Boiler Water Softening System - Efficient Scale Prevention Solution

1. Why must boilers use softened water?

The hazards of scale and industry standards

⚠️ Loss of thermal efficiency: 1 mm of scale increases fuel consumption by 10-15%

⚠️ Safety hazards: Scale causes metal overheating and deformation (Increased risk of pipe bursts)

📊 Hardness Standards:

 • Boiler feedwater requirement: ≤0.03 mmol/L

 • Chemical treatment upper limit: ≤4 mmol/L

Industry Data: 90% of boiler failures are related to water quality (China Special Equipment Inspection and Research Institute report).

2. Softening System Selection Guide

Three-tiered scheme based on raw water hardness

① Single-stage softening (hardness ≤ 6 mmol/L)  

Single-tank system:  

 • Resin capacity: 50–100 L  

 • Regeneration cycle: 24–48 hours  

② Two-stage series (hardness 6–12 mmol/L)  

Dual-tank alternating operation:  

 • Stable effluent hardness ≤ 0.01 mmol/L  

 • Salt consumption reduced by 30%

③ Multi-stage treatment (hardness ≥ 12 mmol/L)  

Pre-treatment + two-stage softening:  

 • Quartz sand filtration (turbidity < 5 NTU)  

 • Activated carbon adsorption (removal of residual chlorine)  

Scheme comparison table:  

3. Detailed explanation of the 5-step regeneration process

Ensuring long-term resin activity

1️⃣ Backwash (5-15 minutes):

 • Flow rate: 15-20 m/h

 • Remove resin bed deposits

2️⃣ Brine absorption (30 minutes):

 • Brine concentration: 8-10%

 • Slow flow rate (4-6 m/h)

3️⃣ Slow rinse (30 minutes):  

 • Replace residual brine  

4️⃣ Fast rinse (5–15 minutes):  

 • Operating flow rate (15–20 m/h)  

5️⃣ Brine tank refill (automatic):  

 • Prepare brine for the next regeneration cycle  

4. Successful case: Boiler renovation at a textile factory

Operational data from a project in Jiangsu Province

1. Original issue:

 • Raw water hardness: 8.5 mmol/L

 • Scale removal once a month (2 days of downtime)

2. Solution:

 • Installation of a two-stage softening system

 • Equipped with a 50 μm security filter

3. Results:

✅ Boiler thermal efficiency improved by 12%

✅ Scale cleaning cycle extended to 2 years

✅ Passed TSG G0001-2012 inspection

5. Key Equipment Configuration

3 Core Component Requirements

1️⃣ Resin Tank:

 • FRP material (pressure-resistant up to 0.6 MPa)

 • Leak-proof resin distributors at the top and bottom

2️⃣ Control valve: Fully automatic multi-port valve (supports time-based/flow-triggered regeneration)

3️⃣ Salt tank: PE material (includes salt solution filter)

Smart upgrade options:

 • Online hardness monitor

 • Mobile app remote monitoring

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