Carryover in industrial boilers isn’t merely an inconvenience—it’s a significant operational impact that can compromise system integrity, reduce efficiency, and lead to costly downtime. At ETI, we have expertise to identify and problem-solve the cause of steam caryover. Causes may include chemistry, design, mechanical and/or operating factors.
Foam in boiler systems occurs is the result of various chemistry factors, such as, elevated dissolved solids, oils, organic materials, and/or treatment chemicals reach critical concentrations and reduce surface tension at the steam-water interface. This seemingly minor issue can cascade into serious operational problems:
Carryover Contamination: Foam facilitates the transport of boiler water impurities into steam lines, contaminating downstream equipment
Reduced Heat Transfer: Foam layers act as insulators, decreasing thermal efficiency and increasing fuel consumption
False Water Level Readings: Foam can trigger inaccurate level gauge readings, risking dry-firing or flooding conditions
Mechanical Damage: Impurities carried by foam can deposit on turbine blades and other critical components
Increased Blowdown Requirements: Attempting to control foam through additional blowdown wastes water, chemicals, and energy
Even well-maintained boiler systems can experience foam formation during load swings, feedwater quality fluctuations, or after maintenance activities. ETI’s anti-foam solution provides the operational stability your system demands in all conditions.
Our advanced anti-foam product and custom-blended formulations represent the culmination of decades of research specifically focused on high-pressure, high-temperature industrial environments.
Thermal Stability Under Extreme Conditions
Standard defoamers can break down under boiler operating conditions, providing only temporary relief. ETI’s anti-foam technology utilizes thermally stable compounds engineered to maintain effectiveness even under extreme pressure and temperature conditions, providing consistent foam suppression throughout your operational cycle.
Our anti-foam solutions are designed to work synergistically with your existing water treatment chemistry, including:
Oxygen scavengers
Scale inhibitors
Corrosion inhibitors
Alkalinity builders
This compatibility ensures foam control without compromising your overall water treatment program effectiveness.
ETI’s formulations effectively suppress foam thus maintaining steam purity standards including compliance with FDA, USDA, Kosher and Organic certified operations. Our products are engineered to:
Minimize chemical carryover
Preserve steam quality
Protect downstream equipment
Meet stringent process requirements
We are committed to delivering the highest quality product and making the process as easy as possible for you,.
Our anti-foam solutions are precisely formulated for specific boiler applications:
Fire-Tube Boilers Provides foam control while protecting tube sheets and fire-side surfaces from temperature excursions caused by foam-related heat transfer inefficiencies.
Water-Tube Boilers Delivers reliable foam suppression while maintaining circulation patterns and preventing deposition on critical heat transfer surfaces.
High-Pressure Steam Systems Specialized formulations for high-pressure applications where foam-related carryover can damage expensive turbine components and reduce generation efficiency.
Heat Recovery Steam Generators Tailored solutions for complex HRSG systems where variable loads and temperatures create challenging conditions for conventional defoamers.
Process Steam Applications Ultra-pure formulations for operations where steam quality directly impacts product quality and process integrity.
Many facilities underestimate the financial impact of foam problems until experiencing significant consequences:
Energy Losses: Foam-insulated heat transfer surfaces require 5-15% more fuel to maintain steam production
Unplanned Downtime: Foam-induced carryover can necessitate emergency shutdowns for cleaning and repairs
Reduced Equipment Lifespan: Deposits from foam-related carryover accelerate component deterioration
Increased Maintenance Costs: More frequent cleaning and parts replacement due to contamination
Production Losses: Process interruptions from inconsistent steam quality or emergency boiler shutdowns
Transitioning to an optimized foam control program requires expertise. ETI’s comprehensive approach includes:
Our specialists analyze your specific operational parameters, feedwater quality, pressure cycles, and existing treatment program to identify foam formation risks and optimal control strategies.
Based on your specific system characteristics, we recommend the ideal anti-foam solution from our product line or develop custom formulations for unique operational challenges.
We design application protocols that ensure optimal dosing during steady-state operation and anticipate increased requirements during risk periods like startups, load swings, and water quality fluctuations.
Our technical support team helps implement monitoring strategies to ensure continuous foam control and system protection while minimizing chemical usage.
ETI’s anti-foam solutions have delivered measurable improvements for industrial boiler operations across multiple sectors:
Power Generation: Maintained steam purity specifications while eliminating turbine deposition issues
Food Processing: Ensured consistent, high-quality process steam while reducing boiler maintenance requirements
Chemical Manufacturing: Eliminated foam-related production interruptions while extending equipment life
Pulp and Paper: Improved steam quality while reducing carryover-related deposition in dryer sections
Healthcare: Maintained reliable steam generation for critical sterilization processes
ETI’s approach to foam control goes beyond simple chemical addition. Our comprehensive solutions provide:
Integration with your complete water treatment program
Water treater training on foam prevention strategies
Troubleshooting support for challenging conditions
Regular program review and optimization
Protecting your boiler system from foam-related problems demands more than basic defoaming chemistry—it requires a sophisticated understanding of boiler operations, water chemistry, and system dynamics.
Contact our specialists today to discover how ETI’s advanced anti-foam solutions can enhance your boiler system stability, improve operational efficiency, and reduce maintenance costs through superior chemistry.
Customer
60 Thousand Oaks Blvd.
Suite #105
Morgantown, PA 19543