Cooling and Process Water Analysis

Cooling Water: Industrial Efficiency and Sustainability

Industrial facilities need cooling processes in order to operate continuously and produce efficiently. Especially in heavy industries such as power plants, chemical plants and steel production facilities, cooling systems play a vital role. Process waters used in this context support production processes and enable plants to cope with high temperatures. In this article, we will examine the importance of process waters used for cooling, their uses, quality requirements and their impact on sustainability.

What is the Importance of Process Water for Cooling Purposes?

Process water is water used to control the heat released during production and to ensure the efficiency of machinery. In most industrial processes, machines need to be cooled continuously. If this heat is not controlled, production equipment is likely to be damaged or fail due to overheating. Process water is therefore essential to ensure the safety of plants and continuity of production.

Uses of Process Water

Process waters used for cooling serve different functions in various industrial processes. Some common uses include:

1. Power Plants: Cooling of turbines and generators used in electricity generation.
2. Petrochemical Plants: To control the heat generated during the processing of crude oil and the production of chemicals.
3. Metal Processing: To compensate for the high temperatures generated during the machining and forming of metals such as steel and iron.
4. Food and Pharmaceutical Manufacturing: In production processes that require precise temperature control, to ensure food safety and pharmaceutical stability while maintaining the quality of products.

Quality Requirements for Process Water

It is important that the process water used in cooling processes meets certain quality standards to ensure efficient operation of the system and extend the life of the equipment. Here are some of the quality requirements for process water:

1. Chemical Purity: Chemicals in the water can cause corrosion or clogging of pipes and machinery. For this reason, it is important to have low levels of hardness ions such as calcium and magnesium in process water.
2. pH Level: The pH value determines the acidic or basic character of the water. It is necessary to keep the pH in balance, especially for the protection of metal surfaces. A pH value in the range of 7-8 is generally preferred.
3. Microbiological Cleaning: Biofouling can lead to the growth of bacteria, algae or other microorganisms in water systems. This causes blockages and corrosion in the system. Therefore, it is of utmost importance that process water is microbiologically clean.
4. Dissolved Solids (TDS): The amount of minerals and salt dissolved in water is expressed as TDS. Keeping this level low prevents mineral accumulation in pipes and equipment.

Recommended Limits for Cooling and Process Water

Parameter	Recommended Value
pH	6.5 - 8.5
Total Hardness	50 - 200 ppm
TDS	< 1000 ppm
Chloride	< 250 ppm
Sulfate	< 250 ppm
Legionella	Yok

 

As Nanolab Laboratories Group, the following parameters can be analyzed as "Boiler Water / Cooling Water / Process Water";

Chemical and Physical Analysis

Sensory Characteristics Determination	Permanganate Index Determination
pH Determination	Phosphate Determination
Odor (Sensory)	Potassium Determination
Color Determination	Sulfate Determination
Copper (Cu) Determination	Total Dissolved Solids (TDS)
Fluoride Determination	Suspended Solids (SS) Determination
Iron Determination	Total Hardness Determination
Lead Determination	Total Alkalinity Determination
Manganese Determination	Turbidity Determination
Nitrate Determination	Chloride Determination
Nitrite Determination	Zinc Determination

Microbiological Analyses

Total Bacteria Count	Total Coliform Bacteria Count (22ºC)
Total Coliform Bacteria Count (37ºC)

Environmental Impacts of Cooling Water and Sustainability

Process water must be carefully managed for environmental sustainability as it is in constant use and recirculation. The environmental impacts of water used for cooling are often highlighted in the following areas:

• Thermal Pollution: Process water used can cause thermal pollution in the surrounding water resources when it is released back into nature after absorbing heat. This can disrupt the natural ecosystem and affect aquatic life. Solutions such as heat recovery have been developed to control thermal pollution.
• Consumption of Water Resources: As water is consumed intensively, pressure on natural water resources can increase. Therefore, reusing water used as process water through recycling systems contributes to prevent water waste.
• Waste Management: The wastewater generated by the chemicals used in cooling systems must be treated carefully to prevent damage to the environment. Safely disposing of wastewater or making it suitable for reuse contributes to the environmental sustainability of industrial facilities.

Challenges in Process Water Management

The management of process water used for cooling purposes involves several key challenges. These challenges often require controlling the quality of the water, the efficiency of the systems and the impact on the environment. The most common challenges are the following:

• Scaling: Minerals in the water can build up in pipes and machinery, leading to scaling. This reduces system efficiency and increases maintenance costs.
• Corrosion: Corrosion in process water systems can shorten the life of pipes and equipment. Preventing corrosion requires regular maintenance and control of water quality.
• Microbiological Growth: Biological contamination of water can lead to bacterial and algae growth, especially in cooling towers. This can cause clogging and odor problems in water systems. Therefore, biological control methods should be used.

Why NANOLAB?

Nanolab offers the most reliable and fastest solution in cooling water analysis with its experience in the sector and strong infrastructure. It meticulously analyzes the chemical and microbiological parameters of cooling water to help you achieve industrial efficiency and environmental sustainability goals. Thanks to ISO 17025 accreditation, analysis results are internationally recognized and system performance and environmental compliance are accurately assessed. With its wide range of equipment and expert technical team, it completes the analysis processes effectively and quickly. Thanks to its regulatory expertise, relevant standards and legal requirements are fully met. Nanolab stands out as the address where quality, reliability and speed combine in cooling water analysis.