This project aims to achieve structural and operational optimization of water use in cooling towers and evaporative condensers through the implementation of a physical-chemical water treatment technology that operates without external chemical inputs. This advanced system integrates three synergistic processes: electroporation, advanced oxidation, and the in situ generation of free chlorine from the natural chloride content in water. The result is a system capable of maintaining hygienic water quality without relying on traditional biocides or costly purge cycles.
The solution is especially suited for facilities with closed or semi-closed circuits that demand intensive water use, such as industrial plants, large commercial buildings, and logistics centers. In these settings, water demand linked to thermal cooling systems accounts for a significant portion of total consumption. The proposed technology aligns with the principles of the VWBA 2.0 methodology, allowing standardized quantification of Volumetric Water Benefits (VWBs) by reducing purge losses and optimizing concentration cycles.
The project addresses shared water-related challenges, particularly scarcity and public health concerns. Conventional treatment methods involve substantial water usage to control salinity and microbiology, as well as a critical dependence on chemicals, which entail occupational and environmental risks. Continuous water purging also overloads wastewater treatment systems and increases energy consumption due to replenishment needs. In contrast, the proposed alternative maintains stable system conditions while significantly reducing water consumption, eliminating the use of chemicals, and enabling automated and remote operational control.
Overall, this intervention delivers a substantial reduction in local water stress, enhances cooling system efficiency, and lowers the risk of pathogen outbreaks such as Legionella pneumophila. Key stakeholders include industrial operators, facility managers, maintenance companies, public water managers, and health and safety authorities.
Traditional cooling towers are designed to dissipate heat via water evaporation in contact with ambient air. Although thermally efficient, this process poses several water-related challenges. Under normal operating conditions, water accumulates salts and organic contaminants, leading to scaling, corrosion, and microbiological growth. To prevent these issues, traditional systems require frequent purges, which entail discharging large volumes of water and replacing it with fresh water.
This practice creates a vicious cycle: each purge represents a significant water loss and necessitates additional water use, thereby increasing overall consumption. The system also heavily depends on chemicals such as biocides, anti-scalants, and pH correctors, which not only raise operational costs but also pose health hazards to workers, generate hazardous waste, and complicate discharge management. Inadequate chemical handling can result in environmental contamination and regulatory penalties.
Structural causes include a lack of automation and real-time monitoring—hindering early detection of system failures or unfavorable conditions—a reactive approach to contamination events, and the absence of clean technologies that support sustainable water cycle management within these systems.
The proposed solution shifts from reactive maintenance to a proactive, automated, and sustainable water management approach in cooling towers. A modular system combining electroporation, advanced oxidation, and in situ chlorination continuously disinfects the water, eliminates microorganisms, and maintains the system’s physicochemical balance without requiring regular purging.
This physical-chemical treatment produces highly oxidizing compounds such as hydroxyl radicals, ozone, and hydrogen peroxide to degrade organic contaminants and prevent biofilm formation. Electroporation directly inactivates bacteria such as Legionella, eliminating the need for external biocides. Simultaneously, free chlorine is generated from naturally occurring chlorides, ensuring residual disinfection without the addition of hypochlorite or other chemicals.
System management is supported by a digital platform enabling real-time remote monitoring of critical parameters (Redox, pH, turbidity, temperature, conductivity), automated cleaning, purge, and maintenance actions, and smart alerts in case of deviations. This reduces operator workload, improves data traceability, and supports regulatory compliance on water quality and public health.
The result is a drastic reduction in water use (up to 90% in purge reduction), a significant improvement in sanitary safety, and a more efficient, climate-resilient operation.
The technology integrates with existing systems through an in-line installation that recirculates water from the tower basin through a modular unit containing the physical-chemical treatment cells. Integration does not interfere with daily operations and requires no structural modifications to existing infrastructure. The system is scalable and can be tailored to various capacities by adding modules based on the flow rate and thermal load of each tower or interconnected tower network.
Equipment is designed for continuous operation with standard three-phase power supply (380 V) and moderate energy demand. Data connectivity can be established via fixed network or proprietary SIM, allowing operation in industrial environments lacking digital infrastructure. Integration includes water quality sensors (pH, ORP, turbidity, conductivity, temperature, filter pressure) and flow meters, along with motorized valves for automatic purging and filter cleaning.
Operations are managed through a cloud-based digital platform that centralizes all system data for real-time analysis. This includes historical records, trend analysis, period comparisons, multivariable diagnostics, and configurable alarms. Digitalization enables predictive maintenance protocols, reduces unscheduled interventions, and enhances traceability. Technicians can remotely control the system, schedule automatic cleanings, adjust dosing, and activate hyperchlorination protocols if needed.
Implementation includes training for client technical staff, operational documentation, and custom action protocols for each installation. The entire system is delivered under a monthly service contract covering installation, operation, maintenance, and technical monitoring. This performance-based model includes a guaranteed water savings commitment (in m³/year), audited through digital records to ensure water benefit traceability and verification.
The technology has been successfully deployed across multiple high-volume cooling applications, including food processing plants, pharmaceutical facilities, logistics complexes, and corporate buildings.
This project addresses a recurring challenge in industrial facilities: the high water consumption of cooling towers and evaporative condensers. These systems, essential for dissipating heat from thermal processes, traditionally operate through evaporation cycles that concentrate salts and contaminants in the water, requiring frequent purges to prevent scaling, corrosion, and health risks. Such purges result in considerable water losses and necessitate constant replenishment, alongside the use of aggressive chemicals such as biocides, anti-scalants, and pH adjusters—raising costs, operational risks, and environmental impact.
The proposed solution implements an innovative technology that completely eliminates chemical usage by deploying a modular, in-line water treatment system. This system integrates three synergistic processes: electroporation, which deactivates microorganisms like Legionella without biocides; advanced oxidation, which degrades organic compounds using free radicals and ozone; and in situ generation of free chlorine from dissolved chlorides, providing a residual disinfectant effect. The system is fully controlled and monitored via a digital platform enabling real-time automation, anomaly detection, scheduled maintenance, and full operational traceability.
The project is specifically deployed in Aragón, in industrial zones across Zaragoza, Huesca, and Teruel, where large cooling towers place significant stress on local aquifers and water supply systems. The intervention can reduce up to 90% of purged water and eliminate up to 95% of chemical use, generating quantifiable benefits in line with VWBA 2.0 methodology. The implementation model includes a monthly service contract, verified water savings, and technical training for plant staff.
This initiative aims to reduce water consumption in industrial cooling systems by applying a comprehensive technological solution that replaces chemicals with advanced physical-chemical processes. The intervention focuses on installing a modular treatment system based on electroporation, advanced oxidation, and in situ free chlorine generation, enabling continuous and automated microorganism control and water parameter management.
The proposal is implemented in Aragón, a region with major industrial and logistics hubs that rely heavily on cooling water. By deploying this technology, the project seeks to permanently reduce water purging, improve thermal efficiency, minimize biocide use, and prevent sanitary risks such as Legionella outbreaks. The system includes real-time monitoring, remote control, autonomous operation, and full data traceability, facilitating regulatory compliance and evidence-based decision-making.
The project follows the VWBA 2.0 framework, allowing quantification of generated Water Benefits (VWBs) under additionality, traceability, and permanence criteria. With a performance-based contractual model, the solution includes audits and technical monitoring, and aligns with multiple Sustainable Development Goals. Proven implementation in reference industrial facilities confirms its scalability, reliability, and strategic value in water-stressed contexts.
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