An alternative to cooling towers in the use of single-pass sea water cooling, where sea water is pumped through a heat exchanger, before being returned to the sea. This has the advantage of not leading to a heghten concentration level of scaling in the water, which in turn leads to scaling. However, these systems tend to suffer from problematic biofuling on the heat exchanger surfaces.

Government City Hall, Hong Kong

The cooling system in this government building was sufferning continualy efficiency reduction due the the biofouling on the heat exchanger blocking heat transfer and impeding its operation. After monitoring the temperature, flow rate and power consumption (without HydroFLOW®) for a year, a unit was installed and the parameters monitored.

It was found that while the efficiency of the unprotected system gradually dcreaased, when protected by HydroFLOW® the efficiency of the heat exchanger actually actually increased, leading to huge savings in energy and electricity costs.

• Electricity saving over trial period of 25,780 kWh
• Represents a saving of 17.3%
• Saving over per year of $23,202 dollars

Factories and manufacturing equipment produce large amounts of heat than need to be dissipated. Cooling systems are vulnerable to limescale, whether that be cooling towers, heat exchangers or cooling channels withing the production equipment itself. Limescale blockages can reuire expensive cleaning procedures and lead to excessive downtime and lost production. HydroFLOW can keep your equipment running smoothly.

Plastmann Corporation, Injection moulding

The Plastmann Corporation had a set of four cooling towers serving 3 chillers and a bank of 40 injection moulding machines. The factory used well water with a hardness of 10 grains (about 170ppm), meaning the chillers and moulds would continually suffer from scale. Despite preventative cleaning every 3-6 months, at least one or two injection machines would block, overheat and need to be stopped in the intervening period.

• 50 -75% Savings on Maintenance Costs
• Chemical usage reduced to near zero
• Injection machines run without stoppage for a year.

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This commercial trucking company from Rosemount, Minnesota, USA, operated a 60 horse power low pressure natural gas steam boiler, with the steam used during the truck wash process. The water used in the boiler was well water with calcium carbonate hardness of over 200 PPM. A water softener reduced the hardness to roughly 30 PPM. Antiscalant was also used. Due to excessive scale accumulation in the boiler, even with softening and chemical usage, the head of maintenance decided to evaluate HydroFLOW®’s ability to descale the steam boiler and prevent further scale formation. A unit was installed on August the 1st, 2013. The boiler was not cleaned on installation to allow for evaluation of the HydroFLOW® unit's ability to remove existing scale.

Results

After 6 months the boiler was inspected. Flakes and layers of scale were gradually being removed and the remaining scale was very brittle. Stack temperature has dropped from 296° F to 272° F in 6 months, which demonstrates an 8% increase in heat transfer efficiency. The efficiency is expected to further increase as scale continues to be removed from the system. The removal of scale can be greatly accelerated if the steam boiler will be fed with unsoftened water, however the water softener was not turned off s it serves the entire truck wash system and there is no bypass for the boiler feed.

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