Cooling Tower Treatment Q&A for Power Plants

For the power generation sector, efficiency is critical. Output must be maintained at all times, while hitting budget and sustainability targets. All areas of a plant must deliver against these objectives and cooling systems are no exception. 

It’s time to shine a spotlight on this often-overlooked area of water treatment and uncover the potential for performance and cost savings. To help, we’ve asked Alex Wilson, Business Development Manager at Xylem, to answer some of the most frequently asked questions about cooling tower water treatment.

How important is water treatment for cooling towers?

Put simply, water treatment is critical for cooling towers. Removing heat from process water is central to power generation and helping ensure the efficiency of a plant. But this water attracts and absorbs airborne contaminants on a continuous basis, leading to the creation of deposits in the system. If left untreated, these deposits can cause a myriad of problems, such as a reduction in heat transfer efficiencies and increased operating and maintenance costs.  

What’s the worst-case scenario if I don’t prioritise water treatment? 

Neglecting water treatment can result in spiralling costs, damaged plant components, and unplanned downtime. Untreated or poorly treated water leads to scaling and fouling:

• Scaling occurs when dissolved compounds like calcium and magnesium deposit on surfaces, forming a hardened layer. This reduces heat exchanger efficiency by insulating surfaces and impeding heat transfer.
• Fouling occurs when scale, algae, and suspended solids build up in water systems, reducing efficiency and increasing maintenance needs. A potential serious consequence is microbial induced corrosion (MIC), caused by bacteria that accelerate corrosion. MIC can lead to:
  
  • Material Degradation: MIC causes pitting, cracking, and general deterioration of materials
  • System Failure: It can lead to leaks, reduced performance, and even catastrophic breakdowns in pipelines and equipment
  • Environmental Concerns: MIC-related damage may release harmful substances, contaminating water and soil

Additionally, untreated water can become a breeding ground for bacteria. One serious risk is Legionella, which can multiply in cooling tower systems and spread throughout a facility’s water network.

Effective water treatment is essential to keep operations running smoothly, extend asset life, control costs, and maintain a safe water supply.

What treatment options should I consider for cooling tower treatment?

There are several effective treatment technologies to consider:

• Ultraviolet (UV): Disinfects and removes organic/inorganic contaminants without the need for bulk chemical storage. Key benefits include low maintenance and running costs without the need for large scale storage, handling or transportation of bulk chemicals.
• Chlorine Dioxide: A powerful pre-oxidation and disinfection with a focus on safety and efficiency. We recommend on-site generation using our Chlorine Dioxide Generators, which minimise the need for transporting and handling hazardous chemicals.
• On-Site Hypochlorite Systems: Generate sodium hypochlorite on demand using only salt, water, and power, offering a safe and sustainable solution. With over 30 years of success, our OSEC^® systems are proven across municipal, aquatics and industrial markets.
• Ozone: One of the most powerful oxidising and disinfecting agents available.
• Filtration Solutions: VAF™ Screen Filters effectively remove suspended solids and support biological control, helping maintain system cleanliness and performance.

How can cooling tower treatment support my plant’s sustainability programme? 

Untreated cooling water leads to reduced energy efficiency, as system components stop work effectively. This increases energy consumption and operating costs. 

Prioritising water treatment will ensure you are using the least amount of energy possible for the cooling process. It’s important to select technology solutions which support this. Xylem’s systems are energy efficient and can help reduce chemical consumption, maintenance requirements and water waste. 

Are retrofitting options available to improve the efficiency of my cooling tower treatment and which is best for my plant?

Yes, it’s absolutely possible to retrofit your cooling tower water treatment system. This is a cost efficient way to improve the performance of your plant, lower operating costs and extend the life of assets. 

At Xylem, we offer expert consultancy to help guide you through the process. We take the time to understand each customer’s site and objectives, so we can ensure they get the water treatment solution that best solves their challenges. We also offer global ongoing service and support, so we’ll have your back today and tomorrow.

Connect with Alex Wilson on LinkedIn.