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Daimler Truck case study
Magcat reduced scale build-up in Daimler’s test facility, cutting downtime and protecting critical cooling equipment.
Client: Daimler Truck
Region: Germany
Application: Engine testing cooling system
Sector: Automotive
Product: Magcat water conditioner
Daimler Truck operates extensive engine testing facilities, where multiple engines run continuously under controlled conditions. Cooling water is circulated through charge air coolers (CACs) and other components, with heat ultimately rejected via a cooling tower. Persistent scale formation in the system was reducing efficiency and causing frequent cleaning shutdowns.
The challenge
Severe scaling across the cooling system, with certain sections identified as the “worst of the worst” (WOW)
Stand 12’s charge air cooler typically required descaling every 1,500 operating hours (around two months at 24/7 running)
Scale accumulation was disrupting Daimler’s essential engine testing programme, leading to many hundreds of hours lost annually
A chemical control programme using sulphuric acid dosing and LSI adjustment helped but did not prevent scaling
The solution
After consultation with Fluid Dynamics and review of system data, a 3” Magcat unit was specified for the WOW stand, sized to treat a design flow of 118 gallons per minute. The dual-treatment Magcat system was installed in March 2016.
Results
Post-installation inspections showed the CAC protected by Magcat remained clean after 1,000 hours of operation
By contrast, unprotected CACs continued to show heavy scale build-up
Reduced downtime and cleaning requirements improved the availability of testing stands
Magcat demonstrated effective scale control even under high-stress conditions with variable water quality
Unprotected CAC
Magcat protected CAC after 1000 hours
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