Concrete batching plant scale kept out of boilers for six years
Concrete batching plant scale was costing a US concrete producer boiler efficiency across multiple plants. Hard water accelerated the build-up, frequent maintenance was needed to remove it, and high chemical usage was the only thing holding it in check. From 2018 HydroFLOW® i100 units were installed on the cold-water feed line to the boilers at each plant, with no shutdown required. Scale stopped forming, the boilers ran efficiently without chemical descaling, and six years on they are still clean. The result was the same at every plant, which is what the producer wanted to see.
The Challenges
- Concrete batching plant scale was reducing boiler efficiency across multiple sites
- Frequent maintenance was required to remove deposits
- High chemical usage was needed to control scale
- Hard water conditions accelerated scaling
- The producer wanted one approach it could repeat at every plant
The Solution
- Units installed: HydroFLOW® i100 at each plant
- Installation point: cold-water feed line to the boilers
- Installed: from 2018, with no shutdown required
- Previous treatment: high chemical usage and frequent maintenance
Rather than treat each boiler directly, the producer had the units fitted on the cold-water feed line, which protects everything downstream. The same installation was repeated at every plant, with no shutdown required. The signal disrupts the conditions that bond scale to surfaces, so deposits do not form. Concrete batching plant scale has been absent for six years.
