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Protecting Concrete Facility Infrastructure: Prolonged Pipe Life in Sand Heating Systems with Aquaguard 841
At a glance
A concrete site using a direct injection steam generator faced issues with high deposit formation, corrosion, and frequent pipe replacements. Guardian Chemicals introduced Aquaguard 841 treatment, which improved the system’s performance and extended the service life of the pipes.
Key metrics
ZERO
Mid-Season Shutdowns
ELIMINATED
PIPE REPLACEMENTS
33% DROP
IN ANNUAL CHEMICAL CONSUMPTION
Why sand heating systems are hard on steam piping
Ready-mix concrete plants heat aggregate in cold weather so concrete can be batched and placed properly. A common method injects steam directly into the sand bins.
That setup is tough on the steam system. Water quality problems show up as scale in the steam generator and corrosion in the steel piping. Scale cuts efficiency. Corrosion leads to leaks, pipe replacement and shutdowns in the middle of the season, when the plant needs heat most.
This ready-mix facility was replacing its steel piping every 1.5 to 2 years, and deposits in the steam generator were raising maintenance costs.
Challenges
A concrete ready-mix facility with a steam generator sand bin heating system suffered from high levels of scale build-up and corrosion. Corrosion of steel piping resulted in pipe replacements every 1.5-2 years while deposit formation in the steam generator reduced efficiency and increased maintenance costs.
Solutions
Conventional treatments were replaced with Aquaguard 841 and HR2. Aquaguard 841 treatment resulted in a protective film preventing corrosion on all system surfaces. Scale and deposit formation were reduced by the addition of Aquaguard HR2, which improved monitoring and water softener maintenance.
Results
Extended Pipe Service Life
Before Aquaguard 841 treatment, pipes were replaced every 1.5 to 2 years. Four years after starting Aquaguard 841 treatment, the original pipes are in good condition and remain in service.
Reduced Chemical Consumption and Maintenance Costs
Using a filming treatment instead of a conventional water treatment program reduced chemical consumption by 33%. Scale prevention and corrosion control reduced maintenance costs and eliminated mid-season shutdowns for pipe repairs.
Improved System Performance
Reduced deposit formation and corrosion, which lead to a more efficient and reliable steam generator system.
Data
Learn more about our Water Treatment chemistry.
The AQUAGUARD 841 utilizes an innovative formulation of film forming and volatile corrosion inhibitors, pH buffering agents, dispersants and cleaning agents to provide complete protection to the boiler and condensate system.
Frequently asked questions
What treatment was used?
Aquaguard 841, which forms a protective film on system surfaces, together with Aquaguard HR2 to reduce scale and deposits.
How long do the pipes last now?
Four years after treatment started, the original pipes were in good condition and still in service. Before, they were replaced every 1.5 to 2 years.
Did chemical use change?
Yes. Using a filming treatment instead of a conventional program cut chemical consumption by 33%.
What happened to mid-season shutdowns?
They were eliminated. Better scale and corrosion control removed the need for mid-season pipe repairs.