Providing Energy-saving, De-scaling and Cost-saving Solutions 【 Chem-Free 】 Non-chemical Anti-scaling System For Boiler

 Water is known as the "universal solvent". Wherever it goes, it dissolves small particles of everything it contacts. It has the capability to entrap other substances and tends to cluster around every non-water particle, forming conglomerations or complexes. The more minerals it carries, the harder it is considered to be.

Hard lime scale resulting from mineral deposits in untreated hard water is a major problem in boilers, cooling towers, heat exchangers & other water carrying systems. The Problem Two of the most common minerals dissolved in water are calcium and magnesium. As the water is heated it expands and the dissolved minerals crystallize. Scale build up is the result of this crystallization process. The crystallization grows in layers until it becomes lime scale which is a very hard substance, and removing from pipes and fixtures is a costly and difficult task. Two of the most common minerals dissolved in water are calcium and magnesium. As the water is heated it expands and the dissolved minerals crystallize. Scale build up is the result of this crystallization process. The crystallization grows in layers until it becomes lime scale which is a very hard substance, and removing from pipes and fixtures is a costly and difficult task.

Scale is primarily calcium carbonate which often forms hard rock deposits in plumbing systems reducing energy efficiency & shortening the lives of expensive components in pipes, boilers, etc. Scale is primarily calcium carbonate which often forms hard rock deposits in plumbing systems reducing energy efficiency & shortening the lives of expensive components in pipes, boilers, etc.

scale chips that broke away from a large pipea 2” diameter pipe lined with about 1” of scale Lime scale deposits in pipes or heat-exchange surfaces can impede both water flow and heat exchange. Photo on the left is an example of a scaled pipe with a decreased inner diameter. Decreasing the diameter of a pipe by having a scale deposit slows down the water and allowing more scale to deposit along the surface. Calcium carbonate deposits along tubing surfaces in heat exchangers or chillers insulate the water from the pipe and diminish heat transfer. If heat is not effectively transferred, higher energy costs and more equipment wear result. Photo on the right shows pieces of scale that were deposited along a large diameter pipe before they broke off.

Major Impacts of Hard Scale  Blocks water pipes  Reduces heat transfer efficiency  Increases energy and cost

Scale Thickness and Energy Consumption The energy loss of trying to heat water through scale is substantial. Just a mere 1/4 inch of lime scale can increase your energy consumption by as much as 40%. A one-half inch thick layer of scale will retard heat transfer by up to 80%. Scale Thickness and Energy Consumption The energy loss of trying to heat water through scale is substantial. Just a mere 1/4 inch of lime scale can increase your energy consumption by as much as 40%. A one-half inch thick layer of scale will retard heat transfer by up to 80%. Scale Thickness Scale Thickness(inches) Increased Energy Consumption (%) 1/ % 1/ % 1/ % 1/ % From the ”Non-Chemical Technologies for Scale and Hardness Control” published by U.S. Department of Energy in 1998

The presence of scale is equivalent to having a thin film of insulation across the path of heat transfer from the furnace gases to the boiler water. The more scale accumulated, the more money wasted.

raw waterfilter soft water chemical agents Scale External Treatment Scale Boiler Internal Treatment SCALE PREVENTION

 There are many ways to prevent scale build-up and they are mainly grouped into external and internal treatment.  External treatment, as the term implies, is applied to water before it goes into the boiler. It usually refers to the chemical and mechanical treatment of the water source. The goal is to improve the quality of this source prior to its use as boiler feed water, outside of the operating boiler itself. Such external treatment normally includes: filtration, softening, demineralization, dealkalization, deaeration, etc.  But even after the best and most appropriate external treatment of the water source, boiler feed water (including return condensate) still contains impurities that could adversely affect boiler operation. Internal boiler water treatment is then applied to minimize the potential problems and to avoid any boiler failure.  To date, the most common solution is the traditional water softener, which takes a portion of the hardness minerals out of the water and replaces them with sodium. Water softeners are expensive to buy and operate, and can cause environmental problems. Also, they do not stop scale build-up, nor do they remove scale that has already built up.  Other scale build-up remedies, such as acid wash and chemical additives have even greater drawbacks, including the risk of contamination and the fact they wear out the surfaces they contact which leads to early pipe damage. Chemical prices are continuously increasing and regular cleaning hinders production due to shutdown time.

The Solution The Solution “CHEM – FREE ” “CHEM – FREE ”

What can “CHEM-FREE” do? RRRRemove Existing Scale PPPPrevents the formation of new heat wasting scale IIIIncreases protection against corrosion EEEEliminates the need for costly chemicals RRRReduces or eliminates the need for periodic acid cleaning PPPPrevent frequent system shutdowns required for de-scaling. RRRReduces energy CCCConserves water SSSSaves time and money LLLLengthens service life of capital equipment PPPPollution control EEEEnvironmental protection

The change from dissolved minerals to lime scale is a phase change from liquid to crystalline. Preventing mineral scale formation entails controlling solubility, clustering and crystal growth. This can be achieved with physical change - by creating a disturbing force in water.

HOW IT WORKS As water passes through CHEM- FREE, a force is induced in the fluid causing the minerals like calcium and magnesium to adopt a very small surface (repelling causing the minerals) charge that causes the minerals to lose their "bonding ability" and affects the manner in which they interact and crystallize. Random bonding of these minerals is reduced and therefore they stay in solution. As water passes through CHEM- FREE, a force is induced in the fluid causing the minerals like calcium and magnesium to adopt a very small surface (repelling causing the minerals) charge that causes the minerals to lose their "bonding ability" and affects the manner in which they interact and crystallize. Random bonding of these minerals is reduced and therefore they stay in solution. Not only do they remain in solution, there is also a break down of the existing scale deposits in pipes and fixtures.

By physical transformation, CHEM-FREE alters the crystalline form of calcium carbonate from calcite to aragonite - a small, soft, less stable crystal that precipitates as suspended particles in water rather than on the heat transfer surfaces. By physical transformation, CHEM-FREE alters the crystalline form of calcium carbonate from calcite to aragonite - a small, soft, less stable crystal that precipitates as suspended particles in water rather than on the heat transfer surfaces.

Crystal Structure (SEM map X120K) Hard water after “CHEM-FREE” after “CHEM-FREE” Hard water after “CHEM-FREE” after “CHEM-FREE” processing and boiling 5x processing and boiling 10x processing and boiling 5x processing and boiling 10x  Small changes in cluster size can produce large differences in crystal form.  Chemically, both aragonite and calcite are CaCO3, but their crystal structure is different. Aragonite is considerably more soluble, crystals are denser and non- adhesive. The resulting sediment is a dusty powder that is easily removed by flowing water and those that settle on heated surfaces have a chalk-like consistency.

Formation of smaller water clusters Low surface tension High solubilityHigh permeability Illustration

 The illustration shows the complete working principle of this process.  Reduction of the binding forces in water reduces cluster size, making molecules smaller.  Because of smaller molecules, water will have lower surface tension.  Small clusters also produce active molecules that increase the capacity of water to dissolve elements (solubility) and let elements pass through (permeability).  As a result of high permeability, old scale gradually fall or can easily be removed.

Results of Experiment on Surface Tension Circulation (no. of times) Temperature ( ℃ ) Surface Tension Reduction Percentage % % % % % Experiment conducted by Taiwan National Kaohsiung University of Applied Sciences Department of Chemical and Materials Engineering (2008/12/22~2009/01/31)

Steam Generated from Tap Water vs. CHEM-FREE processed Water Experiment conducted by Taiwan National Kaohsiung University of Applied Sciences Department of Chemical and Materials Engineering (2008/12/22~2009/01/31)

Energy Saving Mechanism ＊ The primary energy savings from this technology results from decrease in energy consumption in heating or cooling applications. This savings is associated with the prevention or removal of scale build-up on a heat exchange surface, where even a thin film can increase energy consumption by nearly 10%. ＊ Secondary energy savings can be attributed to reducing the pump load, or system pressure, required to move the water through a scale-free, unrestricted piping system.

Cumulative costs on chemical treatment “CHEM-FREE” One-time acquisition cost Continuous fixed costs on acid cleaning Cost recovery COST COST Time “CHEM-FREE” V.S. Chemical Treatment

 This is usually a one-time purchase with a very good return on investment within a short period of time.  In many cases, the savings from the project will be more than you paid for your treatment program. Return on Investment

How do you get a custom solution for your facility? OOOOne of our representatives will survey your site. FFFFrom your current operating data, we will suggest a program that will provide operational improvements to your system.