Sustainable water use is an important goal of many companies and institutions, and significant progress has been realized in recent years that has saved millions of gallons of water while achieving the intended purposes of the systems, such as cooling towers, which use high volumes of water. Saving water has a positive impact on the environment as well as the bottom line.
The ability to justify a business case for applying efficient technologies can be difficult based on water savings, provided by the HydroTech Total Water Management program.
Online Secure Operating Data
In order to manage a process, it should be constantly measured. This is not often the case with cooling tower water systems. HydroTech deploys web-enabled sensors and meters that continuously monitor water chemistry and volumes used and discharged.
Metrics include water, energy and chemical reductions. The business case for supporting a return on investment (ROI) in 12-24 months is common for HydroFLOW, filtration and a sensor/ data network.
Robust Water Efficiency Tools
A successful program requires reliable metrics, benchmarking and a set of tools to evaluate successful operations. HydroTech supports process improvements in the cooling tower industry and believes that online data monitoring from reliable water quality & quantity sensors allow continuous progress toward saving millions of gallons of water per year per building.
Current Water Management Practices Offer Limited Gains
Cooling towers remove heat from water by evaporating a small portion of the water that is recirculated through the unit. Maintaining water quality is essential for optimum operating conditions, which involves controlling bacteria and algae, preventing scale, and corrosion. Scale and bacteria degrade the thermal and flow efficiencies of a water system, and together can cause corrosion of metal that results in high maintenance and replacement costs.
Traditionally, a range of chemicals are added that include scale inhibitors, biocides, corrosion inhibitors and other site specific additives to extend the use of water while preventing accumulation of scale and biologicals in the equipment. Some cooling systems have a side stream filtration system that processes approximately 10% of water to remove suspended solids from the water stream while allowing the primary circulation to continue.
It is our belief that ALL cooling systems should use side stream filtration in order to preserve the useful life of the system, and extending the effective usefulness of water before discharging and replacing it with makeup water.
Under these operating conditions, water is discarded by blow down or bleed off when a sensor records a specific level of conductivity. Accumulated water loss is undesirable for cost and stewardship reasons, and every thousand gallons of purged water contains expensive chemicals that must be replenished.
Water Technologies with Short ROI
In practice, a cooling tower that maintains low levels of suspended solids will have lower conductivity in water, while also eliminating surface area for biologicals to grow. By removing suspended particles, the effective use of water will be increased significantly. Further, the chemicals in the water will be conserved due to less frequent bleed off and they will have less total suspended solids (TSS) and organic matter that consumes them. We believe that a balanced chemistry program is important for consistent cooling tower operation, and offer technologies that reduce chemical use by up to 75%.
HydroFLOW is installed on the exterior of a water line and emits a 150 kHz frequency that extends throughout the system. The patented transducer creates a pulse that includes a pause between signals that allows the positive and negative ions to bond after being excited by each pulse. The result is the dissolved calcium particles form clusters in water, preventing attachment to pipe and system surfaces. Scale is prevented and existing scale is reduced over time. The clustered scale particles are filtered out of the water stream and physical removal of calcium and hardness continues 24/7.
Bacteria and algae are controlled by the HydroFLOW’s frequency which unlike magnetic applications, uses AC current that extends throughout the system. Algae, biofilm and free-floating bacteria are deactivated and flocculated by the HydroFLOW and removed by side stream filtration, along with scale clusters and TSS down to 1 micron in size.
Capturing the Savings
Frequent blowdowns are reduced to brief bleed-off episodes using 50% less water. Due to significantly improved water quality, 75% of chemistry can be conserved. Due to the reduction of chemicals, discharged water may to be reused for irrigation or other beneficial uses rather than disposal in a sanitary sewer.
IoT enabled sensors monitor conductivity, pH, temperature, in addition to make-up and blowdown water volumes. Evaporation credits are calculated and presented in monthly reports, along with key performance data that is also available securely online by customers.
HydroFLOW electronic water conditioning and side stream filtration need little or no maintenance, and require no chemical additives. The cost savings provide a return on investment (ROI) of less than 12-24 months, based on cost savings derived from:
50% Water Reduction
75% Chemical Reduction
12-15% Energy Reduction
Evaporation Credits and Water Cost Savings
Sustainable Water Management requires frequent data collection to measure water, electricity and chemical use. In terms of calculating cost savings, maintenance events may be included, as well as a broader monitoring of asset life cycle management metrics.
HydroTech continues to evaluate improvements for short-term gains in cooling tower water conservation as well as long term OPEX benefits due to extended equipment life cycles.
We welcome opportunities to collaborate with industry members and customers for developing better tools for evaluating cooling system water and energy efficiencies, and enhancing metrics for improved predictive analytics so that resource use is optimized.
HydroTech was formed to provide sustainable water management technologies to commercial and industrial users that save water, energy and chemical use; along with sensors that measure water chemistry and key performance metrics. Contact us with questions or ideas. We would enjoy the opportunity to share perspectives.
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