Cooling towers are concrete structures that help regulate temperatures in many industrial processes by cooling down heated water before it is discharged. They use water evaporation or air circulation mechanisms to absorb heat and recirculate cooled water back into the system.
That is why cooling tower water treatment is crucial if you want to stay compliant with environmental and safety regulations and boost your production efficiency by cutting overall costs.
Why Correct Cooling Tower Water Treatment Matters?
When cooling towers work properly, they maintain optimal system performance and enable production to proceed without a hitch. However, when cooling tower water treatment is neglected or is poorly done, it is a recipe for corrosion, bacterial overgrowth, and system inefficiencies.
Proper cooling tower water treatments allow industries to prevent operational breakdowns by avoiding scale buildup and corrosion. These issues can arise naturally over time if no intervention is made to maintain the cleanliness of the cooling tower through water treatment.
If no proactive measures are taken, untreated water can increase maintenance costs, energy consumption, and even health risks.
There are many examples of what could go wrong when institutions neglect their safety and health protocols.
Here are just a few real-life cases that show the consequences of mismanaged cooling towers:
- The 2015 New York City Legionella Outbreak: In 2015, New York City experienced a massive outbreak of Legionnaires’ disease resulting from poorly maintained cooling towers. The bad bacteria proliferated and was transmitted through contaminated water vapor. To counter the outbreak, NYC officials implemented a mandatory cooling tower registration and inspection program.
- The 2018 Texas Power Plant Shutdown: A major power plant in Texas was forced into an unexpected shutdown because of corrosion and scale buildup in its poorly managed cooling tower. As a result, the plant experienced operational inefficiencies and had to be shut down for a few days, which cost the company $10 million in revenue loss and legal fines.
- 2014 University Campus Cooling Tower Contamination: A university campus in the Northeast U.S. had its cooling tower water improperly treated for some time, which led to the growth of algae and bacteria. The contamination resulted in the closure of several campus buildings due to the risk of Legionella exposure. The university was subsequently required to invest in advanced water treatment technology as well as training to improve future maintenance efforts.
Top Risks of Poor Cooling Tower Water Treatment
1. Corrosion and Equipment Damage
Corrosion is one of the most detrimental effects of poor cooling tower water treatments. So, what is it, and why is it risky? By and large, corrosive water becomes acidic due to lack of treatment and starts to eat away at the cooling tower infrastructure.
Over time, this weakens the whole system and leads to expensive system failures. The proper solution for water corrosion is to use corrosion inhibitors, which protect equipment and infrastructure and save costs on costly repairs.
2. Scale and Mineral Deposits
The build-up of scale is the opposite of corrosion, as it is characterized by the buildup of minerals inside the cooling systems. When hard water and excessive heat combine forces, calcium and other minerals harden and clog pipes.
Scale also causes a reduction of heat transfer, which slows down the efficiency of operations and even causes system breakdowns. The solution for scale is to invest in routine water treatments and anti-scale chemicals to reduce mineral accumulation in the cooling tower water.
3. Bacteria Growth & Legionella Contamination
Harmful bacteria and the outbreak of legionella disease are common health and safety problems arising from stagnant water and poor chemical treatment.
There are many cases of Legionella outbreaks that occurred due to inadequate cooling tower water treatment, some of which resulted in hospitalization and even deaths. The solution for bad bacterial overgrowth is proper biocide treatment and regular disinfection of the cooling towers.
4. Reduced Energy Efficiency & Higher Costs
Inefficient heat transfer caused by poorly treated cooling towers can cause the whole system to work harder than it should to sustain desired temperatures. Ultimately, this sluggish performance increases energy consumption and drives up significant operating costs.
The solution is to invest in regular cooling tower inspections to make sure they are running efficiently and are not causing any excess energy waste.
Best Practices for Cooling Tower Water Treatment
1. Regular Water Testing & Monitoring
Probably one of the best practices for keeping the water in the towers clean is to invest in regular professional check-ups. Essentially, regular water testing and monitoring can help identify any potential problems before they become catastrophic.
These regular checks involve testing pH and chlorine levels, water hardness, and any other water-specific needs that require tending to.
2. Routine Cleaning & Maintenance
Cleaning the cooling tower infrastructure and machinery is also vital to smooth, effective performance. Regular cleaning and preventative measures can go far in reducing any potential costs associated with breaches of safety and smooth operations.
Industrial cleaners can remove the scale, check the filters and pipes for corrosion, and remove any blockages. Overall, these upfront investments can help you save a lot of resources over the long term.
3. Using Water Filtration & Softening Systems
You can also take matters into your own hands and adopt water filtration and softening systems that minimize water mineralization and the accumulation of debris particles.
When these systems are combined, they work together to improve the quality of water, which protects the integrity and longevity of the cooling towers.
The Role of Industrial Cleaning in Cooling Tower Maintenance
The benefits of utilizing industrial cleaning cannot be overstated for all industries! Regular cooling tower cleaning is essential for preventing infrastructural damage, aligning with health and safety regulations, and extending the lifespan of equipment.
At Environmental Remedies, we help Atlanta-based industries set up an effective cooling tower maintenance protocol so that they can focus on running their business and not worrying about what could go wrong operationally.
Check out our industrial cleaning services, which include cooling tower water treatment and cleaning solutions. Reach out and get a quote today!