Evaporative cooling towers

Monitoring cooling water quality
Evaporative cooling towers

Monitoring cooling water quality

Cooling Water Treatment

in evaporative cooling systems

Water cooling for industrial production

Most industries need the largest part (almost 90%) of their used water quantity for cooling. This immense water consumption clearly illustrates the essential role of water cooling for industrial production. Nowadays, hardly any branch of industry can manage without the cooling capacity of open evaporative cooling systems: the chemical industry, food industry, breweries, airports, data centres, etc.

In order to operate an evaporative cooling system as efficiently as possible, the consumption of cooling water should be reduced on the one hand and on the other hand the protection of the entire system against corrosion, deposits and biological growth should be increased. Therefore, a trouble-free, economical operation of an evaporative cooling plant requires an individually optimised water treatment for each system.

Requirements for the operation of cooling towers, evaporative cooling systems and wet scrubbers

Since 2017, in Germany, the 42nd BImSchV – Federal Immission Control Ordinance – defines binding guidelines for the operation of cooling towers, evaporative cooling systems and wet scrubbers. The systems must be designed, constructed and operated according to the state of the art in such a way that contamination of the process water by microorganisms, especially legionella, is prevented.

Operators of these systems must meet the hygienic requirements as well as ensure an economic operation of the cooling towers. The treatment of the cooling water with different chemicals required for this purpose must be individually adapted to the respective system and the prevailing conditions. To ensure the desired effect of the chemicals used and at the same time keep their consumption as low as possible, continuous monitoring of the cooling water is essential.

Cooling Water Treatment with ProMinent

ProMinent offers all components required for automatic monitoring of relevant parameters of your cooling water circuit. Our portfolio includes measuring and control devices, sensors, pumps, disinfection systems, digital fluid management and pre-assembled complete solutions. These products, specifically optimised for cooling water treatment applications, are characterized by a long service life, low maintenance and high reliability.

Cooling water treatment in evaporative cooling systems – Our solutions: Measuring and control devices as well as pumps and sensors.

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Background Information

Focus on evaporative cooling towers

Biology in cooling towers

Biology in cooling towers

The physical and chemical conditions in technical systems carrying water, such as evaporative cooling towers, provide ideal habitats for microorganisms due to their prevailing physical and chemical conditions. Most microorganisms live in biofilms, which can be an optimal environment for Legionella. For this reason, the formation of pronounced biofilms in evaporative cooling towers should be prevented by an appropriate mode of operation.

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Corrosion in cooling towers

Corrosion in cooling towers

An excessive salt and mineral content in evaporative cooling towers can lead to calcification and corrosion in the cooling system and its pipes. Algae and biofilm formation as well as dust particles carried in from the ambient air also have a negative effect on the cooling capacity of the system and also damage the installed materials. The effects of corrosion damage are far-reaching. Continuous monitoring of corrosion enables early detection of incipient damage.

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Water treatment in cooling towers

Water treatment in cooling towers

The concentrated process water resulting from evaporation must be regularly replaced with fresh make-up water. To ensure that the salt concentration does not have a negative effect on the efficiency and materials of the cooling system, the process water should be continuously monitored by means of conductivity measurement. Automatic blow down and an appropriate supply of fresh water minimise the risk of deposits and corrosion. In addition, a corrosion inhibitor and hardness stabiliser are added to protect the system.

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Online measurement of oxidizing biocides

Online measurement of oxidizing biocides

In order to fight microorganisms, either non-oxidizing or oxidizing biocides are added to the cooling water circuit. Non-oxidizing biocides have good material compatibility, but the bacteria present in the cooling water circuit can develop resistance. In contrast, oxidising biocides prevent the formation of resistance, and their effectiveness can be continuously monitored.

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Online corrosion monitoring

Online corrosion monitoring

The chemical and physical conditions prevailing in evaporative cooling towers promote corrosion of metal surfaces. Therefore, in addition to the use of corrosion inhibitors, continuous monitoring of the cooling water parameters is recommended.

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Products and services

Measuring and control system

AEGIS X ensures that evaporation cooling systems are run as efficiently as possible. The controller is highly flexible and suited to large cooling systems with many parameters. Using digital communication options, cooling towers can be conveniently monitored and their data evaluated remotely.

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Measuring and control system

AEGIS S is an easy-to-use water treatment controller for evaporative cooling systems. It is designed to keep the cooling process running reliably. AEGIS S measures conductivity and controls dosing of biocides and corrosion inhibitor, thus preventing biological growth and keeping pipelines and heat exchangers clean.

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Measuring and control system

The controller AEGIS II has been developed especially for the treatment of cooling water in evaporative cooling towers. It monitors, controls and documents all relevant parameters as requested by the regulations.

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Sensors

Sensors that measure cooling water parameters need to cope perfectly with this constantly fluctuating water quality. Measurements must be reliable and reproducible without any need for additional maintenance efforts or shortened service intervals. ProMinent offers sensors for most parameters that are commonly analysed to ensure cooling water quality. These sensors, ProMinent developed especially for this application, are optimised for high performance under challenging conditions.

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Solenoid-Driven Metering Pumps

The amount of chemicals added depends on the specific, local conditions and varies for each system. In addition, the consumption of chemicals must be minimised. As one of the market leaders in the area of solenoid-driven metering pumps, ProMinent has a wide experience that, in combination with continuous innovation and development of new technologies, results in the most modern and reliable metering pumps.

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Pre-assembled panels for cooling water monitoring

Based on years of experience and the close collaboration with our customers we have designed six different versions with varying configuration for the application of cooling water treatment. All pre-assembled panels can be easily integrated in the cooling water circuit and put into operation without the slightest effort.

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Disinfection Systems

The biocides chlorine dioxide and ozone show effective disinfection strength independent of pH and have the additional advantage of not forming toxic AOX-compounds. Furthermore, because of their gaseous state these disinfectants fight microbiological films most efficiently. Due to the high reactivity of these gases, chlorine dioxide and ozone must be produced on-site in special systems and cannot be stored or transported as ready to use biocides. ProMinent developed, explicitly for the treatment of cooling water, reliable and secure complete systems for on-site, on demand production of these disinfectants.

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Digital Fluid Management

DULCONNEX

As digitalization and networking advances more and more, new possibilities arise to monitor, control and optimize processes. Our solution for digital fluid management collects versatile information, processes all data and takes advantage of this information to efficiently control processes. Operators have location independent and real-time access to all available information required for optimal monitoring and control of any installed device, system or compound.

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