Hydrotech Cooling Tower Case Study | Water Treatment Supply
CASE STUDY
Industrial Water Treatment
Hydrotech Manufacturing
Cooling Tower Water Treatment Optimization
Industrial Manufacturing • Midwest, USA • Partner: Kibler Chemical
Project Details
- Client: Hydrotech Manufacturing
- Industry: Industrial Manufacturing
- Location: Midwest, USA
- Project: Cooling Tower Optimization
- Partner: Kibler Chemical
Project Overview
Hydrotech Manufacturing operates a large cooling tower system that supports its machining and production processes. The system circulates approximately 250,000 gallons of water per day to remove heat from multiple process lines.
Over time, recurring water-related issues began affecting system efficiency, maintenance schedules, and energy consumption. To address these challenges, Hydrotech partnered with Kibler Chemical to diagnose the root causes and implement a comprehensive cooling tower treatment and monitoring program.
The Challenge
Prior to partnering with us, Hydrotech Manufacturing faced critical water treatment challenges that were impacting operations and increasing costs.
1. Frequent Scaling
Hard water deposits accumulated on tower fill and heat exchangers, reducing heat transfer efficiency by up to 20%.
2. Corrosion Issues
Imbalanced water chemistry contributed to increased corrosion of steel piping and system components.
3. Microbial Growth
Slime and algae buildup caused blockages, odour issues, and system hygiene concerns.
4. Manual Chemical Dosing
Inhibitors and biocides were manually dosed, leading to inconsistent water chemistry and chemical wastage.
5. Limited Monitoring
Weekly manual testing meant long periods of operation were left unmonitored.
Our Solution
Kibler Chemical conducted a detailed site assessment, analyzing water chemistry profiles, temperature, flow rates, and baseline TDS. Based on this analysis, a comprehensive three-part solution was implemented.
Kibler Chemical developed a customised chemical program tailored to Hydrotech’s makeup water quality and operating conditions:
✓
A phosphate-polymer blend designed to prevent scale formation and control corrosion in recirculating systems.
✓
Used to control microbial growth without damaging system metals or seals.
✓
Maintained system pH within the optimal range of 8.0-8.5 to minimise both scaling and corrosion risks.
All chemicals were selected to ensure effective performance while meeting local environmental and municipal discharge requirements.
To overcome inconsistencies caused by manual dosing, a fully automated feed and monitoring setup from Water Treatment Supply was installed:
1
Precision-controlled pumps ensured accurate and consistent chemical dosing based on real-time water quality data.
2
Automatically monitored TDS levels and managed blowdown cycles. Maintaining optimal TDS levels helped minimise water waste while improving heat exchange efficiency.
3
Enabled real-time monitoring of conductivity, pH, and temperature for immediate response to changing system conditions.
4
Provided verification, manual backup, and trend analysis for in-field measurements.
This automated setup eliminated the need for daily manual chemical adjustments. Treatment rates were regulated dynamically, adapting to temperature fluctuations and evaporative losses.
Following installation, Kibler Chemical provided ongoing service and monitoring support:
On-site system inspections and performance reviews
Validation of automated readings against manual tests
Scale and corrosion coupon analysis
Review of chemical usage efficiency
Remote Monitoring: A remote monitoring setup allowed system data to be reviewed continuously, with alerts generated in the event of abnormal readings or potential system issues.
Results & Impact
After six months of implementation, Hydrotech Manufacturing reported significant improvements across key performance metrics.
Before & After Comparison
| Parameter | Before | After |
|---|---|---|
| Cooling Efficiency | Reduced ~20% | ✓ +18% |
| Maintenance | Frequent stops | ✓ Eliminated |
| Blowdown | High | ✓ -25% |
| Chemical Usage | Inconsistent | ✓ -15% |
| Corrosion | High | ✓ -70% |
| Compliance | At risk | ✓ Compliant |
Client Feedback
Partnering with Kibler Chemical fundamentally improved how we manage our cooling system. The automated controls and water treatment program cut our energy costs and maintenance hours. Our production runs now stay on schedule, and our environmental team appreciates the consistent compliance data.
Equipment Used in This Project
Browse our selection of industrial water treatment equipment used in this case study.
Chemical Metering Pumps
Precision-controlled pumps for accurate chemical dosing
Cooling Tower Controllers
Automated TDS monitoring and blowdown management
Monitoring Sensors
Real-time conductivity, pH, and temperature monitoring
Handheld TDS Meters
Portable testing for field verification
Case Studies - FAQs
We work with industrial manufacturing, commercial facilities, hospitality, OEMs, and process-driven operations. Our equipment supports a wide range of water treatment applications across these sectors.
Case studies show real-world applications, system configurations, and measurable outcomes, helping you understand what solutions work in similar operating conditions. They provide practical insights into equipment performance and ROI.
Each case study covers the problem statement, solution approach, specific equipment used, implementation process, and detailed performance results with measurable metrics.
Yes. Equipment configurations can be tailored based on water quality, system size, application requirements, and specific operational challenges. Contact our team to discuss your unique needs.
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