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Article: Reducing Cooling Tower Operating Costs
By James McDonald, PE, CWT
A midwestern industrial plant had a problem. The plant had a cooling tower that supplies cooling water to air compressors, oil coolers, air dryers, and various process equipment. The local city water and sewer rates were increasing significantly and their molybdate-based chemical treatment costs were skyrocketing as molybdate costs had risen nearly 1,000% lately! In an effort to cut operating costs, the plant looked for ways to decrease their cooling tower makeup water, sewer, and chemical requirements. Various ideas were investigated such as:
- Improved blowdown controller
- Fixing leaks
- Acid feed
- Soft water makeup
- Blended city/soft water makeup
- Water treatment chemistry
- Recycled wastewater
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