Do you know how much water your cooling tower consumes every day? The U.S. EPA reports that for every ton-hour of cooling, an average of 1.8 gallons of water evaporates—equating to a staggering 12,000 BTUs per hour. In commercial buildings, that’s the equivalent of an entire tanker truck of water, while data centers can drain over 21,000 gallons daily.

With persistent droughts gripping the western United States and developing countries, the impact extends far beyond rising costs. Groundwater reserves are depleting, ecosystems are deteriorating, and biodiversity is under threat.

Currently, the U.S. is home to over 9,900 power plants and 5,000 data centers—12% of which are concentrated in California. With these facilities relying on cooling towers, efficient heat management is essential, especially amid growing water supply scarcity. But the real challenge lies in inefficiencies—scaling, corrosion, and excessive water waste don’t just disrupt industrial operations; they compromise performance, drive up costs, and put the integrity of your entire business at risk. So, how efficiently is your facility managing its water?

Let’s talk about how we can manage that.

The Importance of Sustainable Water Management

Water covers 75% of Earth—just like blood in our veins, it sustains life, and fuels ecosystems. But for commercial and industrial businesses, water is more than survival—it’s the lifeline of production and progress. According to the U.S. Environmental Protection Agency’s (EPA) report, cooling towers often represent the largest use of water in institutional and commercial applications, comprising 20 to 50 percent or more of a facility’s total water use. The ripple effect extends beyond facilities—to the broader power grid and causes negative environmental impacts.

Since water is a finite resource, careful management is crucial for ensuring the business will continue to serve people. We can minimize waste, and maintain healthy ecosystems that support economic growth and sustainable development. Plus, with the right management, facilities can save significant amounts of water by optimizing the operation and maintenance of cooling tower systems.

Explore Alternative Water Sources

One of the most impactful strategies in sustainable cooling tower management is utilizing alternative water sources. Relying on treated wastewater, greywater, or harvested rainwater for cooling processes reduces dependency on potable water supplies and supports circular water management practices.

Wastewater treatment, when properly processed, meets stringent quality standards and can be safely reused in cooling systems. Many industrial facilities and municipalities have already implemented reclaimed water programs, significantly reducing fresh water demand while maintaining cooling efficiency. This approach not only conserves drinking water but also minimizes industrial wastewater discharge, alleviating stress on local water treatment infrastructure.

Harvested rainwater and HVAC condensate recovery are efficient solutions that can supplement cooling tower make-up water. By integrating filtration and chemical treatment processes, these sources can be safely repurposed, further enhancing sustainability and cost savings.

The Three R’s of Water Conservation: Reduce, Replace, Reuse

Optimizing water usage in cooling towers requires a shift toward a circular water management approach, and the Three R’s—Reduce, Replace, Reuse—provide a solid foundation for achieving sustainability goals.

Reduce

The first step in conservation is reducing overall water consumption. Facilities can implement high-efficiency drift eliminators, automated chemical dosing systems, and real-time water quality monitoring to optimize sustainable water cycle, reducing unnecessary blowdown and evaporation losses. Preventative maintenance and leak detection programs also play a critical role in minimizing waste.

Replace

Another strategy is replacing potable water with alternative water sources that maintain system efficiency without depleting freshwater reserves. This can include using rainwater harvesting systems, greywater from industrial processes, or even condensate recovery from HVAC systems. These substitutions help preserve municipal water supplies while maintaining operational integrity.

Reuse

Reusing treated water and wastewater systems for cooling purposes is a game-changer in sustainable water management. Advanced filtration and treatment technologies enable facilities to safely recycle cooling tower blowdown, significantly reducing the demand for fresh water. Implementing water reuse programs not only lowers costs but also promotes long-term sustainability by reducing discharge volumes and easing strain on local water sources.

4 Common Cooling Tower Challenges Impacting Your Facility

Regardless of size, every facility—even the ones with most advanced cooling tower systems faces issues over time. Here are the four biggest challenges that can significantly impact your operations:

1. Scaling & Corrosion

Causes: Exposure to various chemicals, oxygen, and water with high mineral content.

Mineral buildup, surface water, and corrosion reduce heat exchange efficiency, forcing your system to work harder and consume more energy. Left unchecked, these issues can lead to reduced airflow, equipment failure, increased downtime, and costly repairs.

2. Microbiological Growth

Causes: Moist and warm environments which situates the growth of suspended solids including algae, fungi and bacteria.

Cooling towers create ideal conditions for bacterial growth, including Legionella, posing serious risks with human health, regulatory compliance and environmental challenges. Microbial fouling further degrades system performance and drives up maintenance demands which calls for biological treatment processes.

3. Inefficient Cooling Tower Management

Causes: Lack of experience, resources and improper maintenance.

Without proper monitoring and proactive treatment, frequent maintenance and unplanned downtime can hinder production, escalate operational expenses, and reduce overall system reliability.

4. Drift and Leaks

Causes: Tiny water droplets carried in the exhaust air, and improper installation of equipment.

Both drift and leaks, while having different causes, have the same impact of water loss, spreading contaminants in the surrounding equipment and high risks of compliance issues.

Incorporate Digital Solutions for Water Management

The integration of digital water management solutions is revolutionizing how cooling towers operate. By utilizing smart sensors, real-time monitoring, and automated control systems, facilities can optimize water usage, improve treatment efficiency, and enhance system performance while minimizing waste.

Smart sensors continuously measure key water quality parameters such as pH, conductivity, and bacterial levels, providing operators with instant data insights. Automated control systems use this information to adjust chemical dosing, blowdown cycles, and water flow rates dynamically, reducing human error and improving precision. These systems also allow for predictive maintenance, detecting anomalies before they escalate into costly repairs or efficiency losses.

Cloud-based analytics and remote monitoring further enhance water management by providing real-time access to system performance data. Facilities can track trends, receive alerts, and make data-driven decisions to optimize sustainable water treatment strategies, reduce costs, and ensure compliance with sustainability goals.

By embracing digital water management technologies, businesses can significantly improve their cooling tower efficiency, reduce water consumption, and support long-term sustainability initiatives.

Advanced Oxidation Processes (AOP)

Advanced Oxidation Processes (AOP) are a cutting-edge solution that leverage hydroxyl radicals to break down organic contaminants at a molecular level. These radicals are highly reactive, targeting organic pollutants effectively without leaving behind harmful by-products. This makes AOP a sustainable alternative to traditional chemical treatments that often contribute to scaling, corrosion, and environmental discharge concerns.

By integrating AOP into cooling tower treatment strategies, facilities can reduce their reliance on chlorine and other harsh chemicals while maintaining superior water quality. The process enhances operational efficiency through mechanisms such as UV irradiation combined with hydrogen peroxide or ozone, generating hydroxyl radicals that rapidly oxidize contaminants. This not only aligns with green initiatives but also supports long-term water conservation and system longevity.

EAI Water’s Solution to Cooling Tower Management

At EAI Water, we take water management to the next level—integrating chemical treatments, advanced equipment, and smart automation to optimize your cooling system. From water and energy savings to improved product delivery and biofilm control, our top-notch research laboratories develop new products and innovative solutions to help meet the unique needs of sustainable water treatment.

Here’s how we do it:

Water Safety Plan

Our plan is to safeguard cooling towers against Legionella outbreaks, biofilm formation, and scaling while ensuring full regulatory compliance. Our strategy integrates in-depth risk assessments, real-time monitoring, and precision chemical treatments to maintain clean, efficient, and reliable cooling systems. With automated dosing, expert-driven maintenance, and tailored operator training, we help facilities minimize downtime, cut costs, and uphold the highest standards of public health and equipment protection.

Tower Cleaning & Disinfection

Our specialized deep-cleaning process utilizes industry-approved oxidizing biocides, membrane technologies, high-pressure washing, and meticulous debris removal to eliminate bacterial growth and optimize system performance. EAI’s expert technicians conduct thorough disinfection to enhance heat transfer efficiency, lower energy costs, and extend the lifespan of your cooling equipment. Regular maintenance isn’t just a best practice—it’s a critical investment in operational reliability and public safety.

Microbial Testing

EAI Water employs cutting-edge microbial detection techniques, including industry-standard culture testing, ATP bioluminescence, and rapid diagnostics, to identify microbial growth before it becomes a problem. Our sustainable approach prevents biofilm buildup, corrosion, and contamination while ensuring compliance with ASHRAE 188 and OSHA guidelines. Routine microbial testing keeps cooling systems cleaner, safer, and more efficient—reducing maintenance costs while protecting both equipment and human health.

On-Line Disinfections

This advanced treatment method ensures continuous protection by injecting precisely controlled disinfection agents while the cooling system remains operational, preventing costly downtime and efficiency loss. By integrating real-time monitoring and automated dosing, EAI’s approach optimizes chemical usage, reduces environmental impact, and extends equipment lifespan, especially for industries that rely on uninterrupted cooling operations, such as hospitals, data centers, and water treatment plants, ensuring safe, compliant, and high-performance water systems.

Tower Inspection

Leveraging advanced diagnostic tools and real-time data analysis, our experts implement preventive maintenance strategies making facilities energy efficient, extend equipment lifespan, and minimize operational disruptions. By prioritizing system health, we help facilities reduce water and energy consumption while ensuring safe and high-performing cooling operations.

Operator Support

Empowering facility teams with the knowledge to maintain peak system performance, EAI Water provides expert-led operator support and training programs. Our hands-on approach equips operators with best practices for water quality testing, chemical dosing, circulation techniques, and compliance with industry standards such as ASHRAE 188 and OSHA guidelines.

Regulatory Compliance & Safety

Navigating today’s evolving regulatory landscape demands more than just compliance—it requires strategic expertise and a proactive approach. At EAI Water, our dedicated compliance team stays ahead of industry regulations, ensuring your operations meet the highest standards while optimizing system performance. We integrate advanced monitoring through energy efficient technologies with a robust documentation framework, delivering a seamless, systematic approach that safeguards your water infrastructure, minimizes risks, and keeps you ahead of regulatory shifts.

This approach includes:

• CDC-aligned Legionella prevention programs
• Market-leading ST-108 cooling tower treatment system
• Real-time monitoring and documentation systems
• Routine in-house safety training for all employees
• Adoption of Leading Sustainable Water Treatment Technologies

Case Studies in Sustainable Cooling Tower Water Management

Real-world data proves that sustainable cooling tower management isn’t just a concept but a game-changer. In 2018, University of California, Irvine (UCI)—which has long prioritized integrating sustainable water treatment practices into its campus operations partnered with EAI Water to implement a reclaimed water program, using treated wastewater for cooling towers and irrigation.

This initiative aimed to conserve water resources while maintaining industry-standard efficiency. However, adopting reclaimed water posed challenges due to its higher mineral content and fluctuating quality. To address this, UCI and EAI Water upgraded water quality monitoring, automated controls, and enhanced management practices to ensure operational stability.

Within just 1.5 years, the program saved 140 million gallons of water, increased system bleed rates by 36%, and strengthened asset protection with zero negative impacts. By investing in automation and dedicated oversight, UCI successfully optimized water efficiency without compromising equipment performance. Today, UCI remains a leader in environmental stewardship clean water first, demonstrating how sustainable water management can deliver long-term economic and ecological benefits.

On a similar note, San Jose McEnery Convention Center, spanning over 520,000 square feet, is Silicon Valley’s largest environmentally friendly convention hub and a leader in sustainability. Aligned with their Green Vision and Climate Smart plans, the center has adopted sustainable wastewater treatment, including water recycling, composting, and an 87% waste diversion rate. Striving for LEED Silver certification, it continuously innovates to reduce its environmental impact.

Partnering with EAI Water, the Convention Center implemented a reverse osmosis (RO) system to reclaim and process over 50% of cooling tower blowdown water, reducing reliance on fresh water. The automated water treatment systems maximizes water reuse by controlling dissolved solids, ensuring efficiency without compromising cooling performance.

This initiative alone saves 3 million gallons of fresh water annually, significantly cutting the facility’s water footprint and aligning with sustainable development goals. By integrating advanced filtration and automation, the San Jose Convention Center sets a benchmark for sustainable systems in commercial facilities, proving that environmental protection agency and responsibility and operational efficiency can go hand in hand.

Why EAI Water?

EAI Water has built its reputation on engineering sustainable, high-performance sustainable water treatment solutions that minimize waste, extend system longevity, and ensure compliance with evolving regulations. Our commitment goes beyond just delivering results—we actively pursue continuous innovation and environmental responsibility to help our clients achieve peak operational efficiency.

We collaborate with industry leaders such as EVAPCO, Dober Smart Release, and Vertical Systems to develop cutting-edge, cost-effective water flow solutions tailored to current industry challenges. Our affiliations extend to AquaClear, enhancing our reach across Southern California, as well as Dioxide Pacific and Clearwater Industries, a recognized leader in water treatment with a nationwide presence.

To stay at the forefront of water treatment advancements, EAI Water actively participates in Association of Water Technologies (AWT) training programs and conferences, ensuring our team remains well-versed in the latest methodologies. We are also a proud member supplier for the Cooling Technology Institute (CTI), reinforcing our dedication to industry standards, education, and best practices.

What’s in it for Your Business?

✔ Reduce carbon footprint and energy costs with optimized cooling tower performance.
✔ Cut the water waste while meeting regulatory sustainability targets.
✔ Extend equipment lifespan and lower maintenance costs
✔ Safety & Legionella Risk Management

Let us know how we can help

For over 30 years, EAI Water has been at the forefront of sustainable water management. Our expertise in industrial water treatment means we don’t just provide solutions—we tailor them to your facility’s unique needs and ensure transformation.

Let’s optimize your cooling tower for a sustainable future. Schedule a consultation with our experts today.