We moved into our 1998, 2100 sqft, 2 story (w/ basement) home 3 years ago. I installed a humidifier in our previous home that was of the hamster filter wheel through the water basin type. This time around I decided to upgrade to the cadillac powered misting style which injects water vapor into the warm air plenum about 20 seconds after the fan and burners kick on.
First off, the humidity in my home is still around the teens and I get shocked every time I take off my coat and my whole family seems to deal with sore throats and bloody noses. I have since installed a free-standing humidifier upstairs to get the levels of the bedrooms up to the lower 40s.
Okay, enough with the history lesson, here is the reason for my posting. I have now noticed rust developing around the seams of my ductwork with the bulk of it closer to the furnace (in some cases it has propagated about 6 inches). Was the powered mister a bad choice or is something else going on? Can I fix this? Should I remove the mister (especially since it does not seem to work well anyway)? Can I just seal the seams with aluminum tape (a process that definitely makes it look better )?
Any advice will be appreciated. Thanks.