Cooling Towers

Optimizing Cooling Tower Efficiency with HydroFLOW

Cooling towers are essential in maintaining the efficiency of heat exchangers and controlling operational costs in large buildings. Traditional water treatment methods often rely heavily on chemicals, leading to high maintenance and operational costs. HydroFLOW introduces a non-chemical water treatment solution that addresses these issues by focusing on reducing limescale, blow-down levels, and biofilm build-up.

The Challenge

A Fortune 100 company's LEED Gold-certified headquarters in Houston, Texas faced significant challenges with its cooling system, including high water consumption and reliance on chemical treatments. With two 1,000-ton cooling towers and a high operational cost, there was a critical need to enhance water conservation, reduce chemical use, and maintain system efficiency.

The HydroFLOW Solution

In April 2016, the company adopted HydroFLOW's Total Water Management Service. This comprehensive approach includes:

  • Physical Water Conditioners: These units control scale, bacteria, and corrosion without the need for harsh chemicals.
  • Side Stream Filtration: This component helps remove suspended solids, further reducing the need for extensive blow-down.
  • IoT Monitoring: Real-time sensors and meters monitor flow rates, temperature, and water quality, feeding data into a cloud-based analytics platform.


The implementation of the Total Water Management Service has led to substantial improvements:

  • Water Savings: Each building now saves over 2 million gallons of water annually.
  • Chemical Reduction: Chemical usage has been cut by 75%, reducing both costs and environmental impact.
  • Energy and Operational Efficiency: Real-time data monitoring and analytics have optimized system performance, reducing energy costs and extending equipment life.

Key Success Factors

  • Effective Scale and Biofouling Control: Preventing accumulation in cooling towers and chillers has been pivotal.
  • Advanced Monitoring Systems: Installation of IoT sensors and cloud-based analytics allows for continuous performance validation.
  • Sustainable Practices: Switching to eco-friendly chemical-free treatments and reducing overall chemical and water usage supports both economic and environmental goals.


HydroFLOW's Total Water Management Service demonstrates a successful model for large-scale cooling systems, balancing cost efficiency with environmental sustainability. This case study highlights the potential for similar systems to achieve significant savings in water, chemical use, and energy, all while maintaining industry standards and enhancing operational efficiency.

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