Cooling tower is a temperature controlling device used for regulating temperature of refineries, petrochemical manufacturing plants, steel mills, paper mills, and electric utilities. These industrial cooling towers control temperatures by transferring heat from hot process fluids to the cooling water.

Illustration for article titled What Problems Are Faced By Industrial Cooling Towers?

Raw or filtered makeup water has dissolved minerals and insoluble content that can affect the cooling. If user doesn’t treat dirt, microbiological organisms, and gases, it can lead to severe reductions in heat transfer efficiency, raise maintenance issues, or even result in total system failure.

When the cooling water evaporates, contaminants enter in the system through makeup water or from air via cooling tower. If user leaves them as it is, numerous serious issues can be occurred-

Algae – This is the most common problem cause of smile problems in open water cooling tower systems

  1. Scale
  2. Fouling
  3. Corrosion
  4. Microbiological growth


Scale formation is injurious to cooling tower as it reduces heat transfer efficiency. Due to this, productivity gets reduced and user has to pay higher fuel cost. If heat transfer reduces below the limit, the entire cooling system may need to shut down and serviced. Scale is formed of inorganic mineral compounds, like magnesium silicate, calcium carbonate, iron oxide, and calcium phosphate.



Waterborne contaminants enter to the cooling systems via both external and internal sources. Cooling tower regularly scrubs dirt and dust particles from air, which adds more contaminants to the cooling water. Microbiological growth, corrosion by-product, and process leaks are the factors causing fouling in a cooling system. Waterborne fouling can be controlled when user combines mechanical and chemical programs.



This problem is caused due to the chemical used for some of traditional cooling water treatment. Under corrosion, metal gets breakdown in the presence of water, air and other materials. Corrosion is a critical issue in industrial cooling tower systems as it reduces cooling efficiency, destroy equipment, increase operating costs, and causes premature failure.


Microbiological Contamination

Microorganisms are present in everywhere in nature. They found in air, water and soil are scattered also They can often be found in cooling tower because Cooling water systems are favourite space for microscopic organisms to grow. Microorganisms are two ways to enter in the cooling system, by water supply or the air that passes through the cooling tower.


There are important microorganisms found in water cooling tower Algae, bacteria and fungi. They are playing are crucial role with health of humans and animals. Here, some of the microorganisms are beneficial, while others are pathogenic for health. So, It is necessary to clean industrial cooling tower often to stop growth of microorganisms as they can cause severe damage to the system.

Microbiological fouling can lead to-

  1. Energy loss
  2. Increased corrosion and pitting
  3. Reduced heat transfer efficiency
  4. Loss of tower efficiency
  5. Loss of structural integrity
  6. Wood decay

All these problems are real and can breakdown industrial cooling tower before time. To avoid these issues and make the system healthy and efficient, users have to maintain the towers and should clean them often.

This article is shared by leading industrial cooling tower manufacturers from India to make sure that your cooling towers have a long life, keeping the environment healthy and safe. For more tips and tricks, visit our homesite.

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