What is boiler carryover? A simple explanation of causes, countermeasures, and how to identify its occurrence.

■What happens during carryover? When carryover occurs, droplets of boiler water mix with steam, resulting in a decrease in steam purity. In applications where steam comes into direct contact with products, this can lead to a decline in quality. Additionally, in superheaters and steam turbines, scaling and corrosion due to salt concentration can progress, potentially leading to ruptures or damage incidents. ■Why does carryover occur? The main causes include excessively high salt concentrations in the boiler water (due to over-injection of chemicals or excessive concentration of water), contamination of feedwater with oils and fats, malfunctioning steam-water separators, and improper settings of operating water levels. The higher the salt concentration, the more likely carryover is to occur. ■How to prevent carryover? 1. Optimize the amount of chemical injection and blowdown to maintain appropriate salt concentration (managed by electrical conductivity). 2. Prevent contamination of feedwater with oils and fats. 3. Inspect steam-water separators (mist separators). 4. Optimize fluctuations in operating water levels and steam loads. ■How to confirm if it is occurring? You can confirm the occurrence of carryover by measuring the electrical conductivity and pH of the condensate from steam immediately after it exits the boiler. Small once-through boilers tend to have a higher incidence of carryover compared to cylindrical boilers and water-tube boilers, so extra caution is needed.

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