Problems Corrected by WCTI Technology
Three main issues must be addressed in the treatment of cooling tower water; scale, corrosion and bio-fouling. The failure to effectively and consistently control even one of these problems can have dramatic effects on tower and chiller performance and the life of the HVAC appliance. Often the blame is placed upon the operators when in fact the failure is most often the failure of the water treatment program itself. Zero Blowdown, Silica Based, WCTI technology is becoming the “standard” for consistent control for scale, corrosion and biologicals.
Scale, corrosion and biologicals are discussed below.
Zero Blowdown Eliminates Scaling Issues
As seen below, scale deposits are built primarily of calcium and magnesium. Even a small deposition of scale will negatively affect chiller efficiency. Left unaddressed scale deposits can and often will sufficiently build up so as to reduce flow rates and lead to increased head pressure. Rock hard scale deposits are challenging to remove and the removal process costs chiller plants in the US millions of dollars annually. The acidizing process of tube and pipe cleaning can further shorten the life span of equipment and piping.
Calcium and magnesium are removed from the cooling tower make up water by the HES Pre-Conditioner. This is the first step in the patented process of creating WCTI conditions. With the elimination of these elements, tower water has no material capable of precipitating out as scale. Towers and chillers can now operate at peak efficiency without reductions in flow rates from occluded tubes or scale deposition impeding the heat transfer parameters of the equipment. Chiller tubes, cooling towers and tower fill, operating under WCTI conditions, will be consistently scale free as seen below.
Zero Liquid Discharge Controls Corrosion
As seen below, corrosion can rapidly and seriously damage HVAC equipment requiring costly repairs, downtime and premature replacement. Chiller tube ruptures, pipe failure and tower sump penetrations due to rust through can all be traced to the failure to effectively control corrosion. The ability of WCTI’s Zero Blowdown, Silica Based water treatment program to consistently control corrosion to <0.20 mpy (mils per year) on all metals is termed to be “Excellent Inhibition” on even the most stringent performance and piping life span tables in the industry.
The unique and patented WCTI Technology is a complete paradigm shift eliminating the need for chemical “feed and bleed” programs. WCTI Zero Blowdown technology develops “sustainable natural green chemistry” by embracing silica causing its natural and predictable conversion from a monomer to a polymer. This conversion develops a microscopic passification layer to develop on metal surfaces protecting them from corrosion. The action is the same as when sodium silicate is introduced at plant start-up in the passification chemistry protocol. With WCTI technology’s ability to operate without tower bleed this protective barrier to corrosion can be maintained indefinitely. HVAC system operating under WCTI conditions, as seen below, can now consistently operate at corrosion rates previously unachievable in the water treatment industry.
- Click here to enlarge the Major Seattle Newspaper Corrosion Report image
- Click here to enlarge the Corrosion Report with Coupon Pictures Attached
- Click here to enlarge the Boeing Corrosion Report
- Click here to enlarge the U.S. Navy Corrosion Report
- Click here to enlarge 120 day coupon results compared to new coupons
WCTI Technology Prevents Bio-Fouling
As shown below, bio-fouling can lead to many performance, health, corrosion and maintenance issues. Bacteria and their metabolic activities on a metal surface are a significant source of corrosion. Bio-film is second only to scale in its ability to reduce the heat exchange capabilities of the chiller leading to dramatic losses in efficiency and significantly higher energy costs. The health concerns related to biological activity in cooling towers, such as Legionella is of major concern in all facilities. The biostatically controlled environment created by WCTI conditions is thoroughly documented and typically controls viruses, spores, pathogens and bacteria to levels in the range of 100 CFU (Colony Forming Units). (Ref: E. A. Anderson Engineering – “Review of The Effects of pH and TDS on Bacteria, Viruses, And Spores in Water“).