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Most Hydronic Heating Systems Use Water, So What is Glycol Used for in HVAC?

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There are many propylene glycol uses in the world, but is it necessary to add glycol to water in hydronic heating systems? What about adding glycol for cooling systems? This article explains why adding glycol to water provides important protections.

Water is the Basic Fluid used in Hydronic Heating and Cooling Systems

Many building heating and cooling systems use water to move temperatures around the building. The water is heated or cooled, and pumps transport the water to the various coils where air takes the heat or cooling into the space.

To maintain good indoor air quality, fresh air must be brought into the building while some air is exhausted. The air is pulled in by fans located in air handling units and is the same temperature as the outdoor air. In northern climates, the incoming air temperature can be very cold. Care is exercised during the design to assure that the ice-cold air does not freeze the water but things can go wrong.

Three Example Systems Where Adding Glycol Can Save the Day

Example #1: Air Handling Unit Freeze Protection

Look at the photo above. This heating coil uses a two-way control valve with the main heating pumps operating on variable speed drives. This will save energy and operating costs.

The downside of the system is the concern about stopping the flow through the coil where cold air is rushing in. Engineers use a piping practice named primary-secondary to assure there is always flow across the coils. The primary-secondary piping depends on a small circulator pump to move the water around.

If the circulator pump fails, the flow may stop, and cold air could freeze the water and damage the coils. Many engineers will use a percentage propylene glycol antifreeze mixed with the water to avoid catastrophic coil damage.

Example #2: Glycol Chillers not used in the Winter

Many HVAC systems have air cooled chillers used throughout the summer. In the winter they are drained so they do not freeze. This provides two problems for owners.

What happens when we get a hot spell in the fall. The people in the building are hot and they do not blame the system, they blame the operations people. Adding glycol to cooling systems will allow the use in both summer and winter.

The second problem occurs when the cooling system is started. Many owners simply open the valves to the air cooled chiller and allow the system and the makeup water to fill the pipe. This causes a large amount of air to be introduced into the system. This air will cause cooling problems for weeks or even months.

When people ask, what is a glycol chiller? The answer could simply be a chiller that can run all year if needed. Remember that not any old antifreeze will do. The glycol used in chilled water systems should be the right percentage and have the right mix of inhibitors. Try our glycol concentration calculator to determine the required concentration for your application or contact us today for help finding the correct solution for your application.

Example #3: Pipe in Unheated Spaces

We showed above the glycol chiller can be used all year round. There is another concern with piping systems where there is no flow at times. Often these pipes may run through unheated spaces or spaces with cold outside air blowing across the pipe.

Sometimes the design included heat in a space to protect the chilled water or heating system. During the life of the building the space becomes unused. To save money, the owner may turn the heat down or even off. Water may freeze but a glycol antifreeze system will protect the pipe.

Additional Advantage of Glycol in Closed Hydronic Heating and Cooling Systems

Not all glycols are the same. The Dowfrost® and Dowtherm® products supplied by Go Glycol Pros include an inhibitor package which protects the pipe much better than water or even water with chemicals added. Click here to learn more about the benefits of inhibited heat transfer fluid.

Adding the proper type, concentration (or mix), and brand of glycol to closed heating and cooling systems will offer protection. Glycols and antifreeze should not be added to systems without an understanding of the effects on pumps and heat or cool output. For assistance in getting started, contact our customer service team today!

For more information, please visit Glycol Water Chiller.

MEET THE PRO: NORM HALL

Norm graduated from Wayne State University in Electrical Engineering. Over the past 40 years at RLD Norm has worked on design/engineering of systems, estimating, outside sales & management. Norm enjoys golf, playing with his grandkids, teaching eighth grade catechism classes, and volunteering at local food banks.

Go Glycol Pros is a distributor of DOW® heat transfer fluid for over 20 years. We sell glycol online with no accounts or order minimums required. Available in 275 gallon tote, 55 gallon drum or 5 gallon pail, high purity DOW antifreeze is premixed with deionized water (DI water) at our in-house facility and ships out within just one business day. Our inhibited glycols include: DOWFROST HD propylene glycol, DOWFROST food grade propylene glycol and DOWTHERM SR-1 ethylene glycol.

Explore more helpful tips and advice at goglycolpros.com. Our knowledgeable glycol experts are ready to help you with your latest hydronic HVAC project.

View Dow Ethylene Glycol, Propylene Glycol and Food Grade Propylene Glycol

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Disclaimer: Go Glycol Pros and it's affiliates can not be held liable for issues caused by use of the information on this page. While the- information comes from many years of experience and can be a valuable tool, it may not take into account special circumstances in your system and we therefore can not take responsibility for actions that result from this information. Please feel free to contact us if you do have any questions.

At ClearWater Industries, we understand that protecting HVAC systems during extreme conditions is critical to maintaining efficiency and avoiding costly disruptions. Glycol plays an indispensable role in preventing freeze-ups, ensuring thermal stability, and protecting key components from corrosion. Our Total Water approach combines industry expertise with advanced glycol solutions to safeguard your systems, enhance energy efficiency, and minimize environmental impact.

What Is Glycol Used for in HVAC Systems?

Glycol is a versatile chemical compound used in HVAC systems as an antifreeze agent and heat transfer fluid. Its primary function is to prevent freezing in pipes and equipment, ensuring uninterrupted operation in sub-zero conditions. Beyond freeze protection, glycol enhances heat transfer, protects against corrosion, and improves energy efficiency in various applications.

Key Applications:

• Chilled Water Systems: Prevents freezing in outdoor cooling loops during winter months.
• Geothermal Systems: Maintains performance in underground heat exchange loops, regardless of temperature fluctuations.
• Solar Heating Systems: Protects solar collectors and piping from freezing, enabling efficient year-round operation.
• Refrigeration Systems: Prevents ice build-up in low-temperature environments, optimizing cooling efficiency.

Choosing the Right Glycol for Your HVAC System

Selecting the appropriate type of glycol is essential for achieving optimal performance and safety.

• Ethylene Glycol: Known for its high thermal efficiency, ethylene glycol is ideal for industrial applications but must be handled carefully due to its toxicity.
• Propylene Glycol: A non-toxic alternative, propylene glycol is preferred in environments requiring food-grade safety or lower environmental impact.

Use Case Scenarios:

• Industrial refrigeration systems often favor ethylene glycol for its superior heat transfer capabilities.
• Food processing facilities and residential systems prioritize propylene glycol for its safety and lower toxicity levels.

Best Practices for Glycol Use in HVAC Systems

1. Optimize Glycol Concentration
   • Maintain glycol concentrations between 30-50%, depending on your system's needs and the lowest anticipated temperature. Over-concentration can reduce heat transfer, while under-concentration increases freezing risks.
2. Regular Monitoring and Testing
   • Use refractometers or lab analyses to monitor glycol concentration, pH levels, and inhibitor strength. Quarterly testing is recommended for systems in harsh environments, while semi-annual checks may suffice for standard operations.
3. Incorporate Corrosion Inhibitors
   • Add corrosion inhibitors like nitrites or molybdates to prevent scaling and rust in system components. Ensure inhibitor levels are regularly replenished.
4. Flush and Replace Glycol Periodically
   • Replace glycol every 3-5 years or as recommended by your manufacturer. Flushing the system removes degraded glycol and contaminants that can compromise performance.
5. Avoid Untreated Water for Dilution
   • Always dilute glycol with deionized or distilled water to prevent scaling and microbial growth. Untreated water introduces impurities that can lead to system inefficiencies.
6. Train HVAC Operators
   • Equip operators with knowledge on detecting signs of glycol degradation, proper handling protocols, and safety measures for accidental spills or exposure.

Environmental Considerations

Proper management of glycol is crucial to minimize its environmental impact:

• Use Biodegradable Options: Opt for glycol formulations with improved biodegradability to reduce pollution risks.
• Dispose Responsibly: Partner with certified recycling facilities to ensure safe and compliant glycol disposal.
• Prevent Spills: Implement robust storage and handling practices to minimize the risk of accidental discharges.

By choosing propylene glycol and adhering to best practices, facilities can meet their operational needs while reducing their environmental footprint.

Common Mistakes to Avoid

1. Improper Dilution:
   • Diluting glycol with untreated water introduces impurities that cause scaling and microbial growth.
2. Neglecting Routine Testing:
   • Failing to monitor glycol levels can lead to inefficient heat transfer, freezing, and system corrosion.
3. Improper Disposal Practices:
   • Disposing of spent glycol improperly poses environmental hazards and can result in regulatory penalties.

Industry Compliance Standards

Ensuring compliance with industry regulations is critical for both operational safety and environmental responsibility. Here's how glycol use in HVAC systems aligns with key standards:

1. ASHRAE Guidelines
   • The ASHRAE Standard 34 specifies safety classifications for refrigerants, including those containing glycol, ensuring the fluid used meets specific safety and toxicity requirements.
   • ASHRAE 15- offers detailed recommendations on the safe design, installation, and operation of HVAC systems using heat transfer fluids like glycol to prevent leaks and system failures.
2. OSHA Regulations
   • OSHA's Hazard Communication Standard (HCS) (29 CFR .) requires proper labeling, storage, and training on glycol use to protect workers from exposure risks.
   • Employers must provide safety data sheets (SDS) for glycol solutions and ensure employees follow established safety protocols, such as wearing PPE when handling ethylene glycol due to its toxicity.
3. EPA Recommendations
   • The EPA regulates the disposal of glycol under the Resource Conservation and Recovery Act (RCRA) to prevent environmental contamination.
   • Used glycol must be recycled or disposed of in accordance with EPA-approved methods to avoid penalties and environmental harm.

How ClearWater Industries Helps

ClearWater Industries ensures that all glycol management practices adhere to ASHRAE, OSHA, and EPA standards, minimizing risks and maintaining operational integrity. We provide tailored solutions that prioritize compliance, safety, and environmental stewardship.

FAQs

1. What is the ideal glycol concentration for HVAC systems?
The ideal concentration is typically 30-50%, depending on the climate and specific system requirements. Over-concentration reduces heat transfer efficiency, while under-concentration increases freezing risks.

2. How often should glycol be replaced in HVAC systems?
Glycol should be replaced every 3-5 years, or sooner if testing shows significant degradation, pH imbalance, or contamination. Regular monitoring ensures optimal performance.

3. What are the environmental risks of improper glycol disposal?
Improper disposal of glycol can contaminate water sources, harm aquatic life, and result in regulatory penalties. Always recycle or dispose of used glycol in compliance with EPA guidelines.

4. How can ClearWater Industries assist with glycol management?
ClearWater Industries provides comprehensive glycol solutions, including system assessments, tailored recommendations, routine testing, and guidance on safe disposal or recycling to ensure compliance and efficiency.

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