Improving Energy Efficiency of Cooling Towers

Improving Energy Efficiency of Cooling Towers


Improving Energy Efficiency of Cooling Towers

Cooling towers are great in terms of ergonomics and economics because they provide sound solution to industrial equipment cooling and are a feasible process that cools down water to the desired temperature and rotates it back in momentum.  Although they are most cost-effective when other cooling technologies are compared, they need periodic checks to sustain their working efficiency and the seamless run in the long run.

How maintaining Cooling Towers Fillips Efficiency:

If an industry maintains its cooling tower efficiency, it will have these benefits:

  1. Extensive energy saving from sound operation without hassles.
  2. Make cooling equipment like film fills, the suction fan and pumps less prone to scaling and rusting.
  3. Reduce the amount of water being consumed.
  4. Reduce the necessity of harsh chemicals to regularly treat water for safe operations.
  5. Extend the service life of equipment and cooling assembly.
  6. Operational costs will be frugal because the damaging parameters are timely controlled.

Ways to maintain the competence of a cooling tower:

To get the most benefits out of a cooling tower, its effectiveness needs to be maintained in a preferred way.  But what is that way and how is it possible?

A different make of cooling unit requires a different treatment altogether and the same handling will not work on another cooling tower type.

First, let us understand the type of cooling tower you have.

The construct of the cooling tower, the function of how it runs and the parts it uses determine its overall service type as they have different levels of contaminant exposure.

Some of the most common types are as follows:

Once-through cooling tower systems:  These towers get water from a natural source like a river or lake which is circulated through pipes to counter heat from steam condensers.  This warm water is drained back into the environment. Although economical, they require Govt. regulations to run.

Open recirculating cooling tower systems:  These systems recycle the water throughout the process and removes heat with evaporation.  Water is reused but its retention increases corrosion and scalene buildup in the system after evaporation occurs.  The heat in combination with open-air conditions can also support bacterial growth and air contaminants.

Closed recirculating cooling towers

They operate like open recirculating systems but the heat ejected is moved to a heat exchanger without open air exposure.  Thus, it eliminates air and water contamination.

Typically, the main factor influencing the working of a cooling tower is the type of water used and the quality required to run it.


In general, we need effective treatment for three process types in a cooling tower:


  1. Feed water to the cooling tower.
  2. Circulatory water in the tower.
  3. Bleed to drain.

A1.  Feed water to the cooling tower

At the initial stage, if feed water is clean enough, we might not need treatment here.  But if at all it is needed, at this part of the water intake process, the hardness, silica or the pH can be adjusted using filtration.  The process improves the evaporation cycle and reduces the water bleed ratio by making it good enough to vaporize. Otherwise, chemicals can clean the water then.

A2.  Circulatory water in the tower

Water during circulation can be cleaned using physical treatment within the tower by deploying side stream filtration which enables water contaminants to get suspended and avoids foul smelling.  By running just 10% of the total circulated water through the side stream filter, clean water circulation can be achieved with the least solid suspension. Here chemical treatment is apparent to reduce scale formation and corrosion of equipment.

A3.  Bleed to drain

This treatment is the blowdown or bleeds from the tower as the last process.  In areas where water is scarce, this treatment means calculating how much least water is required for the plant to properly run and then recycle it through regular treatment like reverse osmosis or ion exchange.  This makes both liquid and solid waste to be concentrated and removed while making a clean return of water to the tower.

B)  Materials used in the tower construction

The next step to run your tower efficiently is to know what materials it is made up of.  Towers might use different materials like steel, iron or plastic. Some also use fiberglass.  A protective coating on the outer surface can reduce corrosion. These materials are durable to withstand environmental deterioration and degradation in different ways.  However, some companies are also making FRP cooling towers in India made of good fiber-reinforced polyester which is both lightweight and resilient to chemicals exposure with a high pH.  Even galvanized metal steel basin can be durable.

Precisely, it is vital to know what your tower is made of and which materials are used because after installation, a sturdy manufacture will need to last harsh water conditions or else corrosion and scalene might lead to a breakdown of equipment fast.

We can have a good FRP Cooling Tower Manufacturer in India as well as cooling tower suppliers who build excellent cooling towers for both big and small industries.  But literally, a little knowhow about the tower’s water consumption losses through evaporation, blowdown, drift or leaking is required to be always checked and corrective measures taken.  Also minimizing the use of chemicals and monitoring timely checks can be an economical option for your tower.

A closely monitored cooling tower will help reduce unnecessary damages like early corrosion buildup, oxidation, silica deposition and improve system efficiency by extending the life of your equipment.  Methods like pretreatment and post treatment can help retain water quality and avoid fouling. But it is always warranted to consult an expert for Improving Energy Efficiency of Cooling Towers since only a specialist can make the right recommendations based to your facility’s merit.


In conclusion, letting your cooling tower water treatment issues at bay is not the solution but hiring a professional to improve its efficiency is the right step forward to improve the life of your cooling tower and retain its efficiency.



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