DEMINERALISATION:

Chemical Free Anti Corrosion solution for Closed Loop Heating and Cooling Circuits.

Background:

In Germany, after extensive independent studies, it was found that to eliminate corrosion from closed loop systems, the following 3 elements must be addressed and treated.

Oxygen
pH
Conductivity

German Standard VDI2035 Part 2 was drawn up and stipulates that in order to prevent corrosion occurring in Closed Loop Water circuits the following values must be achieved.

Conductivity < 100microSiemens/cm
pH must be between 8.2 and 10 and for Aluminium systems between 8.2 and 8.5
Oxygen 0.1mG/Lt

To achieve this, the water within the Heating System must be Demineralised, i.e. all minerals need to be removed from the water, leaving pure H2O.

Once completed the entire system is protected from Corrosion and efficiency increases by between 10-20%

Demineralisation is a Chemical Free and practically maintenance free solution to prevent Corrosion and protect all components of the Circuit; Boilers, Pumps, Pipework, Heat emitter, ( Radiators, Fan Coils, AHU’s etc), Chiller, Tools etc

Benefits:

Reduction in energy costs (Fuel and Electricity)
Reduction in emissions
Even thermal transfer and heat distribution
Less components breaking down (Boiler, Pumps, AHI’s, Pipework, Valves etc.)
No Chemicals
Reduction in Maintenance and operating costs
Reduction in spare parts required
Reduction in Noise in the system

Components of Demineralisation:

Outlined below is a brief description of the various tools available to carry out and maintain the Demineralisation process. There are links to more detailed information and brochures for each component.

The Implementation steps are also listed in sequence.

Water Analysis Kit

Magnetic GmbH offers high quality measuring devices for checking and analysing the composition of heating water. This enables you to measure the heating water at the customer’s site, to establish values for pH, Conductivity and Hardness. Sample bottles available if further Lab analysis of water is required.

Filling Stations:

Magnetic GmbH provides a range of Filling Stations to enable Heating system water demineralisation, appropriate to system capacity. These stations can be utilised in 2 ways and come in 3 different Models/Capacities: Basic Mini, Basic Mobil Plus and Profi Mobil Plus.

Fill new system through filling station to have demineralised water in heating system from the start
Carry out a circulation demineralisation process on existing system. System can still operate whilst being demineralised. For units with one on board measuring computer only, an additional measuring computer will be required to carry out circulation demineralisation.

These stations use a premium quality resin and the amount required will depend upon initial water quality.

Different sized filling stations for resin

Demineralisation Cartridge 300 (LINK)

This new generation of in-line cartridges with a colour indicator, provides a very inexpensive and simple method of demineralising low volume heating systems, e.g. Domestic and small commercial. It is ideal for the customer service fitter who always refills small quantities. These cartridges can handle up to 300 Litres, and can be either left permanently in place to handle Top-up water or can be brought from building to building.

For larger jobs and/or volumes a 1,000litre cartridge is now available
VEP 1000 now available: 1,000 Litre capacity: 600mm x 120mm
Demineralisation: < 35uS/cm

Chemical Free Resin

More info

Magnetic GmbH premium mixed bed resin, the first resin with quality certification. Developed especially for heating systems and filling in accordance with VDI2035 Part 2

Certification verifiable via QR code
100% non-regenerated resin
Vacuum packed
Support pH increase, self-alkalization
Optimal Mixing Ratio
Ideally suited for all materials including Aluminium

The quality of the resin determines the quality of the heating water. Here it is particularly important not to compromise. That is why we only deliver resin of the highest quality standard.

Mobile Heating Water Filtration

Automatic mobile heating filter system for cleaning of heating systems between approx. 10kW and 2,500kW. Also suitable for Air Conditioning and pipe system of a similar capacity.

Existing closed loop systems have to deal with silting and magnetite deposits, which clog pipes and system components reducing efficiency. To remove these, the heating engineer needs to rinse the system several times and completely changing the fill water through flushing. This complex process primarily takes time and requires system shutdown. In addition, despite multiple flushing, there is always some dirt left in the pipes. The newmobile filter station from Magnetic GmbH, filters all dirt out of the system water, offers a reliable and clean alternative.

from Magnetic GmbH, with which dirt is filtered out of the system water, offers a reliable and clean alternative.

Flush Cleaner for Heating Systems Chemical Free

Modern heating systems are now very energy efficient. The fact is, however, that up to 20% of the energy can be lost again due to muddy heating pipes and damage to pumps and control valves. If there is a risk that the heating pipes could be silted up, and a system flush is required, it is recommended to clean the heating system properly with a professional cleaner.

Heating Water Regulator HWR

Degasser, Sludge separator and pH regulation in one unit:

Chemical Free

For the long-term regulation of the heating water and the reliable prevention of new deposits, the installation of a magnetic heating water regulator is recommended. This not only saves energy, but also reduces the risk of damage caused by corrosion products incontrol valves and pumps. Especially in heating systems have an increased risk of corrosion, the HWR (heating water regulator) eliminates all causes of corrosion and sludge formation, by regulating and controlling:

Oxygen
pH
Conductivity

Top Up/Refill Station (LINK)

As heating systems are never completely sealed, system water will need to be replenished with new water. It is critical that a Demineralised system is Topped Up with Demineralised water, or it will contaminate system, leading to corrosion etc.
By installing a Top-Up station on the fill line, it is guaranteed that refill water is demineralised before being added to system water.

Implementation:

Step 1:

Existing Systems: Test water for pH, Conductivity and Hardness to determine quality of system water and what steps are required to follow

Step 2:

For new system fill, the heating system is filled through demineralisation unit, either a VEP300/VEP1000 portable cartridge for domestic or portable Mobil unit for larger installations.

VEP300 Cartridge

MOBIL Unit

For existing systems there are 3 options:

System water is of a good enough quality that it can be demineralised straight away. This is done by carrying out a “Dialysis” of the system water through a circulation loop on the system as per below:

System does not require a full flush but due to existing sludge and particles, the system is run through a Mobile Filtration unit as per below and then Demineralised as per 1.

System water merits a complete flush and then Demineralised as per 1.

Chemical free Solution

In the demineralisation process a premium mixed bed resin is used with cartridges and mobile units.

Steps 1 and 2 have enabled system water to be Analysed and then system water is Cleaned/filtered and Demineralised.

Magnetic GmbH solution to a common problem. Treating heating water in an existing system can be a challenge especially if system cannot be drained and is highly contaminated.

Magnetic GmbH solution is easy to apply and no system shutdown and/or flushing required.

System circulation filtration
System circulation demineralisation.

This process can be performed whilst enabling the engineer to carry out other works.

Steps 3 and 4 below ensure Demineralised system water is maintained and not contaminated.

Step 3:

A: Heating Water Regulator:

Degasser, Sludge separator and pH regulation in one unit:

The HWR controls/regulates the 3 components of corrosion stated at beginning of document, i.e.

Oxygen through valve at top of HWR
pH: through pH Anode which manages pH without need for chemicals
Conductivity, through pH Anode and magnet which collects sludge at bottom of unit.

B: Top Up station

A Top Up station is installed on Feed Water line, so that any top up water required due to leaks etc., is demineralised

Our Location

Floor One Block B, Monksland Business Park, Athlone, Roscommon, Republic of Ireland

Email Address

info@ermensystems.ie

Phone Number

+353 90 649 0050

FAX

+353 90 640 0102