Posted: January 14th, 2022

Boiler Quality Water Softener: How to Reduce Risks to Boilers from Hard Water and Hardness Leakage

Industrial boilers are used in a variety of operations ranging from power generation to chemical processing to food & beverage manufacturing. They utilize water in large quantities and are particularly sensitive to total dissolved solids (TDS), especially hardness such as the ions of magnesium, calcium, and iron. If these solids are not removed effectively, they can cause boiler scaling. Scaling prevents proper boiler heat transfer, increases costs, causes early boiler failure, and increases downtime risk for the boiler and the processes into which it feeds.
The usual solution for hard water is a water softener, but it is important to choose the correct water softener system for an industrial water process. A standard industrial water softener provides good water quality and is suitable for many industrial water softening processes
However, that same standard industrial water softener might not be appropriate for critical water softening applications that require the highest quality soft water. Boilers fall into this category because any hardness can cause costly inefficiencies due to scaling,  unplanned downtime or failure that is not acceptable.
For boiler applications and other critical systems, the patent-pending Zero Hardness™ failsafe water softener system  is the preferred solution. The Zero Hardness™ system is designed to create a continuous supply of very high quality soft water for boilers. It does this by treating the water two times, in series, protecting your boiler and other critical systems through several features including the elimination of offline softening tanks.  Zero Hardness industrial water softener systems can be designed as a twin or a triple softener system.  
The unique double pass worker-polisher design means two softeners in the Zero Hardness™ failsafe system are online all the time. If one softener tank were to fail, the other tank would still soften the water with no lack of soft water at any time. This eliminates the most common point of failure in standard softener systems.
A bonus of the Zero Hardness™ failsafe water softener system is that its lower and more efficient brining rates can achieve water quality similar to that of higher brining rates by having the first softener remove most of the hardness and the second polish the water. Using a lower brining rate while flowing in a worker-polisher design can cut salt consumption upwards of 40 percent, while still reducing hardness leakage and water consumption.
If you have a boiler, industrial reverse osmosis system or other critical water softening requirement, you can have the highest quality soft water for boilers while also reducing risk, cost, and downtime by using the Zero Hardness™ failsafe water softener system. Learn more about our patent-pending system at 888-569-2837 or