Industrial Water Softener Systems for Cooling Tower Source Water

What is a Water Softener?Water softening is a water purification process that uses ion exchange technology to remove naturally occurring minerals such as calcium and magnesium from water to prevent buildup in pipes and appliances. The process is used often in commercial and industrial settings to facilitate ease-of-use and exten

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What is a Water Softener?
Water softening is a water purification process that uses ion exchange technology to remove naturally occurring minerals such as calcium and magnesium from water to prevent buildup in pipes and appliances. The process is used often in commercial and industrial settings to facilitate ease-of-use and extend the lifetime of water-handling equipment.


Due to high levels of calcium and magnesium, many types of equipment fail to work properly or efficiently, which can lead to an increase in energy costs and/or complete failure of the equipment.  Many plants use water softeners for boiler feed, cooling towers, entire water supply and various types of process water.

Cooling towers is a common application for industrial water softeners.  Cooling towers can operate much more efficiently with softened water. This can help to realize a drastic reduction in maintenance, chemical feed quantity, and the volume of water required for operation.

Things to consider when designing a water softener for a cooling tower are:
  1. Tonnage
  2. The current number of cycles before blowdown
  3. Size of feed line to the cooling tower
  4. Water hardness
Flow rate and capacity are major concerns when designing a softening system for a cooling tower.  A thorough understating of daily water usage and required flow rates are critical.

Most customers decide that using water softeners for their entire plant feed water is necessary.  Due to high hardness levels the majority of the time, this is the only option as it is usually the most cost-effective and protects the entire plant from complications and damage that scale can cause.


Water softeners offer a range of cost saving benefits, including:
  • Extended equipment service life. Water softeners extend the life of appliances, boiler systems, pipes, and other water-handling equipment by reducing damaging mineral buildup.
  • Reduced maintenance. Equipment that uses soft water will not require maintenance and repair to remove the buildup of minerals.
  • Energy savings. Soft water prevents mineral deposits that restrict water flow, thereby improving equipment efficiency and reducing energy usage.
  • Enhanced cleaning efficiency. Softened water significantly reduces the amount of cleaning solution necessary, which reduces cleaning costs, water usage, and energy usage by up to 75%.

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