Why Suppress Cooling Tower Scale? Filter Scale Out to Conserve 50% 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 scale accumulation on pipes and equipment surfaces, but over time the scale forms anyway.

Conductivity is monitored in circulating water to prevent too much dissolved scale from developing after 2-3 cycles of water evaporation leaves behind concentrated calcium.  When the calcium reaches a super-saturation point (the conductivity set point), most of 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 improved 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.


Crystallized Scale + Filter + Measure

= Cost Savings

for OPEX and CAPEX reduction.

50% Water Conservation each day

Chemical Dependent Cooling Tower Water Management

HydroTech Total Water Management uses the processes that occur naturally for improving water costs, long term use and equipment asset life. Our approach of forcing scale to form rather than chemically suppressing scale accumulation allows suspended solids to continuously form and be filtered out so that the concentrations of calcium are maintained at manageable levels, and scale formation is prevented. 

Sensors monitor water use and water chemistry and send data to the desktop and mobile devices in real-time, with scheduled reporting that supports sustainability reporting and cost controls. 

We would like to discuss your water management challenges and arrange a demonstration.

Learn More About Total Water Management Services
Hydrotech Total Water Management Process Diagram

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