Why Suppress Cooling Tower Scale When It Can be Filtered Out to Conserve 50% of Water Use?

Technologies continue to improve business processes, and the water management area is undergoing tremendous changes, as the industry is learning to conserve water while reducing chemistry.

The practice of preventing scale formation traditionally relies on constant dosing of anti-scaling chemicals to suppress adhesion to pipes and equipment surfaces, and when calcium reaches a super-saturation point, the water is blown down to the sanitary sewer before scale can form on equipment. More water is added to the system, along with more chemicals and the process continues as evaporation concentrates the calcium that is left behind in the circulating water.

Scale is crystallized and filtered out for cooling water conservation

More water is added to the system, along with more chemicals and the process continues as evaporation concentrates the calcium that is left behind in the circulating water.

The current scale prevention process requires a lot of water and chemistry each day. A 1,000-ton cooling tower may use 6,000,000 gallons of water per year to operate.

Thinking Differently: Deliberately cause scale to form

HydroFLOW on 1,000-ton cooling tower

Not many people give a microwave oven much thought as they heat something. The waves save time and energy to achieve the desired result.

Electronic water conditioning uses a pulsed frequency that causes calcium and magnesium particles to crystallize in the water stream so that scale cannot attach to surfaces. 

While the pulsed frequency is low energy (<$10/ year to operate) the 150 kHz waves safely extend throughout the water system.

Instead of inhibiting scale formation with chemistry, scale particles are deliberately formed as suspended particles that are filtered out of the water stream continuously. The amount of water required is reduced by 50%. Chemical use is reduced by 70%, and energy used by the cooling system is reduced by 10-12% by causing scale to safely form rather than chemically preventing it.

A 1,000-ton cooling tower in Houston has been conserving 300,000 gallons of water per month for a year with Hydrotech’s Total Water Management program, and validating performance with real-time data collection. The cost of the program is paid for and approximately $400 per month in operating expense savings are being captured.

Hydrotech IoT sensors provide data for analytics of cooling water conservation

HydroTech has revised the Cooling Water Process for increased Sustainability

Rather than using chemicals to prevent scale from forming, our systems reduce chemicals and force the scale to form in the water stream, and filter the calcium out of the water. IoT enabled sensors monitor the volumes and water quality in real-time for better management of the entire cooling system. Our customers save considerable operating costs while conserving half of their water use.

Crystallize + Filter + Measure = Cost Savings for OPEX and 50% Water Conservation every day.

Hydrotech total water management for cooling tower scale control

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