The Total Guide to Understanding Fluid Degradation

Heat Transfer Fluids play a crucial role in various industries, from manufacturing and HVAC systems to food processing and pharmaceuticals. However, one common challenge faced across these diverse industries is fluid degradation. Over time, Heat Transfer Fluids can break down, leading to a host of problems. In this comprehensive learning resource from CORECHEM, we explore the causes of fluid degradation and offer valuable advice on preventing it.

To develop a true understanding of fluid degradation, it is essential to understand Heat Transfer Fluids and how they work. These specialized fluids are the lifeblood of many industrial processes, allowing heat to be transferred from one system to another. They are responsible for maintaining consistent temperatures, safeguarding equipment, and ensuring the efficiency of various applications.

However, meeting all of these industrial objectives comes with its challenges. Due to their exposure to high temperatures, oxidative agents, and potential corrosive elements, Heat Transfer Fluids can become susceptible to fluid degradation. By understanding its causes and implementing preventative measures, this risk can be minimized. Keep reading to learn more.

What are the Causes of Fluid Degradation?

Fluid degradation can be attributed to several factors, and it’s crucial to identify these factors to take effective preventive measures. Let’s explore some of the primary reasons for fluid degradation:

1. Oxidation

   When Heat Transfer Fluids are exposed to oxygen, especially at higher operating temperatures, they undergo oxidative reactions that lead to the formation of undesirable byproducts. These reactions result in the breakdown of the fluid’s molecular structure and can manifest as an increase in acidity, the formation of sludge, and the depletion of important additives.

   The consequences of oxidation can be far-reaching. It can diminish the fluid’s heat transfer efficiency, causing reduced system performance. Additionally, oxidation can lead to the thickening of the fluid, resulting in increased viscosity. This heightened viscosity can impede the fluid’s flow characteristics, leading to decreased heat transfer rates and potentially damaging effects on system components such as pumps, valves, and heat exchangers.

   Preventing oxidation is critical to extending the lifespan of Heat Transfer Fluids. This is where the use of advanced oxidation inhibitors, often present in high-quality fluids like CORECHEM’s products, plays a pivotal role. These inhibitors act as protective agents, mitigating the harmful effects of oxidation and enhancing the fluid’s overall stability.

2. Thermal Degradation

   Thermal degradation, or thermal cracking, occurs when heat surpasses the fluid’s recommended maximum bulk temperature or film temperature, leading to the breaking of carbon-carbon bonds within fluid molecules. This reaction can either stop at that point, resulting in the formation of smaller molecules than previously present, or the fragments may combine to form larger polymeric molecules within the fluid. In heat transfer terminology, these degradation products are categorized as ‘low boilers’ and ‘high boilers’:

   • Low Boilers:

     Low boilers are characterized by a decrease in the thermal fluid’s flash point and viscosity, along with an increase in vapor pressure. Elevated vapor pressure can impact overall system efficiency, potentially causing pump cavitation and premature failure. The reduction in the flash point raises significant safety and operational concerns.

   • High Boilers:

     Thermal degradation at extreme temperatures, typically exceeding 752°F, leads to the breakdown of carbon-carbon bonds and the separation of hydrogen atoms from their carbon counterparts, resulting in coke formation. High boilers lead to an increase in fluid viscosity as long as they remain soluble. However, once their solubility limit is exceeded, they solidify, forming deposits that can rapidly foul heat transfer surfaces, potentially causing system malfunction.

3. Corrosion

   Corrosion is another significant challenge that can lead to the degradation of Heat Transfer Fluids and the systems they serve. It involves the interaction between the fluid, system materials, and environmental factors, resulting in the gradual deterioration of system components. Corrosion can compromise the structural integrity of equipment, leading to leaks, reduced system efficiency, and potentially catastrophic failures.

   For instance, it can lead to the formation of rust on metal surfaces, pitting, or the weakening of pipe walls. In extreme cases, corrosion can result in system breaches, posing safety hazards and causing costly downtime.

   To combat corrosion effectively, high-quality Heat Transfer Fluids incorporate corrosion inhibitors into their formulations. These inhibitors form a protective barrier on metal surfaces, preventing corrosive reactions and safeguarding the integrity of the system.

How to Prevent Fluid Degradation

Now that we’ve explored the reasons behind fluid degradation let’s turn our attention to prevention. Here are some essential tips to ensure your Heat Transfer Fluids remain in peak condition:

• Regular monitoring: Frequent fluid analysis and monitoring can provide valuable insights into the health of your system. Identifying issues early allows for timely corrective action.
• Proper fluid selection: Selecting the right Heat Transfer Fluid for your specific application is critical. Consider factors such as operating temperature, system materials, and potential exposure to corrosive elements. For advice on finding the optimum solution, simply contact us.
• Routine maintenance: Implement a regular maintenance schedule that includes system inspections, fluid analysis, and equipment checks. This can also include a system flush and changing degraded fluid. Timely maintenance can prevent minor issues from escalating into major problems.
• Use of corrosion inhibitors: Choose Heat Transfer Fluids that contain corrosion inhibitors, like our glycol range. These inhibitors act as a shield, protecting your system from corrosion-related fluid degradation.

Mitigate Fluid Degradation with CORECHEM

The battle against fluid degradation is one that can be won through knowledge, vigilance, and the right choice of Heat Transfer Fluid. For more advice on selecting the optimum solution, contact one of our heat transfer experts today.