reduced effectiveness of corrosion inhibitors, and potential foaming and carryover
issues. Maintaining the right balance is essential for optimal performance.
Phosphates, primarily sodium-based compounds, are commonly introduced
into boiler feedwater to prevent scale formation, inhibit corrosion, and stabilize the
pH level. However, despite their widespread application, they are not without
challenges. One such challenge is the phenomenon known as "phosphate hideout,"
which occurs under specific operational conditions, leading to the accumulation of
phosphate compounds in areas of the boiler where they precipitate out of solution.
This phenomenon can cause localised corrosion, undermine the efficiency of water
treatment programs, and result in long-term damage to boiler components.

for low-pressure systems, dosing Trisodium Phosphate (TSP) alone is sufficient since
these systems are less susceptible to caustic gouging.
Trisodium Phosphate - reacts with salts like Mg++ or Ca++ in feed water and forms
sludge with them, which is taken out with continuous blowdown (CBD). It also helps
in maintaining pH.
CaCl2 or MgCl2 + Na3PO4 --> Ca3(PO4)3 or Mg3(PO4)2 (sludge) + NaCl. Na3PO4 +
3CaSO4 or 3MgSO4 -->3NaSO4 + Ca3(PO4)2 or Mg3(PO4)2 (sludge)
TSP as PH Booster-: Na3PO4 + H2O --> Na2HPO4 + NaOH Note: Tri sodium
phosphate was most effective at 270 to 340 degree celcius only. otherwise it cause
Phosphate hide out.
Phosphate Hideout:- When the concentration of phosphate in the boiler water is too
high, phosphate will react with boiler scale forming iron and iron sodium phosphates
or precipitate to form a solid phase on the hot boiler tube surfaces and elsewhere.
This phenomenon is called phosphate hideout and it can result in changes of pH, as
well as the concentrations of phosphate and other chemical species in the boiler
water.
Regular monitoring of phosphate levels in the boiler water is crucial.
- Adjusting the feedwater treatment process and maintaining stable operating
conditions can help mitigate the hideout problem.
- Some facilities may implement strategies such as blowdown practices or using
alternative treatment chemicals to address the issue.
What is phosphate hideout?
 It is described as the ionic phosphate (PO4) species in boiler water disappearing
through precipitation or absorption when there is a high heat transfer or high load.
The main cause of phosphate hideout is the temperature-dependent reaction
between iron oxide and sodium phosphate compounds. This reaction results in a low
solubility reaction product that precipitates in regions with high heat flux or under
high load circumstances. Lower heat fluxes and loads cause the precipitates to
return to a solution.
How can I identify it?
When heat input changes or during load swings, phosphate hideout is visible. The
pH rises as the load rises and the phosphate content decreases. Without adding any
chemicals to the boiler, when the load is decreased, the phosphate content rises
and the pH falls.
Chemical charges added to the system during phosphate hideout cause little to no
change in the phosphate and/or pH values because newly precipitated phosphate
may mix with previously precipitated phosphate. When the load is raised during
hideout and then lowered again, the pH and phosphate readings are usually out of
control.
Phosphate hideout is best identified by graphing changes in load, pH, and
phosphate over time. The graphs' variations will make it abundantly evident that
when the load decreases, the pH falls and the phosphate increases.
When the boiler temperature and pressure is increased specially during high load
condition there is phosphate retention and when the load is decreased phosphate is
subsequently released.
Phosphate hideout usually results in an increase of PO4 concentration and a
decrease of pH during load reduction and in an increase of pH and decrease of PO4
concentration during the load increases.
The amount of phosphate fed should be equal to the amount of phosphate removed
by blowdown and the amount of phosphate removed by sampling. If the amount fed
is greater there is possibility of phosphate hideout.
However, it will be recognized that hideout and hideout return become more
prevalent with increasing pressure. Hideout and hideout return are always
associated with large swings of pH causing controlling problems, but if only TSP is
used, then no harmful corrosion reactions can be initiated as was experienced with
CPT using sodium-to-phosphate molar ratios below 3:1. Sometimes hideout can be
so bad that operating phosphate levels are reduced to below the minimum level
(0.3 mg/kg) suggested in this PT guidance.
it may be necessary to supplement the TSP with NaOH but always keeping within
the pH/phosphate boundary range and below the sodium-triphosphate molar ratio
line of TSP + 1 mg/kg of NaOH. Some boilers/HRSG evaporators also need a small
addition of NaOH (<1 mg/kg) to elevate the pH into the required range (>9.0).
trường hợp này, có thể cần bổ sung NaOH vào TSP nhưng luôn giữ trong phạm vi
ranh giới pH/phosphate và dưới đường tỷ lệ mol natri-triphosphate của TSP + 1
mg/kg NaOH. Một số nồi hơi/thiết bị bay hơi HRSG cũng cần thêm một lượng nhỏ
NaOH (<1 mg/kg) để nâng pH lên phạm vi yêu cầu (>9,0).
Đối với HRSG đa áp suất, PT cũng có thể được sử dụng trong mỗi chu kỳ áp suất,
nhưngviệc sử dụng PT ở đây là vì những lý do khác nhau tùy thuộc vào áp suất của
mạch.
Phosphate hideout is a phenomenon that occurs in boilers where phosphate salts
precipitate in the water-steam cycle and accumulate on the surface of the boiler
tubes. This accumulation can lead to conditions like scale formation, reduced heat
transfer efficiency, and ultimately, boiler failure.
The primary cause of phosphate hideout is the fluctuation in the boiler water pH
level due to changes in the rate of steam flow or changes in the load on the boiler.
As the pH level rises, phosphate salts become insoluble, precipitate, and
accumulate on the tubes.
The solution to phosphate hideout in the boiler involves implementing a proper
chemical treatment program that addresses the underlying problem of fluctuating
pH levels. This generally involves using a combination of phosphate and pH control
chemicals in water treatment programs.
Another approach to prevent phosphate hideout is to use a continuous blowdown
system to remove excess solids from the boiler water. This helps to maintain the pH
level and prevent the precipitation of phosphate salts.
The key to preventing phosphate hideout is to monitor boiler water chemistry
regularly and adjust the chemical treatment program as needed to maintain
optimum conditions for the boiler system.
Ẩn náu phosphate là hiện tượng xảy ra trong nồi hơi khi muối phosphate kết tủa
trong chu trình nước-hơi nước và tích tụ trên bề mặt ống nồi hơi. Sự tích tụ này có
thể dẫn đến các tình trạng như hình thành cặn, giảm hiệu suất truyền nhiệt và cuối
cùng là hỏng nồi hơi.
Nguyên nhân chính gây ra hiện tượng ẩn náu phosphate là sự dao động trong mức
pH của nước nồi hơi do thay đổi tốc độ dòng hơi hoặc thay đổi tải trên nồi hơi. Khi
mức pH tăng lên, muối phosphate trở nên không hòa tan, kết tủa và tích tụ trên các
ống.
Giải pháp cho hiện tượng ẩn náu phosphate trong nồi hơi liên quan đến việc triển
khai chương trình xử lý hóa chất thích hợp để giải quyết vấn đề cơ bản là mức pH
dao động. Điều này thường liên quan đến việc sử dụng kết hợp phosphate và hóa
chất kiểm soát pH trong các chương trình xử lý nước.
Một cách tiếp cận khác để ngăn ngừa hiện tượng ẩn náu phosphate là sử dụng hệ
thống xả liên tục để loại bỏ chất rắn dư thừa khỏi nước nồi hơi. Điều này giúp duy trì
mức pH và ngăn ngừa sự kết tủa của muối phosphate.
Chìa khóa để ngăn ngừa sự ẩn náu của phốt phát là theo dõi thường xuyên thành
phần hóa học của nước nồi hơi và điều chỉnh chương trình xử lý hóa chất khi cần
thiết để duy trì điều kiện tối ưu cho hệ thống nồi hơi.
Phosphate Hideout.
Phosphate is doing interesting job in Boiler. It works as an anti scalant since
phosphate react with calcium hardness to create suspended solids (which is easier
to discharge via blowdown) in order to prevent any calcium carbonate (CaCO3)
/calcium silicate (CaSiO3) scale. Phosphate also can act as a ph adjuster. When the
concentration of phosphate in the boiler water is too high, phosphate will react with
boiler scale forming iron and iron sodium phosphates or precipitate to form a solid
phase on the hot boiler tube surfaces and elsewhere. This phenomenon is called
phosphate hideout and it can result in changes of pH, as well as the concentrations
of phosphate and other chemical species in the boiler water.
Phosphate hideout becomes evident in load swings or start-ups with changing heat
input. As the load is increased, the pH increases with the decreasing phosphate.
When the load is reduced, the pH decreases and the phosphate increases, without
chemical additions to the boiler.
During phosphate hideout, little or no change in phosphate and/or pH values occurs
when chemical charges are added to the system since fresh phosphate may
precipitate along with that which has already occurred. The readings for pH and
phosphate are typically out of control during hideout when the load is increased,
and then again when it is decreased. While it seems that the phosphate has
mysteriously disappeared, and that additional charges are unsuccessful in
increasing the phosphate reading, the actual phosphate inventory in the boiler has
not decreased. It has combined with oxide deposits to form a slightly lower Na/PO4
ratio causing an increase in alkalinity in the liquid phase, hence the boiler water pH
increases. When the load is decreased again, these combinations return to the
soluble form and the phosphate returns to the bulk water, causing higher phosphate
readings and lowered pH.
Nơi ẩn náu phốt phát.
Phosphate đang làm công việc thú vị trong nồi hơi. Nó hoạt động như một chất
chống tỷ lệ do phosphate phản ứng với độ cứng canxi để tạo ra chất rắn lơ lửng (dễ
xả hơn qua thổi) để ngăn chặn bất kỳ thang đo canxi cacbonat (CaCO3) /canxi
(CASIO3) nào. Phosphate cũng có thể hoạt động như một bộ điều chỉnh pH. Khi
nồng độ phốt phát trong nước nồi hơi quá cao, phốt phát sẽ phản ứng với quy mô
nồi hơi hình thành natri phosphate sắt và sắt hoặc kết tủa để tạo thành một pha rắn
trên bề mặt ống nồi hơi nóng và các nơi khác. Hiện tượng này được gọi là nơi ẩn náu
phốt phát và nó có thể dẫn đến sự thay đổi của pH, cũng như nồng độ của phốt phát
và các loài hóa chất khác trong nước nồi hơi.
Nội tiết phốt phát trở nên rõ ràng trong các đu dây tải hoặc khởi động với đầu vào
nhiệt thay đổi. Khi tải được tăng lên, độ pH tăng khi giảm phosphate. Khi tải được
giảm, độ pH giảm và phốt phát tăng, không có sự bổ sung hóa học cho nồi hơi.
Trong quá trình ẩn náu phốt phát, ít hoặc không có thay đổi về giá trị phosphate
và/hoặc pH xảy ra khi các điện tích hóa học được thêm vào hệ thống vì phosphate
tươi có thể kết tủa cùng với điều đã xảy ra. Các bài đọc cho pH và phốt phát thường
nằm ngoài tầm kiểm soát trong quá trình ẩn náu khi tải được tăng lên, và sau đó
một lần nữa khi nó bị giảm. Mặc dù có vẻ như phốt phát đã biến mất một cách bí ẩn
và các khoản phí bổ sung không thành công trong việc tăng khả năng đọc phốt
phát, nhưng hàng tồn kho phốt phát thực tế trong nồi hơi chưa giảm. Nó đã kết hợp
với các trầm tích oxit để tạo thành tỷ lệ Na/PO4 thấp hơn một chút gây ra sự gia
tăng độ kiềm trong pha lỏng, do đó pH nước nồi hơi tăng. Khi tải được giảm trở lại,
các kết hợp này trở lại dạng hòa tan và phốt phát trở lại với nước lớn, gây ra các bài
đọc phốt phát cao hơn và giảm pH.