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LOOKING BEYOND EFFICIENCY…INCREASING ROI THROUGH
WATER HEATER MATERIAL SELECTION
Engineered Water Heating Solutions
WHAT IS THE ACTUAL COST OF YOUR COMMERCIAL WATER HEATER?
Water Heater
PVIExisting System
Thermal Efficiency 93% 93%Gallons per Day 1200 1200Temperature Rise 100 100Cost per Therm $1.00 $1.00 Hours per Day 12 12Days per year 365 365Hours per year 4380 4380
Yearly Operation Cost $47,078 $47,078
Yearly Fuel
Cost Savings $0 $0
$5,000
$10,000
$15,000
$20,000
$25,000
$30,000
$35,000
$40,000
$45,000
$50,000
PVI Existing System
Cos
t in
US
Dol
lars
System Comparison
Yearly Operating Cost
Water Heater Efficiency
With Efficiencies Equal… Storage Water Heater Lifespan Becomes the
Critical Factor in Increasing ROI
Corrosion
The enemy of storage water heater long term performance
GLASSEPOXY /
THERMAL PLASTIC
CEMENT METAL PLATING
Water Heating Fundamentals
Preventing Iron Oxidation
Isolating the electrolyte (water) and breaking the electrochemical circuit is the main initiative behind tank linings and barrier protection
BARRIER LINING
more noble metal
less noble metal
LININGS USED ON TANK SURFACES FOR WATER HEATERS and STORAGE TANKS
CEMENTATIOUS (cement)PORCELAIN ENAMEL (glass)EPOXY THERMAL PLASTICCOPPERELECTROLESS NICKEL THERMAL METALIZATION
GLASS APPLICATIONDISCONTINUITY:
THE PROCESS OF CONSTRUCTING PORCELAIN GLASS LINED VESSELS OFTEN INVOLVES COATING AND CURING TANK SECTIONS PRIOR TO WELDING THE SECTIONS TOGETHER.
THIS LEADS TO:SEAMS IN THE VESSEL THAT LACK LINING COVERAGEDAMAGED AREA FROM HEAT OF WELDING TORCH
• DISSOLVED OXYGEN IN WATER
• OXYGEN -”ELECTRON HUNGRY”
• IRON - “LOSES ELECTRONS ”
• TANK CORROSION POTENTIAL
DOUBLES FOR EVERY 25 DEGREE RISE
Water Heating Fundamentals
WHAT SHORTENS THE LIFE OF ANODE RODS?
NON FERROUS MATERIAL EXPOSURE:MAGNESIUM IN THE PRESENCE OF COPPER ACCELERATES THE RATE OF CORROSION
WATER TEMPERATURE: AN ANODE ROD WILL DEPLETE 13% FASTER IF WATER TEMPERATURE IS 140°F COMPARED TO 120°F…DEPLETION WILL OCCUR 28% FASTER AT A TEMPERATURE OF 160°F COMPARED TO 120°F
DEMAND CYCLES: THE GREATER NUMBER OF DEMAND CYCLES..…THE FASTER THE DEPLETION OF THE ANODE……
WATER CHEMISTRY: THE HARDNESS / SOFTNESS OF WATER WILL SERVE TO REDUCE THE SERVICE LIFE OF THE
Corrosion Resistant AlloysWrought and Cast Material
Nickel 200Nickel 200 is commercially pure (99.6%) wrought nickel. The corrosion resistance of Nickel 200 makes it particularly useful for maintaining product purity in the handling of foods, synthetic fibers, and caustic alkali's; and also in structural applications where resistance to corrosion is a prime consideration.
Monel® 400Monel® nickel-copper alloy 400 is widely used in many fields, especially marine and chemical processing. Typical applications are valves and pumps; pump andpropeller shafts; marine fixtures and fasteners; electrical and electronic components; springs; chemical processing equipment; gasoline and fresh water tanks; crude petroleum stills, process vessels and piping; boiler feed water heaters and other heat exchangers; and deaerating heaters.
Inconel® 600Inconel® nickel-chromium-iron alloy 600 is a standard engineering material for applications which require resistance to corrosion and heat. The alloy also has excellent mechanical properties and presents the desirable combination of high strength and good workability.The high nickel content gives the alloy resistance to corrosion by many organic and inorganic compounds and also makes it virtually immune to chloride-ion stress-corrosion cracking. Chromium confers resistance to sulfur compounds and also provides resistance to oxidizing conditions at high temperatures or in corrosive solutions. The alloy is not precipitation hardenable; it is hardened and strengthened only by cold work.The alloy is a standard material of construction for nuclear reactors. It has excellent resistance to corrosion by high purity water, and no indication of chloride-ion stress-corrosion cracking in reactor water systems has been detected. For nuclear applications, the alloy is produced to exacting specifications and is designated Inconel® alloy 600T.
Incoloy® 825Incoloy® alloy 825 is a nickel-iron-chromium alloy with additions of molybdenum, copper and titanium. The alloy's chemical composition is designed to provide exceptional resistance to many corrosive environments. The nickel content is sufficient for resistance to chloride-ion stress corrosion cracking. The nickel, in conjunction with the molybdenum and copper, also gives outstanding resistance to reducing environments such as those containing sulfuric and phosphoric acids. the molybdenum also aids resistance to pitting and crevice corrosion. The alloy's chromium content confers resistance to a variety of oxidizing substances such as nitric acid, nitrates, and oxidizing salts. The titanium addition serves, with an appropriate heat treatment, to stabilize the alloy against sensitization to intergranular corrosion.
Alloy 020INCO alloy 020 is an austenitic nickel-iron-chromium alloy with additions of copper and molybdenum.The nickel content makes INCO alloy 020 resistant to chloride-ion stress-corrosion cracking. Copper and molybdenum give resistance to reducing environments. The molybdenum content also provides good resistance to pitting and crevice corrosion. The chromium gives resistance to oxidizing environments such as nitric acid. The addition of niobium reduces the effect of carbide precipitation during welding, thus increasing the alloy's resistance to intergranular corrosion.
The Main Issue With These Materials Is……
Quality tank material that requires no lining = increased dollars
A corrosion protection systemthat does not rely on tank linings to protect
water side surfaces is now availablecommercially at a market sensitive price
A corrosion protection system
that does not rely on
tank linings to protect
water side surfaces is now available in the commercial marketplace
A base metal solution that offers the ability to overcome specific obstacles with domestic water
heating and
high temperature water storage applications
Steel designation Outokumpu steel EN ASTM Trade Names
1.4162 S32101 AquaPLEX©
LDX 2101®
DUPLEX ALLOY STEEL… A NON-PROPRIETARY MATERIAL
The major types of stainless steel widely used in domestic water applications are:
Austenitic is the most widely used type of stainless steel. Nickel and manganese are two alloying elements that will make the structure fully austenitic if added in appropriate amounts. An austenitic structure promotes ductility, non-magnetic properties, good welding ability and possibilities for a wide range of service temperatures.
Ferritic stainless steel has properties similar to mild steel but with the better corrosion resistance. The most common of these steels are 12% and 17% chromium containing steels.
Austenitic-Ferritic (Duplex) stainless steel has a ferritic and austenitic lattice structure -hence common name: duplex stainless steel. Duplex stainless steels have a smaller nickel-content than the austenitic grades. The structure is 50 % ferritic and 50 % austenitic and this gives a layered structure with high strength.
DUPLEX ALLOYLong Term Test Results
• Long term testing in:• Potable water
• highly acidic (5.0 pH) oxidizing solution – destroys 316L
• highly chloridic (over 650 ppm) solution – destroys 316L
• in stagnant and cyclic flow conditions
• over 190 degrees F continuous
DUPLEX ALLOY
• Potable Water Applications
• High Temperature Applications With Over 190 Degrees F Continuous Temperatures
• Solar Water Storage
DUPLEX ALLOY STEEL
Stress Chloride Cracking
Corrosion Resistance
Ability to Weld and Manufacture
Requires Passivation and
Pickling After Manufacturing
• Metallurgists
• Steel Manufacturers
• Metal Finishing materials suppliers
• Welding industry experts
DUPLEX ALLOY DEVELOPMENT TEAM
Corrosion resistance after fabrication is returned through:
• Passivation (recreating the chromium oxide layer on the surface restoring corrosion protection)
• Pickling (restoring the Ferritic structure damaged during welding) the entire vessel
Total immersion acts like a liquid “eraser” and returns the material to a “passive” corrosion resistant state
DUPLEX ALLOY STEEL
Duplex stainless steels have roughly twice the strength compared to austenitic stainless steels and also improved resistance to localized corrosion, particularly
pitting, crevice corrosion and stress corrosion cracking.
DUPLEX ALLOY STEEL
80% Minimum Post Consumer
Recycled Materials in Base Metal
Less Material Required to Achieve Desired Strength
No Lining Material =
No VOC’s Emitted During Manufacturing Process
Weight Reduction =
Less Energy to Transport and
Handle
DUPLEX ALLOY STEEL
Gains in ROI based on material selection and added to operational efficiency gains
EXAMPLES OF PRODUCTS
w/ DUPLEX ALLOY CONTRUCTION
Engineered Water Heating Solutions
399,000 – 2,000,000 BTU Input 125, 250, and 300 Gallon Tank
Configuration Up To 99% Efficiency (low fire) Full Modulation with 10:1 Turndown Programmable Electronic Control with
Digital Temperature Control Category IV Venting with CPVC Vent
Material Aquaplex Tank and Fireside Material 10 Year Tank Warranty 3 Year Scale Warranty
HIGH EFFICIENCY STORAGE WATER HEATER with DUPLEX ALLOY CONSTRUCTION
399,000 – 2,000,000 BTU Input 125, 250, and 300 Gallon Tank
Configuration Up To 95% Efficiency (low fire) Full Modulation with 10:1 Turndown Programmable Electronic Control with
Digital Temperature Control Category IV Venting with CPVC Vent
Material Aquaplex Tank and Fireside Material 10 Year Tank Warranty 3 Year Scale Warranty
HIGH EFFICIENCY STORAGE WATER HEATER with DUPLEX ALLOY CONSTRUCTION
Engineered Water Heating Solutions
FOR MORE INFORMATION:WWW.PVI.COM.....