Fouling mitigation in a heat exchanger: High cycles of concentration for a cooling-tower application

The purpose of the present study is to investigate the effect of a physical water treatment (PWT) technology on fouling mitigation in a simulated cooling tower operating at high cycles of concentration. Hard water was produced by evaporating pure water in a circulating open cooling tower, where dissolved calcium carbonate ions became concentrated with time. Heat transfer tests were conducted in a rectangular channel by varying the cycle of concentration (COC) from 5 to 10, and fouling resistances were measured over 270 hrs for each case with and without the PWT treatment. Another test was conducted with no blowdown case with and without the PWT treatment. The fouling resistance at 5 cycles with the PWT treatment was about 70% less than that in the case without the PWT treatment at the end of 270-hr tests. Even at 10 cycles, the PWT treatment reduced the fouling resistance by 60% from the value for the no treatment case. Thus, one can conclude that the PWT technology can help circulating cooling-tower water at relatively high COC for significant freshwater conservation, while keeping fouling resistances below industry standards.