looking beyond efficiency…increasing roi through …

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

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