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New Generation
12/07/06
The build up of scale deposits and corrosion are both common and costly problems in many industrial processes and commercial buildings using natural water supplies. The largest issue comes from limescale as two-thirds of the population lives and works in areas where the water is hard. For many years, the preferred choice has been the introduction of water conditioners to the system in an attempt to reduce and control these problems. However, according to Mike Potter of WATERMATIC, there’s a new generation of processes and systems that actually treat and reverse limescale issues – and there’s significant cost savings to be had by using them.
“For as long as people have been heating hard water, limescale has been a problem. In some cases it is a nuisance, such as when it forms a coating of scale on cooking implements. But in appliances, heating systems and industrial processes that use hot water or steam, limescale can be a very costly burden – the cost of limescale to UK industry has been estimated at over £1bn per annum.
“Hardly surprising therefore, that the human brain has long been searching for a solution to this problem. The first generation of chemical inhibitors actually dates back to as early as 1821 when it was found that potato starch would reduce scale formation. Since then many other chemicals and effects have been found to inhibit scale and one of the most effective is zinc, even in tiny quantities. The higher the level of zinc ions in the water, then the greater the effect on scale formation, so much so that it will even remove existing scale deposits.
“Despite this, the most widely and commonly used approach to controlling limescale has been by introducing water conditioners to water systems. This type of approach has been around for some time, but whilst traditional water conditioners do serve to tackle the problem, to a degree, there are a number of ‘variables’ that in a sense undermine their efficacy. For example, electrostatic effect water conditioners lose their effect on the water in a system over time, so the effectiveness of these is compromised and their managing powers over limescale consequently diminish. Also, the distance the water in the system has to travel, and the type of plumbing and water system in place, can impact on the efficiency of the conditioner – too much turbulence in the pipework can again compromise effectiveness.
“The most effective way of dosing the water with zinc is through electrolysis using a zinc anode and copper cathode in the water. There is a high electrolytical potential between these two metals which causes zinc ions to be released into the water in minute quantities.
“This type of treatment has been tested, and proven, independently by specialists at Cranfield University. The tests included assessing the amount of scale formation using a temperature controlled heating element with a removable sleeve that enabled examination the type and build up of limescale on the sleeve. These tests in the laboratory were confirmed by field trials in a range of commercial and industrial applications, which show as a direct consequence, an improvement in energy usage, and a reduction in maintenance and capital expenditure – plus a fast payback on the investment of less than 12 months.
“The unit tested by Cranfield is the KAL-GUARD+. Cranfield’s report stated that: ‘the KAL-GUARD+ unit reduced the amount of scale on the heater sheath by 80 percent when compared to the control. The unit also reduced the level of scale formed in the bulk and when comparing the total amount of scale formed (combined heater + bulk), the KAL-GUARD+ reduced scale formation by 74 percent.’
“These independent tests at Cranfield, together with results delivered out in the field for organisations including various sites within the Whitbread group, Imperial Tobacco’s Nottingham plant, and several care homes run by Somerset County Council, prove that the technology and the unique KAL-GUARD+ unit deliver tangible energy, and cost savings. And these can be seen in just a few months, not years, following installation, and can represent savings of as much as 15 percent of all gas used for all hot water heating needs.
“This cutting edge scientific technology truly represents the next step in the treatment and prevention of limescale in commercial environments. At a time when there is increasing pressure to reduce environmental impact and minimise total life costs, they offer clear benefits. Hot water systems last longer and remain efficient, energy consumption and maintenance requirements are minimal and there is no need for toxic or corrosive chemicals.”
KAL-GUARD+ has been developed by Watermatic, the commercial division of specialist water treatment company Salamander Engineering. Mike Potter is the Product Development Manager of WATERMATIC. For more information, visit www.watermatic.co.uk, or tel: 0121 378 1188. WATERMATIC’s website includes a unique Payback Calculator that will calculate instantly from data supplied, the potential cost savings to an organisation of installing a KAL-GUARD+ unit.
Kal-Guard+ is a registered trademark of Watermatic.
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