Cooling Tower Water Treatment for Manufacturers

Why Is Water Treatment Important?

Industrial water treatment is essential in manufacturing for several reasons. It keeps your equipment clean and efficient and lowers your operational costs. Below are a few problems that can develop in the absence of proper water treatment:

• Scale: Scale forms when minerals such as calcium carbonate and magnesium precipitate out of your recirculating water and form a scaly white buildup on equipment surfaces. Scale impedes water flow and heat transfer, leading to costly breakdowns.
• Corrosion: Corrosion develops when substances in the water react chemically with metal parts and degrade them. Corrosion is particularly dangerous because it can quickly make your equipment structurally unsound.
• Airborne contaminants: When airborne contaminants like silt, dust, soot or smog get into your water system, they can accumulate into a thick buildup that impedes heat transfer and water flow.
• Microbiological growth: When minute organisms like bacteria, viruses, fungi and algae infiltrate your system, they can form a slimy film on your equipment's surfaces. This film can diminish performance and potentially spread illness.

These types of buildup cause harmful effects. They:

• Block water circulation.
• Impede heat transfer.
• Weaken the structural integrity of your pipes and other metal components.
• Necessitate frequent maintenance and costly repairs.
• Send your utility bills soaring.
• Diminish the quality of manufactured products.
• Contribute to the spread of disease.

Types of Cooling Tower Water Treatments

How do you eliminate and prevent issues like scaling, corrosion, rust and bacteria? Below, we'll look at some standard treatments for cooling tower water.

1. Clarification

Clarification is typically the first step in cooling tower water treatment. It removes particles, sediment, organic material and oils from the water. This process allows the water to proceed with subsequent treatment steps.

2. Filtration

Filters catch and remove suspended solids, silt particles and other sediment. Filtration minimizes scaling, corrosion, fouling and bacterial growth, making it essential for water quality. If cooling towers don't trap these particles early on, the debris can reach ion exchange resins and other sensitive equipment.

The particles can become lodged in the equipment and accumulate over time. This buildup can lead to performance issues, higher operating costs and ultimately, a shorter equipment life span. Proper filtration reduces blown-down water and helps the system function more efficiently.

3. Ion Exchange and Softening

After filtration, the water may require softening and ion exchange, depending on its quality and dissolved mineral concentration. Over time, a buildup of calcium, iron, magnesium and other minerals in the water can develop scale and rust deposits on equipment. Softeners remove hardness and minerals from the makeup water.

You can use an ion exchange resin to soften the water. The resin has a higher affinity for the iron, calcium and magnesium particles than its own sodium. It essentially releases the sodium to grab the other mineral particles. This iron exchange process cleans the minerals from the water, rendering it softer.

4. Chemical Feed

The cooling tower water may require chemical feed, depending on its quality. If microorganisms or acidity are prevalent in your local water sources, you'll likely need to add corrosion or scale inhibitor chemicals. You can also add biocides or algaecides to minimize biofilms.

5. Automated Monitoring

State-of-the-art equipment lets you monitor and maintain your water quality. Some examples include:

• Biocide timers: A biocide timer automatically feeds chemicals into your cooling tower system. It uses relay outputs to regulate feed distribution and flow. Proper biocide feeding is essential for eliminating harmful bacteria.
• Conductivity controllers: A conductivity controller provides real-time data to improve your water treatment processes. It automates your system's functionality while removing rust, scale and other contaminants.
• Contact headwater meters: A contact headwater meter helps you avoid overfeeding and underfeeding. You can also monitor cooling tower water usage more accurately.
• pH probes: A pH probe works with your conductivity controller to provide a quick, comprehensive water system analysis. It displays real-time pH levels to streamline water quality monitoring.