The Cooling Tower Process
As water is evaporated in the cooling process minerals are precipitated onto cooling tower fill, basin, and downstream equipment as scale. Increased scale build up on fill reducers the cooling efficiency and scale build up in downstream equipment causes premature failure, increased costs and down time.
The Softerwater cooling tower Watercube is customised designed for your application and reduces running costs by between 30 to 50%. The Watercube is skid mounted and may include a self cleaning screen filter, water conditioner, chemical injection, static mixing, UV disinfection and eductor ring main.
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Australian Made

All Softerwater Cooling Tower Watercubes are manufactured on the Gold Coast Queensland Australia.

Custom Manufactured

Watercubes are custom manufactured to suit your requirements.

Typical Cooling Tower Problems

  • Scaling on cooling tower fill and downstream equipment
  • Corrosion
  • Sediment (dirt and dust) accumulation in cooling tower basin
  • Ineffective chemical and water mixing

Side Stream Skid Mounted Watercubes Include Any Or All Of The Following

  • Recircualting Pump
  • Self Cleaning Filters – Made in Australia
  • Hard Water Treatment – Made in Australia
  • Static Mixing with Chemical/Nutrient Injection Point(s) – Made in Australia
  • Eductor Ring Mains
  • UV – Made In Australia
  • Ozone

The Cooling Tower Watercube

  • Enhances mixing of chemicals and water
  • Mitigates hard water problems in the basin, fill and downstream equipment
  • Mitigates the habitat for biofilm, legionella, and algae
  • Reduced scale build up on fill improves the heat transfer efficiency of the cooling tower
  • Reduces maintenance and running costs by between 30 to 50%

Fast Delivery

Cooling Tower Watercubes are custom manufactured and can be supplied to meet your project schedule.

Fouling In Cooling Towers & Heat Exchangers

What is fouling?

Fouling is the formation of scale deposits on heat transfer surfaces during process heating and cooling.

Fouling occurs when deposits of undesirable materials like bacteria, calcium, magnesium and other minerals or other contaminants deposit on heat transfer surfaces. This accumulation of materials increases heat transfer, reducers efficiency and increase maintenance, replacement and running costs.

What causes fouling?

Contribute to fouling, including water pH “product viscosity”, and the roughness of component surfaces, among many others.

What are the  methods of heat exchanger fouling prevention?

Control material causing scale build-up by installing a Softerwater conditioner immediately before the heat exchanger and if there is a recirculating ring main make sure that it is installed in a position so that all return water and any makeup water is being conditioned.
Perform Regular Cleanings
Setup treatment system

What are different types of fouling?

Fouling is generally divided into one of four categories:-
Chemical fouling (including scaling)
Biological fouling (biofilm)
Deposition (or sedimentation) fouling
Corrosion fouling.

What are the principles of fouling️?

Fouling is the deposition of material on the heat transfer surface which reduces the film heat transfer coefficient.

How do you reduce fouling️?

Continue to dose with chemicals and install a Softerwater conditioner immediately before the heat exchanger and if there is a recirculating ring main make sure that it is installed in a position so that all return water and any makeup water is being conditioned.

However, when using open cooling systems (cooling towers), in addition to the water hardness there will always be atmospheric  particulate being sucked into the cooling system. Installing a side stream cooling tower Watercube will mitigate scale build-up in the fill and downstream equipment, remove sediment and any contaminants in the cooling tower basin and give you controlled chemical injection and mixing in softer water.

What are the negative impacts of fouling on heat exchangers?

Scale build-up
Increased running costs
Increased maintenance costs
Premature failure and costly replacement of components and downstream equipment
Reduced flow &  back pressure
Increased emissions
Downtime

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Understanding and Preventing Legionella Infections

Legionella pneumophila is the bacterium responsible for Legionnaires’ disease, a severe form of pneumonia. This waterborne pathogen infects humans when inhaled in aerosol form, such as mist from showers or cooling towers. The disease was named after a significant outbreak in 1976 among attendees of an American Legion convention in Philadelphia.

Common Sources of Legionella

Legionella bacteria thrive in various water systems, including:

  • Cooling towers
  • Evaporative condensers
  • Mist machines
  • Humidifiers
  • Whirlpool spas
  • Showers

These bacteria are particularly dangerous in stagnant water found in tanks, reservoirs, and piping systems with poor flow. They multiply in temperatures between 68°F and 113°F and feed on nutrients in algae, rust, sludge, and scale.

Preventing Legionella Outbreaks

To minimize the risk of Legionella, health agencies recommend regular monitoring and maintenance of water systems. Key factors affecting Legionella proliferation include:

  • Presence of scale deposits or algae
  • Stagnant water due to low use of outlets
  • Inadequate hot water temperatures
  • Stratification in water heaters
  • Inadequate water treatment

Certain water fittings and materials can harbor Legionella, making eradication challenging. Large, complex systems in hospitals, hotels, offices, and factories are particularly susceptible.

The Role of Scale in Legionella Growth

Scale, primarily composed of calcium or magnesium salts, forms on heat exchangers, cooling tower packing, and other water-fed equipment. This hard deposit impairs heat transfer, disrupts water flow, and provides a breeding ground for Legionella. Even soft water can become highly scaling if not treated properly, leading to increased energy costs, chemical usage, and water waste.

Scale is problematic in both hot and cold-water systems. In hot water systems, scale traps Legionella and biofilm, reducing the effectiveness of disinfectants. In cooling systems, scale and biofilm diminish heat transfer efficiency and promote corrosion.

Effective Bacteria and Scale Reduction

Air conditioning and refrigeration systems, which use water for cooling, are prime environments for bacterial and algal growth. Regular maintenance and proper design significantly reduce the risk of Legionella contamination.

In cooling towers, factors like temperature, water hardness, pH levels, and scale contribute to biofilm and Legionella growth. Effective control measures include using scale and corrosion inhibitors, dispersants, and biocides. Periodic chlorination and descaling are also recommended, though chlorine can have limitations and cause corrosion.

Watercube Water Treatment Solutions

A continuous and effective method to control scale and bacteria, including Legionella, is electronic water treatment. This involves installing electronic descaling equipment at strategic points in the water system. Benefits of this technology include:

  • Reduced energy costs due to efficient heat transfer
  • Elimination of corrosion caused by scale deposits
  • Removal of solids by filtration
  • Reduced downtime and labor costs for descaling
  • Removal of biofilm and Legionella colonisation
  • Improved water distribution efficiency and pressure

By implementing  the Watercube water treatment, facilities can ensure safer, more efficient water systems while reducing the risk of Legionella outbreaks.