Industrial vortex generator (IVG) for chemical‑free cooling (IVG-CT) water reuse in industrial processes

This innovative technique applies controlled vortex conditioning within recirculating cooling systems to prevent scaling, biofouling and corrosion without the use of chemical additives. By im-proving heat transfer and enabling high cycles of concentration, the IVG-CT significantly reduces make-up water demand and facilitates near closed loop operation with high blowdown reuse rates. It is implemented at commercial scale in more than 150 industrial installations in the Benelux and the USA.

TECHNICAL DESCRIPTION
The industrial vortex generator technology for cooling towers (designated and commercialised under the name IVG-CT®) is a physical water treatment process that offers significant water, energy and chemical savings by increasing the cooling tower’s cycles of concentrations while improving the heat transfer in the chiller’s heat exchanger through reduced scaling, fouling and removal of entrained microbubbles from the condenser water flow to the chiller. It is based on the patented Vortex Process Technology (VPT®) which induces a strong, stable vortex and controlled cavitation in the cooling water stream via a passive in line device installed on the recirculation loop. The rapid pressure fluctuations and micro bubble dynamics disrupt microbial integrity, inhibit biofilm formation, and prevent nucleation and growth of crystalline scale (e.g. CaCO₃) on heat exchange surfaces. Concurrent micro aeration maintains an oxidising environment that further limits biofouling. The process does not require the introduction of any chemical reagents or consumables. A schematic of the Vortex Process Technology is provided in Figure 1 included in the supplementary information document attached.

The industrial vortex generator technology for cooling towers can lead to a significant reduction and in some cases the complete elimination of chemical dosing (biocides, corrosion inhibitors, anti scalants), reducing the use of hazardous substances use, procurement logistics and residuals in blowdown streams. By maintaining clean heat exchange surfaces and enabling higher cycles of concentration, this technology also reduces cooling water makeup volumes (water consumption) and the overall energy consumption of chillers and fans.

The industrial Vortex generator for cooling towers is a fully integrated water treatment system, typically hosted inside a modular container . The device is retrofittable and sized to the tower’s recirculation flow. A typical modular IVG-CT® unit is shown in Figure 2 (See Supplementary document attached). It is constituted of the VPT® for removal of entrained microbubbles in the water stream and for generating cavitation but also includes a UV-C light microbiological control system for water disinfection, a filtering unit and all the necessary integrated monitoring and control systems which are used for local or remote monitoring of the unit.

The IVG-CT has a build in monitoring tool (SCADA). SCADA control systems enable continuous tracking of several key performance indicators (make-up water in m³, blowdown water in m³, recirculation flow, approach temperature, conductivity, corrosion, scaling, energy consumption in kWh). The technique supports blowdown reuse rates of up to ~95% (with appropriate side stream filtration) and stable operation at cycles of concentration ≥5 in typical European hardness conditions. SCADA control systems enable continuous tracking of several key performance indicators (make-up water in m³, blowdown water in m³, recirculation flow, approach temperature, energy consumption in kWh).

DEGREE OF MATURITY
The technology readiness level of this innovation is considered above 9 considering that the system is complete and qualified and proven in operational environments across multiple EU industrial installations. Its scalability is reported as modular, passive in line devices scalable from small HVAC cooling loops to large industrial towers (>5 MW / >1 500 Tons of Refrigeration – ToR).

This technology is industry agnostic and can be applied to a wide range of industrial sectors / manufacturing sites which employs cooling towers, including energy intensive industries (e.g. iron and steel, cement, oil and gas refineries, pulp and paper, pharmaceutical production), the food and beverage sectors, the energy production sector (e.g. large combustion plants) and finally data centers.

CROSS-MEDIA EFFECTS
 Electrical load: Small additional hydraulic head loss through the in line device leads to a negligible increase in pump power relative to system wide energy savings.
 Waste generation: Potential minor increase in filter solids due to biofilm/scale removal, but this can easily be managed with standard operation and maintenance practices.

Basic information about the technique

Participant Companies