COST REDUCTION THROUGH CREATIVE CHEMICAL TECHNOLOGY

 

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Technical Data Sheet

HEAT TRANSFER EFFICIENCY

 

A CLEAN BOILER OR CONDENSER SYSTEM PERFORMS MORE EFFICIENTLY TO SAVE OPERATION AND MAINTENANCE EXPENSES AS WELL AS COSTLY DOWNTIME. 

Boiler and condenser scale reduces efficiency in boiler and cooling tower operations, because all forms of scale possess a low degree of heat conductivity.  The presence of scale is like spreading a thin film of insulation across the path of heat transfer, thus reducing boiler and condenser efficiency. 

The rate of heat transfer may be reduced as much as 15% by the presence of scale.  In a 200 hp. boiler, a 15% loss in heat transmission increases fuel costs as much as $120,000 a year based on a 10-hour day, 260-day year. 

Even more important than heat loss is the effect scale has in causing boiler metal to overheat.  This condition results in tube failure. If sufficient scale is formed, the insulating qualities of the scale can cause the tubes to heat to more than 900F/482C.  This is usually the maximum temperature that is considered safe for boiler tubes.  Costly repairs and boiler downtime are the result of such a condition.

With high boiler water pressures and temperatures, there is less temperature difference between the boiler water temperature and the failing temperature of the metal.  Consequently, tube failures result at higher boiler water pressures with scale of considerably less thickness.  This condition explains the need for close control of boiler water conditions in high pressure boiler operation. 

BOILERS

Percent of Heat Transmission Loss Due to Scaling
Nature of Deposit Thickness of Incrustation Percentage Heat Transfer Loss
Carbonate Scale

.0138 inches

.0315 inches

.0938 inches

5.4%

7.2%

15%

Sulfate Scale

.0590 inches

.0984 inches

.2282 inches

10.8%

11.5%

15.9%

 

 

AIR CONDITIONING CONDENSERS

Percent of Heat Transfer Loss Due to Scaling
Tubes Cooler Condenser
Clean 0 0
.006 inch of scale 16.7% 30.0%
.012 inch of scale 28.5% 45.9%
.024 inch of scale 44.5% 62.9%
.036 inch of scale 54.6% 71.8%

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Updated: Friday, May 10, 2002