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To those in charge of using boilers in fiber manufacturing, dyeing processing, heat treatment, etc., are you struggling with the dilemma of cost and safety? - The refractory materials of the boiler that has been in use for many years are deteriorating, and it's about time for an update. - The estimate provided by the manufacturer I approached for the update is high. - Honestly, the budget is tight. It's not urgent, but leaving it as is is also concerning. Our company will check the structure and use of the boiler and propose a refractory material update plan that can be handled by manufacturers other than the original one. ◇ Achieve significant cost reductions compared to requesting the manufacturer. ◇ Restore the operational efficiency of the boiler and maintain stable heating performance. ◇ Avoid the risk of unexpected failures by addressing aging components early. ◇ Clarify future update timing, making it easier to establish medium- to long-term plans. We are currently offering free case studies on cost reduction through refractory material updates.

Are you facing any of these concerns regarding your boiler's efficiency? - I feel like the boiler's efficiency is decreasing. - The fuel consumption is increasing, yet the steam startup is poor. - Could it be related to iron content? By using a fiberscope to assess the current situation and performing internal cleaning of the water tank, we can resolve these issues. ◇ Reduced boiler startup time ◇ Improved fuel efficiency through the removal of iron from the heat transfer surfaces ◇ Prevention of future re-deposition by removing iron from inside the tank ◇ Visualization of the situation also contributes to preventive maintenance We are currently offering free examples of our one-stop service that includes investigation, cleaning, and chemical treatment.

■ What regulations exist for boiler wastewater? There are additional regulations regarding the water quality standards for boiler wastewater under the Sewerage Act, the Water Pollution Control Act, and municipal ordinances. The Sewerage Act and the Water Pollution Control Act stipulate that the pH must be discharged between 5.8 and 8.6. ■ Why is the standard set around neutral? It is generally said that strongly acidic or alkaline wastewater can corrode sewer pipes and weaken the activity of microorganisms that clean wastewater at treatment plants. By establishing standards close to neutral, it is believed that such impacts are prevented. ■ Why is neutralization necessary? As mentioned previously, it is desirable to maintain the pH of boiler water between 11.0 and 11.8 for corrosion prevention inside the boiler. Therefore, high pH blowdown water must be neutralized before discharge, as discharging it directly would exceed the standards. ■ How is neutralization done? Typically, the pH of alkaline wastewater is lowered by adding an acid to adjust it within the standard values. Please feel free to consult us for more information.

■What is the structure of a once-through boiler? It is a type of boiler composed of pipes, where water is fed in from one side and steam is extracted from the other. It has a small water capacity, allowing for quick steam generation. Additionally, it is compact, requiring less installation space for the boiler. ■Why can it produce steam quickly? Having a small water capacity means there is less water to heat. The less water there is to warm, the quicker it can reach boiling and vaporization. Therefore, both water tube boilers and once-through boilers have the advantage of being able to produce steam relatively quickly compared to cylindrical boilers. ■Does this also make it unstable for the same reason? On the other hand, having a small water capacity means there is also less water reserve to maintain pressure and water level when the steam usage suddenly changes. As a result, pressure and water levels can fluctuate easily due to load variations, making operation more unstable, which requires quick control measures such as adjusting the feed water flow. ■Summary The same characteristic of having a "small water capacity" creates both the advantage of quick steam production and the disadvantage of potential operational instability. Please feel free to consult with us first.

■What is blowdown? Blowdown is the process of discharging a portion of the boiler water from the bottom of the boiler to keep the concentration of hardness within permissible limits. If the blowdown amount is excessive, it results in significant heat loss and unnecessarily wastes water (leading to extra make-up water). ■Why does boiler water become concentrated? A boiler heats water to produce steam, but impurities such as hardness that were dissolved in the water do not transfer to the steam and remain in the boiler water. As evaporation continues, the ratio of impurities in the remaining water increases, so blowdown is the measure taken to discharge this water and dilute the concentration. ■What are the differences between the two types of blowdown? In addition to continuous blowdown, there is also bottom blowdown in boilers. Continuous blowdown: This is the constant discharge during operation. Bottom blowdown: This is used to remove scale and sludge that accumulate at the bottom of the boiler during shutdown. They are differentiated by their roles: continuous blowdown serves to continuously dilute from areas prone to water quality deterioration, while bottom blowdown is used to remove settled solids all at once. ■How is the blowdown amount determined? Generally, a method is employed where the electrical conductivity is measured, and if it exceeds a pre-set standard value, the blowdown amount is automatically adjusted. Please feel free to consult with us.

■Why is steam and condensate prone to corrosion? Boiler steam has a low level of impurities, making it easy for iron ions and copper ions to dissolve. Generally, high-purity water with few impurities has a poor buffering capacity to neutralize acids, and even a small amount of acidic components can significantly lower the pH, thereby increasing its corrosive nature that can dissolve metals. ■Why does the pH of condensate decrease? Condensate that has been heat exchanged and condensed tends to dissolve oxygen and carbon dioxide (CO2) easily. When CO2 dissolves in water, it forms carbonic acid, which lowers the pH. This decrease in pH is a cause of corrosion in piping. ■Why does maintaining alkalinity help prevent corrosion? Maintaining the pH of boiler water between 11.0 and 11.8 is considered desirable for corrosion prevention. In the alkaline range, a dense oxide film (magnetite) forms on the surface of iron, which is thought to protect the metal and suppress corrosion. ■What are some often-overlooked points of caution? Since the steam line is not included in the annual boiler performance inspection items, it requires attention from the management side. Please feel free to consult us first.

■There are various types of boilers! Boilers can be broadly classified as follows: Round boilers (vertical boilers, smoke tube boilers, fire tube boilers, fire tube boilers) Water tube boilers (natural circulation type, forced circulation type, once-through boilers) Cast iron boilers Specialty boilers (waste heat, special fuels, heat transfer fluids, electric boilers, etc.) To handle these various types of boilers, qualifications corresponding to the heat transfer area are required. ■The qualifications are divided into three categories: 1. Second-class boiler technician Can handle boilers with a heat transfer area of less than 25 square meters. 2. First-class boiler technician Can handle boilers with a heat transfer area of 25 square meters or more and less than 500 square meters. 3. Special-class boiler technician Can handle all boilers, including those with a heat transfer area of 500 square meters or more. ■Please consult us first. Feel free to consult us regarding the installation, inspection, or repair of boilers.

When it comes to boiler failures, people tend to imagine a large explosion, but the gradual progression of "corrosion" is also a significant factor that affects the lifespan of the equipment. ⬛︎ Types of Corrosion Corrosion in low-pressure boilers can be broadly classified into general corrosion, where the metal surface uniformly diminishes, and localized corrosion, where only specific areas are intensely affected. Localized corrosion includes pitting, which progresses deeply in spots, and crevice corrosion, which occurs at overlapping parts of components. From the perspective of maintaining healthy operation, localized corrosion is particularly concerning. Even if the overall structure appears sound, localized areas can progress deeply, leading to holes or leaks. ⬛︎ Key Points for Countermeasures To mitigate corrosion, managing water quality is fundamental. Specifically, it involves maintaining an appropriate pH (between 11.0 and 11.8), keeping harmful corrosive components below standard levels, removing dissolved oxygen (oxygen dissolved in water) that promotes corrosion, and ensuring that water is always flowing to prevent stagnation. Continuous maintenance of these factors requires regular water quality testing and chemical adjustments. Measures against corrosion through water treatment and guidelines for inspecting boiler equipment are explained in this document. Please download the document!

◼️ What is a steam trap? While steam is flashy, the real troublemaker in a factory's steam piping is the "water" that forms when steam cools. A steam trap is a device that automatically discharges condensate (drain) that accumulates in equipment and piping handling steam, such as boilers. It holds back the steam and allows only the condensate that has turned into water to escape. It can be understood as a "checkpoint that lets water through but not steam." ◼️ Purpose of installation When condensate accumulates in the piping, high-speed steam pushes the water out, causing water hammer (hydraulic shock) that impacts the piping and fittings. It is installed to prevent damage to equipment and leaks. ◼️ Points to be aware of There are multiple types of traps, such as bucket-type, each with different structures, so it is essential to understand the type when repairing or replacing them. Additionally, failures have two faces. If it breaks while closed, the condensate will not be discharged, leading to issues; if it breaks while open, steam will continue to leak, quietly wasting fuel. The latter is harder to notice, making regular inspections important. The structure of traps and how to conduct inspections and energy-saving diagnostics are explained in this document. Please download the material!

We received a message from the boiler manager of a certain chemical manufacturer’s factory. "Recently, the efficiency of the boiler has been declining. Is there any way to improve the efficiency?" The first thing our employee suspected was the deterioration of thermal efficiency due to scale buildup. Scale, in the first place, is a deposit of minerals such as magnesium, calcium, and silica that are contained in water. A common example of scale is the limescale that accumulates in kettles and electric pots. *For more details on the column, you can view it through the related link. For more information, please download the PDF or feel free to contact us.*

We offer boiler system upgrades and boiler replacements. As a main support case, when the softener for the boiler used in a tourist facility's experience train broke down, we proposed a refurbished used softener. We conducted a reinstallation tailored to the on-site environment, restoring soft water supply in a short period and at a low cost (about one-third of the price of a new unit). We were able to continue safe operations without stopping steam supply, quickly avoiding any impact on facility operations. [Proposal Details] ■ Selection of a well-maintained used machine in good condition ■ Proposal of a reinstallation plan tailored to the on-site piping and wiring environment ■ Balancing implementation within budget and short-term construction *For more details, please download the PDF or feel free to contact us.