Physical Multi-Element Alloy Anti-Scaling & Descaling Device
Scale is solid or powder-like substance formed by attachment of minerals contained in hard water to surfaces of containers (such as heat exchangers, boilers, pipelines, etc.) after being heated over time.
Under high temperatures, calcium sulfate in water continuously precipitates through evaporation. Its carbonate ions combine with calcium and magnesium ions to form insoluble calcium carbonate and magnesium carbonate. When saturated, they form scale on the inner walls of pipes.
I Hazards of scaling
Water scale has very poor thermal conductivity, only 2-5% of that of ordinary steel.
Thermal conductivity coefficient of steel is 46.5-58.2W/m.ºC, while coefficient of water scale is 0.116-6.96W/m.ºC.
| Thickness of scaling |
0.5mm |
1mm |
2mm |
3mm |
4mm |
5mm |
| Reduced heat transfer efficiency |
3% |
6% |
10% |
20% |
30% |
42% |
| Carbon dioxide (metric ton) |
39.88 |
79.76 |
132.933 |
265.866 |
398.8 |
558.32 |
II Development History of Descaling Technology
Conventional Methods:
-Chemical antifouling and descaling
- Membrane technology
-Water softening
- Ultrasonic descaling
- Electromagnetic descaling
History
- Beginning with the Industrial Revolution
Since the Industrial Revolution, water scaling has been a global industrial problem. Chemical descaling has been the main method used, but it is associated with issues such as heavy pollution, low efficiency, and high corrosion.
- Rapidly developed since the beginning of the new century
Electromagnetic, membrane and water softening systems come out in the new century.
However, their effectiveness are not significant and water resource waste is too big. Chemical descaling is still the mainstream method in the market.
- Physical special multi-element alloy (copper-based catalytic alloy) has emerged
In 2013, a physical special multi-element alloy was developed as a pure physical antifouling and descaling method. It is effective, energy-saving, carbon-reducing, water-saving, leading a new industry development orientation.
Comparison of antifouling & descaling methods (based on DN100 pipe)
| Item |
ESEP multi-element alloy |
Ultrasonic descaling |
Electromagnetic descaling |
Water softener |
Chemical Treatment |
| Power consumption |
None |
500w.h |
2000w.h |
2000w.h |
2000w.h |
| Duration |
Internal chip for 10 years |
8 years |
5-8 years |
5 years |
Annual dosage |
| Distance |
5km |
200m |
500m |
/ |
/ |
| Maintenance frequency |
Maintenance-free |
Once a year |
Once a year |
Twice a month |
Daily |
III Introduction of Multi-element Alloy Anti-fouling & Descaling Device
3.1 Product characteristics
1) Magnetic-free, pollution-free, high safety performance
- No external power source required, not affected by external magnetic fields.
- No need to add any chemicals, no secondary pollution to environment.
2) Activation time: 72 hours
3) Carbon reduction, energy saving and efficiency improvement
- No heat or chemical reactions, reduces carbon emissions, saves energy and improves equipment efficiency
4) Extend equipment lifespan
- Effectively solves scaling issues, while also sterilizing and preventing corrosion, effectively extending equipment lifespan.
5) Easy installation, 10 years maintenance-free
- 10-year chip lifespan, maintenance-free, effective range up to 5km
6) Widely application
- Flexible installation in various environments with multiple specifications to meet different needs.
3.2 Material Introduction
This special multi-element alloy is prepared by high-temperature melting of 9 metals with different electronegativities. By strictly controlling proportion of various metals and adopting special processing technology, this multi-element alloy is formed in columnar crystals oriented along the S100 crystal axis (similar to a battery).
3.3 Technical Principle - anti-scaling
Special multi-element alloy continuously release free electrons. When fluid medium flows through, the special multi-element alloy can continuously release free electrons to the fluid. Without changing composition of the water, it polarizes the fluid, prevents the combination of anions and cations in the fluid, and thus prevents scale formation.
3.4 Technical principle - descaling
During long-term operation of the equipment, the current value generated by the direct movement of free electrons released by the alloy in water becomes stable.
Under continuous action of microcurrent, crystal structure of CaCO3 canges from a marble structure to an aragonite structure, which makes scale layer to gradually dissolve and fall off.
The scale inhibition and descaling effect of alloy is proportional to the flow rate of water.
3.5 Technical Principle - Anti-wax
Asphaltum and gelatine in crude oil are the key inducements of scaling and waxing. And metal kations such Ca and Fe will cause and advance waxing.
Copper-based multi-element alloy always release free electrons which may reduce scale forming and wax precipitating accordingly.
Furthermore, microcurrent generated by the alloy can restrain wax crystal generation.
3.6 Technical Specifications of the alloy
| Item |
Data |
| Hardness |
≤1500 mg / L |
| PH value |
3.0~10.0 |
| Steady-state current |
60μA |
| Operating temperature |
5~280 ºC |
| Flow rate |
≥0.6m/s |
| Scale inhibition rate |
>92% |
| Usage effect |
10-year anti-scaling, descaling, corrosion-resistant, and anti-waxing |
3.7 Product Classifications
1) Ground Installation
2) Downhole installation
3.8 Scope of Application
This product is suitable for those areas where flowing media in petrochemical and power systems cause pipeline scaling:
A) Circulating water systems & desalination systems
- Plate heat exchangers
- Reverse osmosis system
- Condensers, oil coolers
- Circulating water pipelines
- Geothermal heat pumps, air conditioners
- Cooling systems
B) Oilfield gathering and transportation systems
- Heating furnace pipelines
- Water treatment system pipelines
- Injection and steam injection system pipelines
- Single-well oil gathering pipelines
- Oil and gas well pumps and tubing
3.9 Application Cases of physical anti-scaling and descaling device
A) Oilfield system
Downhole Installation
> Blow well
> Pumping well
> Gas extraction well
Ground Installation
> Boiler or any heat water devices
> Cooling system
> Heat water system
> Manufacturing devices
> Water filling well
> Petrochemical plant
> Gathering & transmitting pipeline
Site Installation at China Daqing Oilfield Third Oil Plant
The gathering system of this oil production plant had severe pipeline scaling owing to hot water flushing. The serious scaling causes insufficient inlet pump pressure. Especially in the transition zone, pipeline scaling affects the water mixing pressure and return oil temperature, and so causes backpressure increasing which affects productivity.
After installing two ESEP devices, each technical index reaches expected goals. The anti-scaling results on hot water flushing pipeline continuously increase running efficiency, reduce production cost, reduce possible pipeline perforations and pipeline pressure, thus keep oilfield safety.
Site Installation at China Yanchang Oilfield
The oil, transportation, and water injection system pipelines and equipment at the plant were severely scaled, resulting in high cleaning and maintenance costs and affecting oil production and transportation. Based on survey results, downhole scale inhibitors were installed in various oil wells.
Before installation, the plant had to inspect the pumps 54 times a year, with an inspection cycle of 135 days. After installation, the plant only had to inspect the pumps 33 times a year, with an inspection cycle of 221 days. The installation greatly extended the maintenance-free period of oil wells.
Site Installation at CNOOC Project
This offshore platform had severe scaling issues in its sewage treatment pipelines. After installing the ESEP device, the scaling issues were resolved, and the system operated normally, reducing maintenance costs in terms of manpower and materials.
B) Cooling water circulation system
Cooling water accounts for about 70% of industrial water usage, and therefore, the cooling water circulation system plays a significant role in saving a lot of industrial water.
ESEP will be installed at the inlet of plate heat exchangers, tube heat exchangers, oil coolers, cooling tower distributors, condensers, fan coolers, vacuum pump coolers, and air compressor coolers.
Onsite Installation After Installation, only TWO weeks later
C) Heating system - Installation schematic diagram
The device is installed at the inlet of the internal heating system equipment such as plate heat exchangers, heat source boilers, pipelines, and bathing water.
Onsite Installation Before Installation After Installation
D) Reverse Osmosis System - Installation schematic diagram
The device is installed at the front end of the reverse osmosis membrane in the leachate water treatment plant and at the front end of the reverse osmosis membrane in the boiler desalination water system. Using the ESEP device can extend the cleaning cycle of the reverse osmosis membrane and therefore prolong the service life of the reverse osmosis unit.
Onsite Installation Before Installation After Installation
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