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Page 1
Nu-Calgon Glycols for the HVAC/R Industry
Page 2
Why talk about Glycols?
Its Simple….
It’s a big market with plenty of opportunity!
Page 3
Market & Customers
Page 4
Where to Use Glycols
• Water systems exposed to varying extremes in temperature
• Where extreme may approaches freezing point
• To protect the system it becomes necessary to suppress the
freezing point
• A heat transfer solution (glycol) prevents freezing or bursting
pipes
Page 5
Applications
HVAC heating/cooling
Refrigeration-secondary
coolant
Process cooling/heating
Waste heat recovery
Sprinkler systems
Floor heating
Misc.
Page 6
Glycol Types
Various types of closed
systems may need to be
protected from freezing as
well as corrosion
This can be accomplished
with an ethylene glycol or
a propylene glycol
The glycol product
selected should be
formulated as a heat
transfer fluid for
HVACR systems
Avoid automotive
antifreezes
Page 7
Propylene Glycol
• Primary glycol type used in the HVAC/R market
– Used in many applications due to product’s greater
environmental safety
• Excellent heat transfer fluid
• Low toxicity
– For use around potable water and foodstuffs
• Options include food grade and GRAS formulations
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What does GRAS mean?
Ingredients used in its manufacture of the glycol product
are GRAS (generally regarded as safe), under Title 21,
Part 182 of the US Code of Federal Regulations, where
accidental or incidental contact with potable water could
occur.
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What is Food Grade
Propylene Glycol?• Propylene glycols that are classified as food-grade or GRAS are the
same chemistry. It’s how the glycol (and other ingredients) are handled!
• Ingredients in food grade formulations are manufactured with strict
guidelines (dedicated process equipment / packaging).
• Paperwork is supplied with product certifying its handling
• Cost more than formulated glycol products that are classified as GRAS
• Potential Application: USDA process facility
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Ethylene Glycol
• Primarily used in industrial applications
• Excellent heat transfer fluid
• Higher toxicity
– Can’t be used around potable water/ foodstuffs
• Lower viscosity
– Allows for energy savings in pump operation
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Formulated Products• Glycols supplied to the HVAC/R market are formulated products.
Products include:
– Corrosion inhibitors to protect system metals
– Non-concentrate products are formulated with high quality
water
• For closed loop systems, water or glycol by itself is corrosive.
Glycol must be formulated with corrosion inhibitors to provide
metal protection (long life).
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Corrosion Protection of
Freez-Kontr’l®
Aerated tests @ 190°F for 2 weeks per ASTM D1384
Corrosion rates in milligrams penetration per year (mpy)Rates below 0.5 mpy (2.5 mpy for Al) are considered adequate
* weight gain
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Corrosion Protection of
Freez-Therm®
Aerated tests @ 190oF for 2 weeks per ASTM D1384
Rates below 0.5 mpy (2.5 mpy for Al) are considered adequate
Corrosion rates in milligrams penetration per year (mpy)
Page 14
System Design Considerations
Acceptable Materials:
Steel, cast iron, copper, brass, bronze, solder and most
plastic piping materials
Aluminum Considerations: Popular inhibited glycol products can be
used with aluminum in applications up to 150°F.
Systems equipped with an aluminum heat exchanger require special
propylene-based glycol for the elevated temperature (above 150°F).
Page 15
System Design Considerations
Galvanized Steel
• Galvanized steel is not recommended with formulated
glycol products
• Zinc will react with inhibitors in the glycol causing potential
deposit formation, depletion of corrosion inhibitor, and
removal of protective zinc coating on steel component
• Precipitation can also lead to localized corrosion
Page 16
System Design Considerations
Depending on propylene or ethylene glycol
concentration, formulated product can provide
the following:
• Operating temperature range of -60°F to
250°F
• Provides freeze protection to -60°F
• Provides burst protection to -100°F
Page 17
Determining Protection
When to use Burst Protection:
• System will remain dormant when temperature is below
freezing point
• Adequate space to accommodate expansion of ice/slush
formation
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Determining Protection (cont.)When to use Freeze Protection:
• System solution must be pumpable at the lowest
anticipated temperature
• When there is little to no room in the system for expansion
of ice/slush formation
• Systems that require protection for start-up after a
prolonged shut-down
Page 19
Corrosion Protection:
• Sometimes in a tempered application only a minimal
amount glycol is required for freeze/burst protection.
• In this circumstance, to maintain corrosion protection of
system metals, a minimum 1/3 of the system volume
must be the formulated product – even though it
exceeds the freeze control requirement.
Determining Protection (cont.)
Page 20
Preparing System for GlycolThoroughly clean and flush system with water
before adding a glycol to the system
• New System
– May be coated with cutting oils, grease,
solder, flux, etc.
• Old System
– May have chemicals not compatible with
the propylene of ethylene glycol
Page 21
System Cleaner
• Mix one gallon of System Cleaner per
75 gallons of system water
• Circulate for 4-8 hours. Adjust cleaning
time to amount of debris suspected in
circuit
– Warm water will assist in cleaning rate
• Flush circuit thoroughly with water
Page 22
Next Step – Glycol Addition
• Select propylene or ethylene glycol based
product for the application.
• Determine freeze or burst protection
requirement
Page 23
Glycol Addition (cont.)
• Consult appropriate product
chart for amount of glycol
needed for protection
requirement
• Always enough glycol to
provide additional 5°F
protection for the application
% Volume of
Freez-Kontr’l
Freeze
Protection
Burst
Protection
100% < -60°F -100°F
80% -58°F -74°F
70% -35°F -61°F
60% -18°F -48°F
50% -3°F -35°F
40% +8°F -20°F
30% +16°F +5°F
Page 24
Glycol Addition (cont.)Example:
• Propylene glycol requirement
• 100 gallon circuit
• Need 0°F freeze protection
Answer:
• Approx. 52% (52 gallons) of the system
volume must be product, diluted with 48
gallons of quality water
Page 25
Water Dilution
• It is imperative to use high quality water if the propylene
or ethylene based glycol needs to be diluted.
• Quality water ensures long-term effectiveness of
inhibitors in glycol formulation
– Water impurities can behave adversely with inhibitors
• Minimum water specifications should be followed to
maximize propylene or ethylene glycol life in system.
Page 26
Water Dilution (cont.)Water Quality Requirements
Impurity Level
Chlorides 25 ppm, maximum
Sulfates 25 ppm, maximum
Total Hardness, as CaCO3 100 ppm, maximum
Page 27
Issues with Diluting with
Poor WaterExcessive impurities in poor water can cause:
• Metal corrosion
• Aggravate pitting of cast iron and steel
• Reduce effectiveness (and deplete) corrosion inhibitors
• Formation of scale and other deposits in system
• Clogging of system components
Page 28
Other Notables
• Never leave the jobsite without test
the protection level of the glycol
added to the system!
• Ideally, circulate for 24 hours to
ensure complete mixing.
• Check liquid with glycol refractometer
Page 29
Other Notables (cont.)Depending on application, base lining the glycol chemistry can provide
valuable diagnostic information.
• Within a week after commissioning system, have a glycol sample sent to
a laboratory to baseline glycol health of the system.
• Laboratory provides inhibitor levels and pH of glycol at start-up
• On yearly intervals, take glycol sample and resubmit to a laboratory for
review. Monitor inhibitor levels and pH of glycol.
• If adverse inhibitor decay occurs and/or the pH of glycol drops below 7,
this is indication something undesirable is occurring within system.
Note: Nu-Calgon can provide laboratory recommendations.
Cost of the analysis is inexpensive and often with a
quick turnaround.
Page 30
Other Notables (cont.)
Foaming in the glycol circuit can be caused by:
• Entrapped air that is being ’churned’ by the pump
• Particulate matter (corrosion byproducts or dirt) that can
agitate the glycol
• Poorly design system that has numerous bends/turns that
could agitate the glycol.
Note: First two items can be fixed, the third is
more problematic. Some times silicone deformers
can assist in ‘breaking’ foam in adverse situations.
Page 31
Other Notables (cont.)
Bacterial Activity in the glycol circuit can be caused by:
Too little glycol in the system. This is a common
occurrence if less than 20% glycol (by volume) is added to
a system.
Rule: Keep glycol content above 30% concentration to
prevent bacterial activity from developing (need if for
corrosion protection anyway).
Page 32
Other Notables (cont.)
• Do not mix ethylene and propylene glycols in a system.
• Nu-Calgon does not recommend mixing competing
glycol products within a system.
– Inhibitors can vary in glycol formations on the market.
– Unknown chemistries can behave adversely and cause the
inhibitors not to perform (deplete in time). Deposits within a
system are also possible.
Page 33
Nu-Calgon’s Line-Up
Page 34
Glycol Application
Nu-Calgon
offers both a
propylene
glycol …
Freez-Kontr’l®
An inhibited
propylene glycol
heat transfer fluid
Page 35
Glycol Application (cont.)
and an ethylene
glycol technologyFreez-Therm®
An inhibited
ethylene glycol
heat transfer fluid
Page 36
Freez-Kontr’l®
Freez-Kontr’l is an
inhibited propylene
glycol product (70%
concentration)
Excellent heat transfer
& freeze protection
fluid
Effective over a wide
temperature range
Corrosion inhibitors
last up to 20 years
Formulated with high
quality, long lasting
corrosion inhibitors
that were designed for
HVACR systems
Extremely low toxicity
suitable for use where
potable contact could
occur (GRAS)
Page 37
Freez-Kontr’l ®
Packaging Options
One Gallon Bottle
Five Gallon Pail
55 Gallon Plastic Drum
Totes (Special Quote)
Page 38
Freez-Kontr’l
Other
Applicable
Concentrations
Freez-Kontr’l® 95/5
Freez-Kontr’l ® FG
Freez-Kontr’l® 35
Burst-Kontr’l® AP-100
Page 39
Freez-Kontr’l® 95/5
Concentrate form of standard
Freez-Kontr’l
Freez-Kontr’l 95/5 is 95% inhibited
propylene glycol vs. 70% conc. in
standard Freez-Kontr’l
Non-toxic, non-flammable
Optimized freeze, burst protection
Fully inhibited to prevent corrosion
protection
Page 40
Freez-Kontr’l® 95/5
Packaging Options
5 Gallon Pail
55 Gallon Plastic Drum
Page 41
Freez-Kontr’l® FG
Applications:
– Cooling/heating equipment in food
processing facilities where incidental
food contact is possible.
– Geothermal systems where state laws
dictate
• Formulated with 95% USP grade
(food grade) propylene glycols
• Food grade corrosion inhibitor
• Food grade orange colored dye
Page 42
Freez-Kontr’l® FG (cont.)
• NSF Listed for Category Codes
HT1 and HT2
• Freeze protection: -60°F
• Burst protection: -100°F
• Fully inhibited to prevent corrosion
• Packaging: 55 gallon plastic drum
Page 43
Freez-Kontr’l® 35
Product specially formulated for
medium temperature secondary
coolant circuits
Also suitable when customer wants a
premix product with minimum freeze
protection for any application
Formulated to meet OEM glycol
specification
Ingredients used are generally
regarded as safe (GRAS) FDA Title 21
Page 44
Freez-Kontr’l® 35 (cont.)
Formulated with:
35% propylene glycol
Dipotassium phosphate (inhibitor)
Deionized water
Food grade dye per specification
Provides +2°F freeze protection
Corrosion protection
Premix formula (no dilution at site)
Available in 55 gal. drum, p/n:4188-35.
Page 45
Burst Kontr’l® AP-100
Developed specifically for aluminum
heat exchangers
Non-toxic and non-corrosive propylene
glycol based (60% concentration)
Page 46
Burst Kontr’l® AP-100 (cont.)
Provides burst protection to -100°F and
freeze protection to -60°F
Maximum protection for all metals-
especially suitable for aluminum
Near-neutral pH meets OEM
specifications for aluminum heat
exchangers
Formulated for optimum heat transfer
and maximum fluid life
Now available in
55 gallon drum
Page 47
Freez-Therm®
Freez-Therm is an inhibited
ethylene glycol product
Excellent heat transfer &
freeze protection fluid
Effective over a wide
temperature range
Page 48
MonitoringFor monitoring freeze point, use a Nu-Calgon glycol
refractometer:
• Test freeze protection of propylene or ethylene glycol (type
must be known)
• Results given as lowest temperature to which protection is
provided
• Recommended in all heat transfer fluid applications
Page 49
Glycol/Oil Transfer Pump
Model Number: 4817-0
• Service item to assist in
transferring product from drums
to application
• Heavy-duty/long-life pump
• Electric motor (115volt / 7amp)
• Thermal protection
• UL recognized component
Page 50
Our Value Proposition
• Array of Products
• Product Availability
• Support
• Training
