In collaboration with a confidential client, Verdantas conducted a targeted investigation into mitigating leakage in condenser tubes—critical components in power plant heat exchange systems. The challenge centered on persistent leakage through defects in heat exchanger condenser tubes, which can compromise system efficiency and reliability.

To address this, our team designed and built a custom flow loop to simulate real-world operating conditions, while allowing for visual observations in real time. Over a series of controlled tests, we evaluated the performance of a novel additive under varying flow and pressure conditions. The solution—an advanced, environmentally safe, powdered additive—was introduced into the system and monitored for its ability to seal varying simulated defects.

The results were immediate and measurable. At concentrations as low as 12.5 mg/L, the additive successfully reduced leakage to near-negligible levels. Across all tests, flow velocities averaged 4.9 ft/s with a differential pressure of approximately 30 psid. Post-treatment leakage rates slowed to intervals of 42–120 seconds per droplet, as compared to a pre-treatment constant emanating stream, demonstrating the additive’s effectiveness in real-time leakage mitigation.