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William F. Harfst
As a simple example, a cooling tower handling a 1,000-ton load operating at 3.5 cycles of concentration with a 12F temperature drop across the tower has a makeup demand of 61,775 gallons per day (gpd). Increasing the cycles to eight has the effect of decreasing the makeup demand to 50,400 gpd. This reduces the makeup requirement by 18.4%. The wastewater produced by the cooling tower decreases from 17,640 gpd at 3.5 cycles to 6,336 gpd at eight cycles, which is equivalent to a 64% decrease. And by using less water, chemical treatment consumption and disposal requirements are proportionately reduced. Potential cost savings vary from plant to plant, depending on the cost for raw water, waste disposal costs, chemical treatment dosages, and energy. Nevertheless, in addition to the environmental, health, and safety improvements, the return on investment for improving cooling tower efficiency is typically less than one year.