HVAC&R MODULE

103 MANAGING
Skills CONDENSATE
Workshop FOR CONDENSING
BOILERS
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Over the past decade, the number of condensing boilers and water heaters
being installed has continued to rise. All indications are that this trend will
continue and eventually become mandatory due to their higher energy efficiency
and cleaner emissions compared to standard boilers. In this month’s
Skills Workshop, we provide an overview of condensing boilers
and how to correctly manage condensate.
PULLOUT

WHAT IS A However, even when running at traditional,

CONDENSING
BOILER?
A condensing boiler, also known as a condensing
hot-water heater, is a type of boiler that is
considered by many as more efficient than the
traditional-type appliance. Extra efficiency is
achieved by extracting more energy out of the
flue gas as compared to that of a conventional
boiler, and using this energy to pre-heat the return
water flowing into the boiler.
To understand how this process works, we have
to consider some basic chemistry. When gas
burns, it combines with oxygen to produce carbon
dioxide and water, and some other by-products.
For instance, methane gas (natural gas).
non-condensing temperatures of 80/60
a condensing boiler typically offers 4–5 per cent
better efficiency than a non-condensing boiler
due to the superior heat exchanger and burner
control in a condensing boiler.
A conventional boiler will typically have a
minimum entering water temperature of around
60°C, with an exit temperature of 80°C, and will
not have the heat-exchange elements in place
to achieve the extra heat recovery in any case.
Indeed, if condensing does occur in a conventional
boiler it’s a bad thing, because the condensate
does include acidic by products that will corrode
the inside of the boiler and ultimately cause it
to fail. Condensing boilers have additional heat-
exchange elements and are manufactured of the
right materials to withstand corrosive condensates.
HOW EFFICIENT
IS A CONDENSING
BOILER?
The efficiency of a boiler is measured by the ratio
of energy output to energy input. To complicate
matters, there are two conventions for measuring
the energy content of gas:
• Gross calorific value: this is the energy released
in combustion assuming that the water in the
flue is liquid
• Net calorific value: this is the energy released
in combustion assuming that the water
in the flue is vapour.
The correct figure to use when considering
a condensing appliance is always the gross
calorific value, which is the larger value.

CH4 + 2O2 → CO2 + 2H2O + ∆E

Condensing vs. non-condensing boiler efficiency
Where ΔE is the energy released in combustion.
The size of ΔE depends on the final state of the
carbon dioxide and water. The cooler they are,
the more spare energy there is. For the water,
this is particularly important because if the water
is vapour, then it carries a lot more energy than
if it is liquid. So, if on leaving a boiler, the flue gases
are cool and the water is liquid, then the amount
of energy ΔE that we can use is going to be larger.
In a condensing boiler, the water is condensed
inside the boiler so more energy can be extracted;
in a conventional boiler, the water escapes as
vapour and the energy is lost.

To be able to condense the water vapour

from the flue gas, the condensing boiler should
operate using a lower entering water temperature
than a conventional boiler. This is because Figure 1:  illustrates the superior financial and environmental benefits achieved by
the condensing process occurs at around 54°C. condensing water heaters over conventional water heaters.

July 2017 | www.airah.org.au/nation | HVAC&R Nation | 15

HVAC&R Skills Workshop
Return water temperature and efficiency
Figure 2:  Shows the increase of efficiency achieved when return water temperatures are below 54°C.
Effectively what this means is that the lower the return water temperatures, the greater the boiler efficiency.
However, some promotional literature for
conventional boilers will use the net calorific value,
because this makes their conventional boiler look
more efficient.
Using gross calorific values, conventional boilers
are typically around 80–83 per cent efficient at
full load. By contrast, a condensing boiler using
the same basis is around 95 per cent efficient
at full load.
Using net calorific values, these figures both
increase by about 10 per cent, so that the
condensing boiler has an apparent efficiency
of 103 per cent – because it is extracting more
heat from the flue gas that the net calorific value
recognises.
So, the immediate benefit of a condensing
boiler is an improvement in efficiency of at least
10–15 per cent. However, it’s actually much better
than that, as can be seen in Figures 1 and 2.
CONDENSING
BOILER CONDENSATE
AND WHY IT NEEDS
TO BE MANAGED
CORRECTLY
Over the last decade, the number of condensing
boilers and water heaters being installed has
continued to rise every year and all indications
are that this trend will continue and eventually
become mandatory due to energy efficiency and
cleaner emissions compared to standard boilers.
Condensing boilers discharge a corrosive
condensate as a by-product of their operation.
Because of the long-term effects of the sustained
introduction of this corrosive condensate
into drains and sewer lines, there is a growing
awareness of the need to educate code
enforcement officials, contractors, building owners,
facility managers and homeowners of the need
to neutralise this corrosive outflow and the means
available to do this.
16 | HVAC&R Nation | www.airah.org.au/nation | July 2017
WHAT IS
CONDENSING BOILER
CONDENSATE?
Condensing water heaters achieve higher energy
efficiency than standard boilers by condensing
the water vapour in the flue gasses and using
the latent energy recovered through this process
to heat the return water going into the water
heater.
The condensing process is achieved by passing
the piped hot flue gases through the cooler return
water flowing back into the boiler. Flue gas starts
to condense when it drops below its dew point
of 55°C. Therefore, condensing boilers are designed
to accommodate a return water temperature
of 54°C or less.
It is this resulting condensate liquid that is acidic
and requires treatment to avoid damage to piping
systems, sewerage systems and other items it may
come in contact with.
Figure 3: This image shows high-efficiency condensing boilers with condensate neutralisers installed
in the pipes that connect the boiler drains to the point of discharge.
HOW MUCH
CONDENSATE
IS PRODUCED?
A general rule of thumb, 3.5 litres of condensate
is produced for every 30kW of input providing
the boiler is operating in full condensing mode.
A boiler having 30kW of input operates for
1200 hours annually will produce approximately
4200 litres of condensate.
ACIDITY LEVELS
The acidic level of the condensate is measured as
pH. Most condensate from natural gas appliances
will have a pH of between 2.0 and 4, with 7 being
neutral. The actual pH will vary according to the
actual chemical makeup of the fuel that is being
burned.
Condensate contains different types of acids
that are corrosive to many materials and contain
concentrations of nitric, nitrous, sulfuric, and
sulfurous and hydrochloric acids. These acids
can become more concentrated by repeated
condensing and evaporation on heat exchangers
and flues.
A pH of 4 can damage drainage pipes, septic tanks,
treatment plants and other materials handling
waste water. The pH scale is not linear. Each whole
number step below 7 is 10 times more acidic than
the next higher number.
HOW TO TREAT
CONDENSATE
Treated condensate should be as close to
7 (neutral) as possible with 5 being the minimum.
Most national and state codes prohibit anyone
from allowing acidic liquid into a drainage system
without treating it to raise its pH.
To increase the pH to acceptable levels, whereby
it no longer has the potential to damage the sewer
system or environment, a condensate neutraliser
should be installed. Condensate neutralisers are
designed specifically for this task, and consist
of a tank or module containing alkaline limestone
aggregate or chips.
 HVAC&R Skills Workshop

CONDENSING BOILERS FOR RETROFIT INSTALLATIONS

Here, we’ll be answering a question often
encountered in the industry – whether
condensing boilers offer a benefit in retrofit
80°C/60°C installations.
Modulation is key
Typically, boilers are replaced like-for-like when replacing
an existing boiler that has reached the end of its life. However,
performance data shows that even though optimum performance
of condens ing boilers occurs at temperatures below 60°C,
condensing boilers can still provide substantial energy efficiency
benefits when retrofitted to a conventional 80°C flow/60°C return
hot-water system.
The major increases in efficiency are available in times when the
heating load is less than the peak design value and can be achieved
by varying the boiler operating temperatures from 80/60 at times
of peak load to lower temperatures when heating loads are lower.
This is quite simple to achieve using the on-board controls available
on most condensing boilers, which permit the supply hot water
temperature to be reset by an outside signal. The total efficiency
gain achieved is almost as good as if the system was being run
at low temperature all the time.
PULLOUT
Efficiency benefits
It’s important to remember as a starting point that even in non-
condensing conditions (such as 60°C return hot-water temperature),
a condensing boiler will still provide an efficiency benefit of around
5 per cent relative to a conventional boiler. This is because the
additional heat-exchanger area of the condensing boiler improves
efficiency even when no condensing occurs.
However, once we drop the return-water temperature below
55°C, the condensing efficiency benefits kick in and we start seeing
combustion efficiency impacts of 10 per cent and better – as well
as reduced distribution pipework thermal losses.
Conclusion
Condensing boilers are an ideal retrofit for an existing
80°C flow/60°C return system. Modulation of the supply
temperature, typically across the range 80°C-60°C across
normal operating conditions, enables the system to serve the
full system demands of the hot water system while still achieving
the significant efficiency benefits of a condensing boiler system.
This is an excerpt from the third of a series of articles
contributed by Dr Paul Bannister, F.AIRAH, a thought leader and
public speaker on energy and energy efficiency issues in Australia.
For further information, go to www.automaticheating.com.au

There are several models that accommodate

water flow rates from 6.05l/hr to 155l/hr depending MAINTENANCE A fully condensing appliance will produce
up to 3.5 litres of condensate per hour for every
on the size of the condensing water-heater system. AND SERVICING 30kW of input.

The acid is converted to water, carbon dioxide
and mineral salts when exposed to the media.
The carbon dioxide will generally stay diluted
in the water and pass out of the neutraliser.
The mineral salts generally settle at the bottom
of the neutraliser. Over time the media dissolves
and must be replenished.
If applied properly and maintained regularly,
damage associated with acidic condensate
in the drain piping can be avoided.
CONDENSATE
DRAINS
The best way to check if the condensate The neutraliser media is reacting with the solution
neutraliser is working properly is to test the to raise the pH and does need to be replaced.
treated condensate with a pH meter, which Most manufacturers recommend replacing media
are available at a reasonable cost and should and checking operation at least annually.  n
be added to the technician’s tool arsenal.
All manufacturers of condensing boilers
recommend annual maintenance and the service
technician should check and service
the condensate neutralizer during this service.
It is the responsibility of the HVAC&R professional
to follow state and local plumbing codes including
proper disposal of condensate and equally
important for the end user to provide ongoing
maintenance ensuring proper function of the unit.

The condensate expelled from a condensing-water Damage can occur underground and in unseen,
heater is acidic with a pH of between 2 and 4, remote locations. Imagine digging up your
so it is critical that the appropriate materials are basement floor to replace a rotted out metallic
used in all piping where this liquid is present. drain line!

In high temperature areas, like the flue, stainless

steel must be used to prevent corrosion.
The low-temperature piping, such as
that which drains the condensate from the
heat-exchanger condensate draining system,
should be PVC or ABS to also mitigate corrosion.
This system normally consists of a short length
of PVC or ABS pipe with a water trap to prevent
exhaust gases from being expelled into the drain
and building.
IN CONCLUSION
Condensate from condensing boilers is acidic and MORE INFORMATION
corrosive to many materials and should be treated
to maintain a pH of no less than 5 before disposal.
This month’s Skills Workshop
There can be a wide variation of the pH has been provided by Automatic Heating.
of condensate from condensing appliances For more information, go to
due to the chemical make-up of the gas being www.automaticheating.com.au
combusted or from the way in which the appliance
is operating in a particular application.

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