Boiler Design Research Articles

Numerical Study on Flame Geometric Characteristics of Ammonia-Fueled Small Boiler

Amidst global efforts to cut carbon emissions, the carbon-neutral fuel sector is at a crossroads of opportunity and challenge. The pursuit of clean, sustainable energy alternatives is critical. Ammonia, with its zero-carbon and hydrogen-rich profile, is emerging as a promising clean fuel, yet its combustion behavior in industrial boilers demands further study. This paper presents a numerical analysis of the flame geometry characteristics of ammonia combustion at an equivalence ratio of 1. The study delineates the dimensions of the flame, specifically its diameter and length, offering valuable insights that can inform the design of industrial boilers. This research contributes to the broader understanding of ammonia's role in the transition towards more sustainable energy solutions in industrial settings.

Improved sprayed water boiler design for steam production

The lengthy time required for conventional boilers to attain a steady state, their sizable size, the substantial pressure drop, and their high cost are all disadvantages. The objective of this study was to develop a novel design for a boiler to achieve better performance based on a sprayed water boiler (SWB) through injectors with a specific spray rate in a near-atomized form over tubes containing hot gases. As the water temperature in the SWB is equal to the temperature of the water sprayed by the injectors, the temperature difference between the hot gases and the water is higher than in the conventional boiler. A parametric study was conducted to investigate the main parameters affecting the boiler performance, such as the steam quantity and quality, the time required to reach the steady state condition, the size of the boiler, and the drop pressure on the hot-gas side. The results showed that the size of the SWB was significantly smaller than that of a conventional boiler. When generating steam of the same quantity and quality, the size of the SWB is one-third of the conventional size. This reduces the manufacturing costs of the boiler and the pressure drop of the hot gases inside the boiler. It was also found that the thermal efficiency of the SWB was higher, and the start-up time to reach a steady state of operation was less than 1% of the time required for the conventional boiler. To close the gaps in the theoretical design, an experimental test should be performed.

Оценка эффективности завихрения воздуха при распылении водоугольных суспензий пневматической форсункой

Due to modern requirements for environmental protection, introduction of environmentally friendly power engineering technologies involves search and development of new energy sources. One of the ways to meet these requirements and maintain the same level of energy production by thermal power plants is to use multicomponent fuels. The most promising and affordable heavy fuel oil from the point of view of energy, ecology and economy are coal-water slurries (CWS). In this regard, the study of the properties and characteristics of such fuels is relevant. The coal-water slurries have been prepared in a rotary hydrodynamic cavitation generator. A pneumatic atomizer with external mixing is used to spray the coal-water slurries. Interferometric Particle Imaging method is used to determine the average size of fuel droplets after atomization. The authors have conducted experimental studies of the characteristics of atomization of coal-water slurries based on lignite and pyrogenetic liquid with a pneumatic atomizer with a tangential supply of a spraying agent. A three-stage method to prepare lignite-based slurries with pyrogenetic liquid has been tested. It has been established that when using this technique, the fluidity of coal-water fuel is maintained even with the introduction of 20 % by weight of pyrogenetic liquid into the composition of coal-water slurries when replacing both water and coal in equal proportions. The kinematic viscosity of coal-water suspensions increases when pyrogenetic liquid is added, despite a decrease in the concentration of the solid component. The change of suspension density is insignificant. The results of the study of atomization process have shown that the tangential air supply to the atomizer leads to an increase of the jet spraying angle by 6° compared with direct supply. At the same time, the average droplet size in the jet of a two-component CWS with direct air supply is 8 % smaller. The results of the study have made it possible to obtain completely new knowledge that can significantly advance domestic and world science and technology in the field of power engineering, namely the technology of coal-water fuels atomization. Experimental studies have determined the main patterns of influence of the CWS properties and the method of spraying agent supply on the formation of a gas-drop jet. Such patterns will provide conditions for the effective atomization of quite viscous CWS in the combustion chambers of energy boilers. The results obtained will enable designers and constructors to develop highly efficient designs of steam and hot water boilers and gasifiers fueled by CWS.

Design and modifications of boiler mounting device in Asmara brewery factory

Energy and environment are closely related and important issues in the present all over world. Present industrial and others organization thought the unique of energy utilization and diverse source reviles such as coal, oil, gas, nuclear, hydropower, solar, wind and biofuel. The Non-renewable energy sources are being limited in this world and energy conservation is one of growing need nowadays. The major issues in the world’s energy consumption are getting used in boilers. Thus, this energy used has to be wisely consumed with great efficiency in industries. Boilers are considered as an important and an expensive property in many industries. In addition to initial cost, boilers have high operational and maintenance cost in order to secure production in safe and acceptable working conditions. In this study concerned with an energy saving, economic and environmental analysis of the fire tube boiler in ASMARA BREWERY. In this project, we concentrated on the improvement of boiler efficiency by recovering a portion of heat content of the flue gas. This is possible due to the most dominant device which is the economizer. The preexisting boiler was designed without an economizer. The present modification involved about the design of economizer in the boiler to reduce fuel consumption and thermal shock. Furthermore, in this type of boiler attain higher efficiency and little enhancement in the efficiency of the boiler will save an outsized amount of fuel and also help to reduce CO2 emission.

Numerical simulations and an experimental study for optimal design of a 1500 [formula omitted] water-tube condensing boiler

The present study is focused on investigating the condensation process and numerical simulation for optimal design of a 1500 kW water-tube condensing boiler. The specific geometry of the heat exchanger of this boiler involves compact arrangement of spiral coils to enhance heat transfer efficiency and achieve high capacity. Experimental validation is conducted on a 580 kW condensing boiler. Numerical simulations of the flow for gas and water sides of the boiler are performed in parallel using the ANSYS-FLUENT software with the k-omega (SST) turbulence model. Twelve models with different combustion chamber dimensions, coil numbers and revolutions are considered. Important design criteria include flue gas temperature, combustion chamber pressure and water pressure drop in the coils. The results indicate that increasing effective heating surface area and reducing coils gap decrease flue gas temperature to the dew point. Increasing coil revolutions has a greater impact on flue gas temperature and boiler weight compared to increasing coil numbers. With the same number of coils, by adding an extra revolution the weight is increased approximately 17 % and the effective heating surface area about 21 %. On the other hand, for the same number of revolutions, each additional spiral coil increases both of the weight and the effective heating surface area approximately 4 %. Moreover, with an increase in the number of the coils and a decrease in the number of revolutions, the pressure within the combustion chamber is decreased. By reducing the gap size, the flue gas temperature is reduced approximately 2 °C and the combustion chamber pressure is increased about 18 %. Base on the design criteria, the model six with 27 spiral coils and 7–8 revolutions, is identified as the optimal design. This progress and capability allows the design and manufacture of high-capacity boilers for residential sector as well as for industrial applications.

Analytical study on improving the efficiency and environmental friendliness of solid organic fuels

The purpose of this study was to analyse methods of increasing the efficiency and environmental friendliness of the use of solid organic fuels (SOF) in electricity generation. This study employed a comprehensive approach to the analysis and optimisation of technological processes, operational systems, and environmental aspects of the use of SOF. The study found that the use of modern technologies, such as gasification and pyrolysis, considerably increases the efficiency of converting SOF into electricity. Optimisation of boiler and turbine designs and automation of fuel supply systems helps to reduce energy losses and improve overall system efficiency. It was found that the use of new materials for boilers increases their resistance to corrosion and erosion, which extends the service life of the equipment. The study also showed that the introduction of gas cleaning and secondary combustion systems significantly reduces emissions of harmful substances, which improves environmental performance. An analysis of ash utilisation opportunities showed that its use as a fertiliser or construction material is a promising area. The study proved that an integrated approach to the use of SOF can substantially increase their efficiency and environmental friendliness. The findings of the study suggest that the use of innovative methods of combustion process control allows achieving more stable and efficient power generation. It was proved that the introduction of automated monitoring and control systems reduces operating costs and increases the reliability of equipment. The study also found that the use of advanced analytical tools to predict equipment wear and tear allows for prompt preventive maintenance, which further increases the efficiency and duration of uninterrupted operation of energy systems

Experimental and simulation study on coal-fired power generation coupling with fluidized bed biomass gasification

Positive-pressure fluidized bed technology utilizes the pressure generated by biomass gasification to facilitate further combustion within the furnace. This technique addresses the safety risks associated with external pressure in fluidizing medium and high-temperature situations and reduces equipment investment and operating expenses. However, research on the effects of the positive-pressure process in fluidized beds on gasification coupled with coal-fired power generation systems is scarce. To fill this research gap, extensive experimentation and Aspen Plus simulation were conducted to investigate the impact of equivalence ratio (ER), gasification pressure, and gasification temperature on the gasification performance. A 660 MW coal-fired boiler model was established to reveal the coupling effect on flue gas temperature and thermal efficiency by gasification from a positive-pressure fluidized bed on the boiler, and its accuracy was proved by comparing the actual boiler design parameters. The power generation cost of the positive-pressure gasification coupled coal-fired power generation system is calculated with the established model. The results indicate that an increase in gasification pressure from 4000Pa to 8000Pa resulted in no significant change in the operating indicators of the boiler, with the tail gas temperature near 132 °C and a boiler thermal efficiency of 92.68 %. Gas yield, carbon conversion rate, and gasification efficiency were positively correlated with gasification temperature and ER. However, the heat value of combustible gas increased with the gasification temperature and decreased with an increase in ER. With the rise of the biomass gas blending ratio, the power generation cost of the unit gradually decreases. Respectively, the positive -pressure would lower the power generation costs of a 660 MW coal-fired boiler by 5.76 × 105$/year. This study demonstrates that positive-pressure fluidized bed gasification may retain high gas yields and efficiency, significantly lowering equipment investment and operating expenses, as a very efficient energy-saving and carbon-reduction technique.

Multi-objective optimization design of high-pressure plate-fin ammonia boiler based on MO-SHERPA algorithm

With the rapid development of electrification, the high-pressure plate-fin ammonia boiler has been widely used as an effective thermal management solution, which has stimulated the demand for its structure design and optimization. The aim of this study was to establish a multi-objective optimization design method for high-pressure plate-fin ammonia boiler based on the hybrid and adaptive search strategy of MO-SHERPA and CFD simulation. Based on this method, a set of pareto-optimal solutions were obtained, and then the optimal configuration with lightest weight and high heat transfer performance was determined by calculating the deviation for weighted sum of comprehensive performance factor, entropy generation rate and structure weight. The effects of fin structural parameters of ammonia boiler were further examined on its performance. The results showed that increasing the spacing and height of offset strip fin and reducing its thickness could effectively improve the heat transfer performance. This study provides a theoretical method and some guidelines for the structural design of ammonia boiler with high operating pressure.

Enhancing Resistance to Corrosion, Erosion and Oxidation of Boiler Steels by Surface Modification Techniques

In coal based thermal power plant, the boiler components (superheater, combustion chamber, superheater tubes, boiler walls, reheater etc.) are subjected to harsh environment characterized by high temperatures, aggressive combustion products, and abrasive particles. Corrosion, erosion, and oxidation relentlessly reduce their lifespan and efficiency, posing significant economic and safety concerns. This review explores the potential of surface modification techniques to act as a valiant shield against these destructive forces, extending the life, enhancing the performance, and ensuring the safe operation of boiler components. In this articles various surface modifications techniques including their merits and demerits are discussed with emphasis on thermal spray techniques. From established methods like thermal spraying and laser cladding to innovative approaches like nanocoatings and electrochemical treatments, each technique is meticulously examined for its effectiveness in boosting corrosion resistance, mitigating erosion wear, and minimizing oxidation at crucial boiler locations. This review culminates in a compelling vision of the future, where sophisticated surface modification techniques become an integral part of boiler design and maintenance strategies. By harnessing the power of these technologies, we can usher in an era of more efficient, reliable, and sustainable boiler operation, safeguarding investments and protecting the environment.

Concept Design of the WRB-6 Water-Tube Boiler with a Stepped Grate and a Furnace for Burning Straw Bales in a Cigar System

The article presents the conceptual design of the solid fuel from the forest and sawmill production waste and agricultural waste biomass-fired water boiler. The project was supported by thermal and flow calculations. The designed WRB-6 boiler is a 3-pass unit with a fully screened furnace chamber and is equipment of a local biomass heating plant. It is fired with biomass, transported over no more than 30 km. The furnace has a double function – dual fuel. Both fuels can be burned simultaneously or alternately, depending on seasonal availability. In the front part there is a channel for feeding and burning large bales of cereal straw. The lower closure of the chamber is a mechanically inclined grate for the combustion of wood biomass in the granulation of chips. As part of the work, calculations of the amount of biomass fuels possible to be obtained on the local market with economy of delivery were also performed. As a result of the calculations, the temperatures of water and flue gas at the outlet, boiler efficiency, slagging and impurity indices for biomass were also presented.

Experimental Study on Gas-Solid Two-Phase Flow Characteristics of a Vertical Cyclone Combustor System.

According to the design and operational parameters of the cyclone liquid slag-discharging boiler, an experimental platform for the cyclone burner was designed and constructed in a cold state based on the principle of similarity. The experimental study investigated the effects of parameters, such as swirl-vane angles, coal concentration, operating parameters, and particle size, on the flow distribution and vertical riser resistance characteristics of the vertical cyclone burner. The results showed that there were differences in flow distribution among the cyclone burners, and the most uniform flow distribution was achieved when the swirl-vane angle of the primary air was 30°. The concentration of pulverized coal significantly influenced the pressure drop in the vertical ascending section, which increased with higher concentrations of pulverized coal. When the concentration of pulverized coal remains constant, the pipeline pressure drop is minimized at a primary air velocity of 7.5 m/s. As the secondary wind speed increased, the pressure drop consistently rose; when the secondary wind speed is 22 m/s, the pressure drop of the pipeline is the maximum; however, excessively high secondary wind speeds were found to be detrimental to the formation of an optimal aerodynamic field in the burner. Furthermore, when the pulverized coal concentration was held constant, materials with larger particle sizes exhibited the highest pressure drop. When the particle size increases from 50 to 150 μm, the pressure drop of the vertical riser segment also increases. Finally, based on the Barth additional pressure drop theory, the pressure drop formula of the vertical riser is fitted by a dimensional analysis method, and the correlation formula of the pressure drop test of gas-solid two-phase flow in the vertical riser is obtained.

Optimizing biomass combustion in a 130 t/h grate boiler: Assessing gas-phase reaction models and primary air distribution strategies

Grate-firing technology is widely used for biomass combustion for heat and power production due to its good fuel flexibility. However, grate boilers often suffer from high unburnout, low efficiency, and high emissions, and require optimization to improve their performance. The distribution of primary air along the grate length significantly affects combustion and pollutant formation behaviors in the furnace; however, this effect is often under-investigated and poorly quantified. In this study, combustion of corn stover in a 130 t/h grate boiler is investigated experimentally and numerically. To establish a reliable baseline computational fluid dynamics (CFD) model and provide valuable reference for modeling and optimizing this industrial grate boiler, this study first investigates the applicability of the commonly used gas-phase reaction models. The finite rate/eddy dissipation model is found to outperform other gas-phase reaction models such as eddy dissipation model and eddy dissipation concept, which well predicts the temperature and shape of the flame in both the kinetics-controlled primary combustion zone and the diffusion-controlled burnout zone and shows the best agreement with the measured and site observations. Then, the study simulates and quantifies the effects of different primary air distribution modes (uniform, staged and refined-staged) on combustion performance of the boiler. Compared with the uniform primary air distribution, both the staged and refined-staged primary air distribution show an obvious increase in the char burnout ratio, from 76.5 % to 87.8 % and 95.5 %, respectively. Furthermore, the CO concentration at the furnace outlet is remarkably reduced, from 3178 ppm to 2766 ppm and 1917 ppm, respectively. This demonstrates that reasonable air supply in the latter two primary air distribution cases facilitates complete combustion in both the fuel-bed and freeboard. Moreover, in the latter two cases, the temperature distribution in the freeboard becomes more uniform, and the local oxygen-rich regions are eliminated. These are beneficial in suppressing the NO formation, as the emission of which decreases from 172 mg/m3 (at 11 % O2) to 161 mg/m3 and 156 mg/m3, respectively. This work provides important theoretical guidance for the accurate modeling and optimization of grate-firing boilers as well as the design of new grate boilers.

Influence of the Main Working Parameters and Geometrical Parameters on the Supercritical CO2 Flow Instability in a Heated Tube

Supercritical CO2 (sCO2) flow instability is an issue that must be considered in the reasonable design of sCO2 boiler. Because it can cause equipment vibration and heat transfer deterioration. In this article, a numerical model for the sCO2 flow instability in the single tube was developed. Different from the traditional model, the effects of metal heat storage and axial heat conduction in the tube wall were considered. The influence of main parameters on trans-pseudo-critical number (N TPC) and oscillation period (t 0) was studied, with the tube length (L) from 3 to 11 m and the inner diameter (D in) from 10 to 22 mm. N TPC increases with increasing the inlet pressure (P in), mass flux (G), inclination angle (α), and the inlet local resistance coefficient (K in). N TPC decreases with D in and outlet local resistance coefficient (K out). The effects of the sub-pseudo-critical number (N SUBPC), wall thickness (WT) and L on N TPC are nonlinear. With increasing N SUBPC, WT, L, D in, and K out, t 0 increase. As G, α, and K in increase, t 0 becomes smaller. When N SUBPC is lower than 0.9146, t 0 rises with P in increasing. It is opposite with N SUBPC higher than 0.9146.

Experimental study on the sintering characteristics of biomass ash

The alkaline metal content in biomass is high, which leads to a low initial sintering temperature. Therefore, during the process of direct biomass combustion for power generation, there are serious problems such as ash deposition and slagging on the heating surface, which has become a technical bottleneck for the safe, stable and long-term operation of boilers. In industry, the melting characteristics of ash are commonly used to guide boiler design and operation. However, traditional measurement of ash melting temperature has a large subjective error, and the releasing of alkaline metals during the measurement process results bit higher value, which affects the accuracy of the measured characteristic temperature. Comparingly, the initial sintering temperature is lower than the deformation temperature of the ash. This article provides a device for measuring the sintering temperature of biomass ash by using the pressure drop method. A novel two ash chamber system was invented, in which the alkali element released from the first ash chamber was captured by the downstream second ash chamber to compensate the escaping of alkali element. The initial sintering temperature of the second ash chamber has more accuracy with lower value than that measured by the traditional single sample chamber. XRD was used to analyze the mineral composition and causes of sintering of the ash samples before and after sintering. The results show that the sintering mechanisms of different types of biomass are different. In addition, combined with SEM analysis of rice husk, fruit core, rapeseed straw, and corn straw, the results show that the initial sintering temperature of the ash samples measured by the double chamber measurement method is more accurate than that measured by the single chamber measurement method, further validating the reliability of the two ash column system.

Reduction of emissions and improvement of dynamic responses of a supercritical clean coal generation unit via neural network inverse control strategy

Coal power plants have been a major source of undesirable emissions. Despite the technological advancements in renewable energies, coal units are still in-service in many developed and developing countries due to their reliability, adequacy, and flexibility for power delivery. There are some promising technologies for cleaner operation during power production from coal, including supercritical boiler (SC) design and carbon capture and storage (CCS), however, the challenging in innovating effective methods is still open to expand the boundary of knowledge in this speciality. This paper introduces a novel and simple method for reducing CO2 emissions and improving the dynamic responses of a 600 MW SC coal power plant by Artificial Neural Network (ANN) technique. A wide-range data-driven feedforward ANN model has been identified and verified for the various operations recorded as closed-loop data-sets, which covers all situations of startup, once-through mode, and even emergency shutdown of the unit. The closed-loop SC plant model has been augmented with an inverse multivariable coordinate NN controller, developed by analogous learning algorithm to improve the plant automation. With precisely selected setpoints, as operational rules, of temperature, pressure, and earliest possible power demand signals, the automated SC plant has been capable to operate with lower coal consumption - and thus lower emissions – than the existing operation strategy during startup, normal operation, and emergency shutdown modes. The improvement in dynamic responses have been quantified through simulations with comparison with existing performance, which have resulted in an overall average reduction of 2.143 Kg/s in coal consumption.

State of art on FEM approach in inverse heat transfer problems for different materials

The present study investigates the utilisation of the Finite Element Method (FEM) in addressing Inverse Heat Transfer issues associated with diverse materials. The Finite Element Method (FEM) is a widely utilised methodology in engineering design that effectively tackles thermal problems and heat transfer. The versatility of this technology transcends the domain of engineering and has been found to have practical applications in various fields such as biomedical science, aerospace, and chemistry. The Finite Element Method (FEM) has demonstrated its proficiency in addressing inverse heat transfer problems that are linked to a variety of materials, each of which has unique characteristics. The following discourse proceeds to conduct a thorough analysis of the application of the Finite Element Method (FEM) in resolving inverse heat transfer predicaments with a view to achieving optimal results. The present paper expounds upon the inherent benefits and drawbacks associated with the utilisation of finite element techniques for the purpose of resolving inverse heat transfer problems. Furthermore, the present study examines the pragmatic implementation of the Finite Element Method (FEM) in addressing heat transfer issues in diverse fields, such as Boiler design, Heat exchanger design, Cooling tower design, and Nuclear reactor design. The paper offers tangible illustrations of how the FEM method can be utilised to tackle practical heat transfer difficulties by emphasising these particular applications. This paper provides a contribution to the comprehension of the effectiveness of the Finite Element Method when addressing inverse heat transfer problems. The aforementioned statement highlights the adaptability of this methodology in managing diverse substances with distinct characteristics and furnishes discernment into its benefits and drawbacks. Moreover, the article elucidates the multifarious implementations of the Finite Element Method (FEM) in the domain of thermal energy transfer, providing pragmatic exemplars of its efficacy in areas such as the design of boilers, heat exchangers, cooling towers, and nuclear reactors.

Evaluation of the Optimal Conditions for Oxygen-Rich and Oxygen-Lean Torrefaction of Forestry Byproduct as a Fuel

Wood biomass is an alternative to fossil fuels. However, biomass use has several limitations. Torrefaction, in which reduction conditions prevail to overcome these limitations, has been suggested. Here, torrefaction using different wood chips (Liriodendron tulipifera, Populus canadensis, Pinus rigida, and Pinus koraiensis) was conducted under oxygen-rich and oxygen-lean conditions to determine the effects of oxygen. Torrefaction was conducted at 230–310 °C for 1 h. A mass yield difference of 3.53–20.02% p (percentage point) was observed between oxygen-lean and oxygen-rich conditions. The calorific value increased by a maximum of 50.95% and 48.48% under oxygen-rich and oxygen-lean conditions, respectively. Decarbonization (DC), dehydrogenation (DH), and deoxygenation (DO) occurred in the following order because of dehydration and devolatilization during biomass torrefaction: DO > DH > DC. The calorific value of the torrefied biomass increased linearly with the extent of all three processes. The combustibility index and volatile ignitability were calculated based on proximate composition to suggest the optimal conditions for replacing anthracite and bituminous coal. This study provides suggestions for stable operation in a standard boiler design.

Redesign of Boiler Heat Recovery Steam Generator (HRSG) on The Utilization of Waste Gas in The Cement Industry

Approximately, 20%-50% of the total energy consumption during cement production is disposed of unintendedly as waste heat. This is very unfortunate considering that this waste heat still has the energy that can be further utilized. The heat recovery steam generator (HRSG) boiler system is one of widely used solutions in the chemical industry process to save operating costs in the chemical industry process. The purpose of this research is to determine the amount of energy that can be saved by implementing the HRSG system under ideal operating conditions. Based on the simulation results, the HRSG boiler design can produce steam with a temperature of 235°C and subsequently reduce the flue gas temperature from 244°C to 140.6°C. The HRSG system produces energy in the power turbine up to 1,756 kW with total energy exchanged in the system of 17,567.38 kW from the total energy in the flue gas of 20,693.96 kW and provides an overall efficiency of 84.61% at steady state conditions.Keywords: Aspen HYSYS, Waste Heat, Heat Recovery Steam Generator (HRSG)

Numerical Simulation of Flow Characteristics in Circulating Fluidized Bed Boiler

Considering the different particle sizes in the circulating fluidized bed boiler furnace, the binary-component method is used to analyze the flow characteristics in the circulating fluidized bed boiler furnace. The particle dynamics principle is used to solve the gas-solid two-phase mass equation, momentum equation and turbulence equation using the two-fluid model. The model uses more mature boiler design drawings, reproduces the flow characteristics of particles in the furnace, obtains the shape of the lower bubbling bed and the fast upper bed, and analyses the gas phase velocity and particle distribution in the furnace under the design parameters.

Film-forming amine product as an alternative to carbohydrazide oxygen scavenger in high pressure boilers

Hydrazine has been largely replaced by carbohydrazide (CHZ) as an oxygen scavenger due to safety and health concerns and CHZ is now used in Saline Water Conversion Corporation (SWCC) high pressure boilers. However, the operational problem of phosphate hide-out has become a continuous challenge for the plant operators. Advances in boiler water treatment have shown that effective corrosion control and prevention of scaling can be achieved by using a mixture of film-forming and alkalizing amines and polycarboxylates [Film Forming Amine Product (FFAP)]. With the use of FFAP, carbohydrazide/ammonia treatment of make-up water and phosphate treatment in the drum will not be required. A uniform FFAP formulation was used throughout the test.The evaluation study was carried out at a boiler of the Yanbu Phase 1 Desalination and Power Plant (Mitsubishi) generating 60 MWh, with make-up water of 15 t h−1 producing 330 t h−1 steam at a pressure of 67 barg and temperature of 480 °C.The trial provided evidence that FFAP was a good alternative to use of an oxygen scavenger. Changeover from CHZ to FFAP without phosphate addition in the drum was done initially by dosing FFAP from both hydrazine tank and phosphate tank so that pH was maintained to the required values in both feed water and drum water. With the optimal dose rate (0.6 ppm) maintaining FFAP in the range of 0.3–1.0 ppm in feed water, all the key parameters (pH, ammonia and specific conductivity) were within the specified boiler design limits. The average corrosion rates on the water side were low for both CHZ and FFAP treatment (0.009 ± 0.001 mm y−1), however FFAP treated coupons showed much lower corrosion rates compared to CHZ in the steam side (0.0006 ± 0.0003 mm y−1 cf. 0.0075 ± 0.0006 mm y−1).