HydroFLOW Boiler Case Studies

HydroFLOW will prevent and control the formation of scale and deposits that cause tube failures, restrict circulation, reduce system efficiency, and compromise a boiler system’s reliability. Boiler scale forms directly on heat transfer surfaces when constituent solubility limits are exceeded due to temperature and pressure, and the resulting compounds precipitate onto the tube surfaces as hard scale.

The suspended particles are filtered from the water stream. HydroFLOW performance results in significant reduction of scale accumulation on elements and the frequency of replacement and repairs. HydroFLOW saves cost of chemicals, energy, labor and maintenance.  HydroFLOW is a physical water conditioner so there is no need to operate and maintain a water softener.

Please click on the image for the following Case Studies to view the details.

Chemical Plant Scale Removal

1 Boiler.jpgDue to excessive lime scale accumulation, the diesel steam boilers were on the verge of being decommissioned for a week in order to be acid cleaned; a process which typically costs over $15,000. During inspection, the steam boilers were evaluated for potential replacement ($350K each). The head of maintenance decided to evaluate HydroFLOW’s ability to clean the steam boilers and possibly avoid acid cleaning. Within 2.5 months, fuel consumption went down from 400 to 275 gallon per day; which translates to roughly $150K savings annually (return on investment of 2-3 months).

Scale Control on Heat Exchanger

Heat Exchanger.jpgAfter more than six months of using a Hydropath MARINE system on the Fresh Water Generation unit, biofilm was eliminated, and the surface areas where HydroFLOW conditioned water made contact were free from scale. The 6 month operation clearly demonstrated that this method of water treatment greatly reduces maintenance costs, equipment damage and chemical usage.

60 HP Low Pressure Steam Boiler - Scale Control

60 HP Steam.jpgDue to excessive scale accumulation, even with softening and chemical usage, the head of maintenance  decided to evaluate HydroFLOW’s ability to descale the steam boiler and prevent further scale formation.  Stack temperature has dropped from 296° F to 272° F in 6 months, which demonstrates an 8% increase in heat transfer efficiency. Scale was removed in large volumes from the system through blowdown twice per day during initial activation, resulting in quantities of soft scale which was easy to manage.

Boise Paper Mill, Washington State

HydroFLOW Paper mill process water fouling prevention.pngHydroFLOW was installed at a paper bleaching plant that encountered frequent clogging of nozzles. The objective of the application was to decrease new limescale accumulation inside of pipes and nozzles. Hydropath Technology is recommended by the plant operator as a chemical-free method of treating limescale related problems in boilers and process water systems at industrial plants similar to a paper mill bleach plant. 

British Gas - Thousands of Water Heaters rely on HydroFLOW

British Gas.jpgOver 20 years ago, the largest residential gas provider in the UK, British Gas was looking for a chemical-free water conditioning device to protect their customers' residential water heaters. The test results led to an investment in the company and a long-standing business relationship. To this day, British Gas purchases many thousands of HydroFLOW units each year.

Also view the British Gas video that presents HydroFLOW.


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