Corrosion-Resistant Heat Exchange Coils

HVAC coil corrosion is a complex issue that may have substantial effects on the efficiency of the system and its cost of operation. Studies have revealed that corrosion costs industries billions of dollars every year globally. In the case of heat exchange coils, it translates into lower thermal efficiency, higher power consumption, and equipment failures.

Types of Coil Corrosion:
• Galvanic Corrosion: Occurs when contact between dissimilar metals happens (copper tubes and aluminum fins).
• Pitting Corrosion: Localized corrosion which produces small holes in metal surfaces.
• Formicary Corrosion: Caused by organic acids in the indoor environment.
• Environmental Corrosion: Effect of exposure to severe atmospheric conditions.

The manufacturing plant of Mistcold is situated in Bawal, Haryana and uses high-tech technologies to fight corrosion in various creative ways through advanced material science and coating technologies.

Mistcold emphasizes the adoption of high grades of aluminum alloys to compose coils. The firm uses 3000 series aluminum alloys (Al-Mn-Cu) on tubes and special compositions on fins which show great resistance to corrosion, welding characteristics, and mechanical properties. These alloys generate a stable oxide layer self-generating further oxidation in pH 4 to 9.

Mistcold applies several types of coating based on specific needs:

• Epoxy-Based Coating: Seven-stage cathodically-coated epoxy systems that survive hostile industrial environments.
• Phenolic Topcoats: Industry standard coating that is air-dried forming almost impregnable layers.
• Pre-Coating Systems: Coated on fin materials prior to stamping, forming electrical insulation between dissimilar metals.

Mistcold employs electrocoating (e-coating) technology in case of application in very corrosive environments. This technology is based on deposition of organic coatings uniformly over complex geometries using electrical current, and has the benefit of:

• Corrosion resistance at high level
• Excellent adhesion characteristics
• Flexibility to mechanical deformation
• High-quality chemical resistance
• Uniform thickness (15-40 microns)

Mistcold coils that are required in seacoast or marine locations are equipped with salt-spray resistant finishes. These systems incorporate flexible e-coat base and industry standard topcoats to resist cracking and at the same time preserve protection against salt and moisture.

In industrial applications where chemical contaminants are a problem, Mistcold uses multi-metal corrosion inhibitors and state-of-the-art barrier coating to isolate coils against environmental contaminants without compromising heat transfer efficiency.

In the case of urban installations where pollution is high, the company employs coating with increased resistance against sulfurous environment as well as organic acid compounds which usually contribute to the development of formicary corrosion.

Mistcold's commitment to corrosion resistance is approached through extreme test protocols:

• SWAAT Testing: Salt water acidified acetic acid testing (ASTM G85:A3) proves very long coil life when compared to uncoated versions.
• Accelerated Corrosion Testing: Testing of harsh environment conditions on a laboratory scale.
• Field Performance Monitoring: Long-term monitoring of coil performance among installations.

Investment in corrosion-resistant coils delivers substantial economic gains:

• Long Life Expectancy: Coated coils can increase their life by a factor of three.
• Energy Savings: Thermal efficiency prevents the energy cost increases of up to 30 percent seen in corroded coils.
• Less Maintenance: Coating prevents frequent replacement and repair.
• System Reliability: Eliminates unwanted failures that have the potential to interrupt operations.

Mistcold continues working on corrosion resistance through:

• Smart Coating Technologies: Self-healing coating and antimicrobial additives that offer active protection.
• IoT Integration: Integrating corrosion monitoring devices to give real-time feedback related to coil status for predictive maintenance.
• Sustainable Solutions: Environmentally friendly coating systems that contribute lower levels of VOC and better sustainability.

To fully realize the advantages of Mistcold's corrosion-resistant coils, the firm suggests:

• Frequent Inspections: Performance checks every quarter.
• Proper System Design: Well-drained and well-ventilated to avoid moisture.
• Water Quality Management: Application of appropriate water treatment in closed-loop systems.
• Professional Installation: Following right procedures in handling and installations.

The corrosion-resistant coils manufactured by Mistcold have proved exceptional in several areas:

• Manufacturing Plants: Long working hours and few maintenance needs.
• Coastal Hotels: Salt-spray does not bother performance.
• Industrial Installations: Good performance in chemical hostile working conditions.
• Commercial Buildings: Urban pollution long-term efficiency maintenance.

With the growing importance of environmental issues and the relevance of energy efficiency, Mistcold's comprehensive approach to corrosion resistance makes the company a pioneer of sustainable HVAC solutions. Mistcold achieves superior life cycle and performance of their heat exchange coils through the use of innovative coating technologies and strict quality standards with the help of advanced material science.

The constant improvement and technology underlying the company reinforces their obligation to offer the most dependable and most affordable HVAC solutions to customers. Purchasing Mistcold's corrosion-resistant coils means investing in technology that guarantees the safety of HVAC systems at minimum possible operational expenses and environmental impact.

To learn more about Mistcold's advanced corrosion-resistant coil technologies and production capacity, visit mistcold.com or talk to their technical experts to have a customized solution to meet particular environmental challenges.