In industrial cooling systems, scale formation and biofouling are persistent challenges that impact efficiency, increase energy consumption, and demand frequent chemical dosing. In response to these issues, we introduce the Auto-BFSR System — an innovative, sustainable, and fully automated water treatment solution for cooling towers.
This proposal outlines the functionality, features, and key advantages of the Auto-BFSR system designed to enhance operational efficiency, reduce water and chemical consumption, and promote eco-friendly practices in industrial cooling processes.
System Overview
Auto-BFSR (Befouling & Scale Removal) System is a state-of-the-art, chemical-free treatment system that leverages the principles of water electrolysis. Installed in a side-stream configuration, it seamlessly integrates with existing cooling tower setups—without interfering with the main cooling water flow.
The system comprises
- Electrolytic reactor (with anode & cathode)
- PLC-based control panel
- DC power supply
- Self-cleaning hydro cyclone filtration unit
- Automated reactor cleaning mechanism
- Control valves and user-friendly HMI display
Working Process of BFSR Auto System
Water from the cooling tower tank is pumped in to
the electrolytic chamber. DC current is passed
through anode & cathode for the electrolysis
reaction.
● Primary Anode Reaction (Oxidation of Water)
2H2O – 4e-1 => O2 + 4H+1
● The OH ions is generated on cathode, resulting
in high pH condition on cathode surface.
● Primary cathode reaction (reduction of water)
4H2O + 4e-1 => H2 (g) + 4OH
Electrolysis reaction causes precipitation of calcium
& magnesium minerals in electrolytic chamber,
resulting in generation of chlorine gas on anode.
Chlorine gas acts as a biocides and preventing
biofouling in cooling tower water.
● Secondary Cathode Reactions
Ca2+ + HCO-3 + OH- => CaCO3 (Pre) + H2O Mg2+
+ 2 OH- => Mg(OH)2(Pre)
● SecondaryAnode reactions
2Cl- => Cl2 (g) + 2e
The TDS level is continuously monitored and displayed on a touchscreen HMI. Users can set a target TDS value, and the system will automatically initiate blow-down cycles to maintain the desired level—leading to minimal water wastage.
The self-cleaning reactor ensures uninterrupted operation without manual intervention or downtime.
Key Features
- Fully automated IoT-enabled system powered by electrolysis technology
- Zero chemical usage, offering a 100% saving on chemical cost
- Hydrocyclone filtration with automatic backwash for debris removal
- Intelligent HMI panel for real-time monitoring of conductivity/TDS
- Auto-cleaning electrochemical chamber with programmable control
- Easy installation with no requirement for system shutdown
- Eco-friendly, low maintenance, and user-friendly design
Benefits
- 100% elimination of chemicals
- Reduction of blow-down & make-up water by up to 80%
- Inhibition of corrosion in cooling water circuits
- Increased efficiency & life of cooling systems
- Energy & water conservation
- Blow-down water can be reused for gardening
- Prevents biofouling, enhancing system hygiene
Our Auto-BFSR System is a futuristic, eco-friendly solution engineered to meet the water treatment needs of today’s environmentally-conscious industries. With its smart automation, proven electrochemical process, and sustainable approach, it offers a highly reliable and cost-effective alternative to traditional chemical treatment methods in cooling towers.
We look forward to partnering with you in your journey towards operational excellence and sustainability.