How Scale Forms
Temperature/pressure shifts cause calcium & magnesium carbonates to precipitate and adhere to metal surfaces.
The Hidden Efficiency Loss Inside HVAC & Water Circuits
Scale forms an insulating layer on heat transfer surfaces. Even thin deposits cause rising compressor and pump energy, reduced capacity, and accelerated wear.
10–40%
Typical reduction in heat transfer efficiency from 1–3 mm scale layers
Heat Transfer Degradation
1 mm of scale can cut heat transfer 10%+, forcing higher kW to meet the same load.
Increased Pumping Load
Deposits narrow the hydraulic path, raise friction losses, and increase pump power and wear.
Chiller & Compressor Stress
Scaled condensers run higher head pressures, driving up compressor energy and maintenance.
Energy & Fuel Waste
Scaled systems often see 15–30% higher electrical consumption; thermal fuel follows suit.
Shortened Equipment Life
Under-deposit corrosion and thermal stress push assets beyond design limits.
Why Chemical Treatment Falls Short
Conventional dosing means recurring cost, handling risk, and environmental burden—plus exposure to dosing interruptions and human error.
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Dosing Dependency
Any interruption can trigger immediate scaling.
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Human Error
Manual testing/adjustment creates variability and blind spots.
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Over-Dosing Risk
Excess chemistry may induce corrosion and water issues.
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Sludge & Disposal
Byproducts add labor and compliance overhead.
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Recurring OPEX
Perpetual purchases with no permanent fix.
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Environmental Impact
Discharge complicates ESG and regulatory reporting.
AE-Flux™: Physical Water Conditioning
Electromagnetic conditioning changes mineral crystallization to prevent adherent scale and progressively remove deposits—without altering water chemistry.
How AE-Flux™ Electromagnetic Water Conditioning Works
A controlled electromagnetic field interacts with the water column, altering nucleation and growth so calcium carbonate favors soft, non-adherent aragonite crystals that stay suspended and flush through the system.
01
Pipe Charging
An inline AE-Flux™ unit couples a controlled field through the pipe into the flowing water.
02
Flux Interaction
Ion transport and collision behavior shift under Lorentz forces—impacting nucleation.
03
Surface Effects
Modified electrostatic conditions lower adhesion probability at the metal surface.
04
Deposit Repulsion
Crystals remain suspended and are carried away by flow.
05
Calcite → Aragonite
Morphology shifts to soft, non-adherent aragonite—key to prevention.
06
Progressive De-Scaling
Legacy deposits dissolve over weeks without harsh cleaning.
07
Efficiency Restored
Clean surfaces recover thermal performance and reduce kW/ton.
Critical Principle: Nothing is added or removed from the water. AE-Flux™ modifies only mineral behavior; chemistry stays unchanged.
Applications
Designed for demanding industrial and commercial systems where heat transfer efficiency and reliability are critical.
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HVAC Chilled Water
Prevent scale in chillers, AHUs & distribution piping—restore capacity and reduce compressor kW.
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Cooling Tower Loops
Mitigate scaling in recirculating systems; reduce blowdown and water use.
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Heat Exchangers
Maintain U-values in shell-and-tube, plate, and brazed designs.
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Condensers
Keep tubes clean to preserve approach temp and head pressure.
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District Cooling
Protect distribution from flow restriction over time.
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Process Water
Safeguard production against scale-related loss and downtime.
Business Impact
Engineering outcomes that translate into measurable energy, maintenance, and ESG gains.
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Lower Electricity
Reduced pump & compressor loads often deliver 10–25% energy savings.
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Design Efficiency
Recover heat transfer without the thermal penalty of scale.
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Cut Chemical OPEX
One-time capex replaces recurring chemicals, testing, and handling.
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Fewer Shutdowns
Minimize mechanical/chemical cleaning and downtime risk.
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Asset Life
Reduce under-deposit corrosion and thermal stress.
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Better ESG
Non-chemical operation simplifies compliance and reporting.
De-Scaling & Efficiency Assessment Calculator
Estimate potential efficiency recovery and energy savings. Results are shown on screen and can be shared via WhatsApp.
Get Your Personalized Efficiency Report
Enter your details to proceed. Your results will appear on-screen. You can also send the report via WhatsApp.
System Information
Provide system details for a more accurate estimation.
Your Efficiency Assessment Results
Indicative results based on your inputs. Actual outcomes vary with water hardness and existing scale levels.
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Estimated Efficiency Loss
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Potential Efficiency Recovery
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Annual Energy Savings (kWh)
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Annual Cost Savings (₹)
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CO₂ Reduction (tonnes/yr)
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Indicative Payback
Report Options: Share via WhatsApp or schedule a technical discussion with an expert.
A summary can be emailed to — (kept private).
Representative Use Cases
Illustrative examples. Performance depends on water chemistry, design, and operating conditions.
Commercial HVAC
System Capacity500 TR
Flow Rate450 m³/hr
Efficiency Improvement18%
Energy Savings~280,000 kWh/yr
HVAC System Efficiency Improvement
High-hardness water (≈350 ppm as CaCO₃) raised condenser approach. After AE-Flux™, approach improved by ~2.5 °C over eight weeks, recovering near-design kW/Ton.
Metered data showed ~18% energy savings vs baseline under similar load/ambient conditions.
Industrial Process
Equipment TypePlate Heat Exchanger
Operating Hours20 hrs/day
De-Scaling Period6 weeks
Maintenance ReductionQuarterly cleaning eliminated
Heat Exchanger De-Scaling
Borewell water induced rapid fouling. AE-Flux™ cleared deposits over six weeks; monitoring showed sustained cleanliness.
Recovered U-values (~95% of design) removed the need for periodic chemical/mechanical cleaning.
Infrastructure
Pipeline Length2.5 km
Diameter300 mm
Flow Improvement22%
Pump Energy Reduction~15%
Long Pipeline Flow Restoration
Rising differential pressure indicated scaling. Installing AE-Flux™ at pump discharge improved flow ~22% over four months.
Pump energy fell ~15% as friction losses reduced with de-scaling.
Note: Results are indicative of typical installations. Site-specific performance depends on water chemistry, system design, and existing scaling severity.
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