In Cooling Tower systems, circulating water quality directly affects heat-transfer efficiency, water consumption, energy consumption, and the service life of equipment such as chillers, heat exchangers, and compressors.

During operation, circulating water continuously undergoes evaporation, causing Calcium, Silica, Magnesium, inorganic substances, and organic matter to become increasingly concentrated. If these components are not properly controlled, they can cause scale, slime, and corrosion-related problems, resulting in reduced heat-transfer efficiency and increased maintenance requirements.

Conventional methods generally use various water treatment chemicals to control circulating water quality. However, chemical treatment requires continuous replenishment, storage, handling, and concentration control throughout operation.

ECOION by ALPHA TECHNICAL RESEARCH CO., LTD. takes a different approach by using an Advanced Electrolytic Oxidation-Reduction Reaction with special electrodes to promote electrolysis, causing scale-forming components in the water to agglomerate, precipitate, and be removed from the system.

The solution is designed for chemical-free water quality management, while also supporting water saving, energy saving, and remote monitoring of circulating water quality.

1. Overview of ECOION by ALPHA TECHNICAL RESEARCH

1.1. What is ECOION?

ECOION is a circulating water quality treatment system for Cooling Towers that uses electrochemical reactions instead of conventional chemical dosing.

According to the product documentation, ECOION causes scale-forming components in circulating water to form agglomerates through an electrolytic reaction using special electrodes, thereby supporting their removal from the system.

The treatment focuses on components such as:

• Calcium;
• Silica;
• Magnesium;
• Inorganic components;
• Organic matter;
• Substances that may contribute to scale and slime formation.

The objective of the system is not only to treat scale that has already formed but also to control circulating water quality during continuous operation.

1.2. Introduction to ALPHA TECHNICAL RESEARCH

ALPHA TECHNICAL RESEARCH CO., LTD. is the developer of the ECOION solution for Cooling Tower systems.

The technology is designed for plants that aim to:

• Reduce dependence on water treatment chemicals;
• Control Calcium and Silica in circulating water;
• Reduce scale and slime;
• Support corrosion control;
• Reduce blowdown volume;
• Save water;
• Maintain heat-transfer efficiency;
• Monitor water quality remotely.

The ECOION documentation also refers to patents registered in Japan and several other countries. When this information is used in technical or commercial documentation, it should be verified against the manufacturer’s current patent records.

1.3. ECOION for Cooling Tower Circulating Water Systems

A Cooling Tower operates by circulating water between the cooling tower and equipment that uses water as a cooling medium.

A basic circulation cycle can be described as:

Heat Source → Cooling Water → Heat Exchange → Cooling Tower → Evaporation → Return Water

During this process, a portion of the water evaporates. Dissolved substances that do not evaporate with the water remain in the system and become increasingly concentrated.

Therefore, the system generally requires:

• Make-up water;
• Blowdown;
• Water treatment;
• Conductivity control;
• Scale control;
• Corrosion control;
• Microbiological growth control.

ECOION is introduced into the circulating system to support the control of scale-forming components and improve circulating water quality.

1.4. Chemical-Free Water Treatment Approach

One of the key features of ECOION is its Chemical-Free Water Quality Management approach.

Instead of continuously adding chemicals to control scale and slime, ECOION uses electrical energy and special electrodes to promote electrochemical reactions.

According to this treatment approach, the system does not require chemical dosing for water treatment.

This can help reduce the need for:

• Chemical procurement;
• Chemical replenishment;
• Chemical storage;
• Chemical handling;
• Chemical concentration control;
• Management of blowdown containing water treatment chemicals.

However, chemical-free should not be interpreted as meaning that every Cooling Tower can completely eliminate all chemicals under all operating conditions. Actual application should be evaluated based on make-up water quality, thermal load, system design, microbiological control requirements, and specific operating conditions.

2. Advanced Electrolytic Oxidation-Reduction Reaction – Core Technology of ECOION

2.1. What is an Advanced Electrolytic Oxidation-Reduction Reaction?

ECOION uses electrical energy to promote oxidation-reduction reactions in water.

From a scientific perspective, advanced electrochemical technologies may involve various mechanisms in which electrical energy is used to drive electron-transfer processes and generate the chemical conditions required for treatment.

The term Electrochemical Advanced Oxidation Processes – EAOPs refers to a broad group of electrochemical water treatment technologies. However, EAOPs should not be considered completely synonymous with ECOION.

In the case of ECOION, the product documentation focuses on the Advanced Electrolytic Oxidation-Reduction Reaction, with the primary objective of treating Cooling Tower circulating water and causing scale-forming components to agglomerate, precipitate, and be removed from the circulating water.

2.2. Advanced Electrolytic Oxidation-Reduction Reaction

The basic ECOION mechanism utilizes two processes occurring at the electrodes.

At the Anode

An electrolytic oxidation process occurs.

According to the product documentation, the special electrode promotes electrolytic oxidation and generates metal ions and O₂.

At the Cathode

An electrolytic reduction process occurs and H₂ is generated.

Through the combination of reactions occurring at the anode and cathode, the water environment is modified in a manner that promotes the scale-forming components to form precipitates or agglomerates.

2.3. Role of the Electrolytic Oxidation-Reduction Reaction

Several reactions illustrated in the ECOION product documentation include:

Ca²⁺ + CO₃²⁻ → CaCO₃

Calcium carbonate.

Mg²⁺ + OH⁻ → Mg(OH)₂

Magnesium hydroxide.

For Silica, the documentation illustrates its conversion into a polymerized/precipitated silica form:

Si(OH)₃O⁻ + H⁺ → (SiO₂)n + (H₂O)m

These reactions illustrate how dissolved components in water can be converted into agglomerated/precipitated forms and subsequently separated from the system.

2.4. Electrode Design and Material Selection

The electrode is an important component of the ECOION system.

According to the product documentation, ECOION uses special electrodes selected to enhance the efficiency of the electrolysis process.

Electrode material selection affects:

• Electrochemical reaction efficiency;
• Operational stability;
• Agglomerate formation;
• Electrode service life;
• Operating and maintenance costs.

The product documentation indicates an electrode replacement interval of approximately 3 years; however, actual service life depends on water conditions and operating conditions.

2.5. Automatic Removal of Oxide Film on the Electrodes

During electrolysis, an oxide film may form on the electrode surface.

ECOION is designed with a mechanism that supports the automatic removal of oxide film formed on the electrodes in order to maintain electrode operating conditions.

This is an important consideration for electrochemical water treatment systems because surface deposits on electrodes can affect current transfer and reaction efficiency.

3. How Does ECOION Treat Cooling Tower Water?

3.1. Circulating Water and Accumulation of Calcium and Silica

As water evaporates in a Cooling Tower, dissolved substances remain in the remaining water.

If not properly controlled, the concentrations of:

• Calcium;
• Magnesium;
• Silica;
• Carbonate;
• Inorganic salts;

may increase.

When their concentrations exceed the solubility limit, these components may form scale.

This is one of the main reasons why Cooling Towers require blowdown.

3.2. Electrolysis of Circulating Water

Circulating water passes through the ECOION treatment area.

At this point, electrical energy is used to generate oxidation and reduction reactions at the electrodes.

This process promotes scale-forming components to transition from a dissolved state into agglomerated/precipitated forms.

3.3. Coagulation – Agglomeration

Components such as Calcium, Silica, and certain inorganic substances are induced to form agglomerates.

Instead of remaining dissolved in the water, they tend to aggregate into larger particles.

3.4. Precipitation

Following agglomeration, substances capable of precipitation are converted into solid forms.

Typical examples include:

• Calcium carbonate;
• Magnesium hydroxide;
• Silica/polymerized silica.

Converting these components into precipitated forms helps reduce the amount of dissolved substances capable of contributing to scale formation on heat-transfer surfaces.

3.5. Separation – Removal

The agglomerates and precipitated substances are discharged from the system through the drainage stream.

According to the ECOION description, scale-forming components are processed through:

Electrolysis → Agglomeration → Precipitation → Separation/Drainage

Therefore, the scale-forming components are not simply “dissolved” or dispersed in the water; rather, they are intended to be separated and removed from the system.

3.6. Reduction of Scale-Forming Components in the System

This is an important difference in ECOION’s treatment approach.

If scale that has already formed is treated only by chemical cleaning, the system primarily focuses on removing or dispersing the existing scale layer.

ECOION aims to remove scale-forming components from the circulating water before they continue to form scale on heat-transfer surfaces.

According to the product documentation, the published illustrative results include:

• Calcium hardness reduction: 35%
• Ionic silica reduction: 60%

These improvements were observed approximately 3 weeks after system introduction in the case presented in the product material.

Actual performance depends on make-up water quality, circulating water quality, and operating conditions of each system.

4. How is ECOION Different from Conventional Chemical Water Treatment?

4.1. Conventional Chemical Treatment

Conventional methods commonly use chemicals to control scale, corrosion, and slime.

The system may use:

• Scale inhibitors;
• Corrosion inhibitors;
• Biocides;
• Dispersants;
• Other water quality conditioning chemicals.

Chemical selection and dosing depend on water quality and operating conditions.

4.2. Limitations of Maintaining High Circulating Water Concentration

To save water, plants often attempt to increase the cycles of concentration.

However, as water continues to evaporate while blowdown is reduced, the concentration of dissolved substances increases.

When the solubility limit is exceeded:

Scale formation → Heat-transfer reduction → Increased energy consumption

Therefore, increasing the concentration factor always needs to be accompanied by an appropriate ability to control water quality.

4.3. ECOION Treatment Mechanism

According to the ECOION documentation, the conventional method tends to use chemicals to control or disperse scale/slime.

In contrast, ECOION is designed to promote:

Electrolysis → Agglomeration → Precipitation → Drainage

Scale-forming components are converted into agglomerates and removed from the system.

This represents an approach intended to address the accumulation of scale-forming components in circulating water rather than simply treating the scale after it has already formed.

4.4. Comparison Between Chemical Treatment and ECOION

4.5. Blowdown and Water Consumption

One of the notable benefits of ECOION is its potential to reduce blowdown requirements when system conditions permit.

In the example presented in the product documentation, the system was operated at a concentration factor of approximately 3 times before ECOION installation.

After ECOION was introduced, water consumption was reduced from approximately:

1,473 m³ → 496 m³

over the period illustrated in the documentation.

This corresponds to a reduction of more than two-thirds of the water consumption in this particular case.

However, this is a case-specific result, not a fixed water-saving rate applicable to every Cooling Tower.

4.6. Reduced Dependence on Water Treatment Chemicals

When water treatment chemicals are not used under the ECOION treatment method, the plant can reduce activities associated with:

• Chemical procurement;
• Chemical replenishment;
• Chemical storage;
• Chemical transportation;
• Chemical control;
• Troubleshooting related to chemical dosing.

This can be particularly beneficial for plants with multiple Cooling Towers or systems located in difficult-to-access areas.

5. Scaling in Cooling Towers – A Problem That Requires Control

5.1. How Does Scaling Form?

Scale forms when the concentration of ions and dissolved substances in water exceeds their solubility limit.

For example:

Ca²⁺ + CO₃²⁻ → CaCO₃

Calcium carbonate can crystallize and deposit on heat-transfer surfaces.

5.2. Calcium and Silica in Circulating Water

Calcium is one of the common components associated with hardness and scale formation.

Meanwhile, Silica is more difficult to control in many water treatment systems.

Silica can form strongly adhering deposits and reduce heat-transfer efficiency.

Therefore, controlling both Calcium and Silica is important for Cooling Tower operation.

5.3. Effect of Scale on Heat Transfer

Even a thin layer of scale on a heat exchanger surface can add thermal resistance.

As a result:

Scale thickness ↑ → Thermal resistance ↑ → Heat-transfer efficiency ↓

The equipment may need to operate for a longer period or consume more energy to achieve the same thermal load.

The ECOION documentation provides an example in which approximately 0.6 mm of scale formed over 3–5 years was associated with approximately a 23% reduction in heat-transfer efficiency.

This is an illustrative figure from the product documentation and should not be considered a fixed rate applicable to every type of heat exchanger.

5.4. Scale and Energy Consumption

When heat-transfer efficiency decreases, the refrigeration/chiller system may need to operate more intensively to meet the required load.

Therefore, scale control can contribute to:

• Maintaining heat transfer;
• Reducing energy loss;
• Supporting energy saving;
• Reducing the load on refrigeration systems.

5.5. Impact on Equipment Performance

Scale may affect:

• Heat exchangers;
• Chillers;
• Compressors/refrigeration equipment;
• Cooling Towers;
• Circulating piping.

In addition, slime and corrosion can increase the risk of performance degradation and maintenance requirements.

5.6. Why is Continuous Scale Control Necessary?

Scale is not a one-time problem.

In an operating Cooling Tower, water continuously undergoes:

Make-up → Circulation → Evaporation → Concentration → Treatment → Blowdown

Therefore, water quality must be continuously controlled.

ECOION is designed to treat scale-forming components during circulation rather than only treating the scale after it has formed.

6. Key Benefits of ECOION

6.1. Chemical-Free Water Quality Management

ECOION enables water quality management based on electrolysis without requiring water treatment chemical dosing under the treatment approach described in the product documentation.

This helps reduce dependence on chemicals and associated handling activities.

6.2. Water Saving

By controlling scale-forming components, the system can support increased reuse of circulating water and reduced blowdown requirements when operating conditions permit.

The case presented in the product documentation shows water consumption reduced from approximately 1,473 m³ to 496 m³.

6.3. Energy Saving

Scale increases thermal resistance.

Therefore, scale control can help maintain heat-transfer performance and reduce energy loss.

ECOION is designed to support:

Scale Control → Heat-Transfer Maintenance → Energy Saving

6.4. Scale Control

ECOION focuses on Calcium, Silica, and other scale-forming components in circulating water.

These substances are promoted to agglomerate and precipitate so that they can be removed from the system.

6.5. Corrosion Prevention

According to the product documentation, ECOION can support corrosion control.

However, actual corrosion-control performance also depends on:

• Water chemistry;
• pH;
• Conductivity;
• Dissolved oxygen;
• Chloride;
• Temperature;
• Heat-exchanger material;
• Operating conditions.

Therefore, actual water quality should be evaluated before determining corrosion-control performance.

6.6. Support for Equipment Service Life Extension

When scale, slime, and corrosion are better controlled, heat-transfer surfaces can be maintained in better condition.

This can support:

• Reduced fouling;
• Reduced heat-transfer degradation;
• Reduced cleaning frequency;
• Reduced maintenance;
• Extended equipment service life.

6.7. Legionella Bacteria Countermeasures

The ECOION documentation refers to suppression of bacterial growth.

However, the bacterial-growth suppression function is identified as an option in the product material.

Therefore, ECOION should not be interpreted as automatically replacing a complete Legionella control program for a Cooling Tower.

For Cooling Tower systems subject to strict Legionella control requirements, a dedicated microbiological management program should be established in accordance with applicable standards and regulations.

7. ECOION and Environmental Considerations

7.1. No Discharge of Water Treatment Chemicals

An advantage of a chemical-free treatment approach is that water treatment chemicals do not need to be introduced into the circulating water under the ECOION treatment mechanism.

According to the product documentation, avoiding the mixing of water treatment chemicals into blow drainage can contribute to reducing environmental impact.

7.2. Wastewater from the ECOION System

ECOION does not make scale-forming components disappear.

Instead, they undergo:

Electrolysis → Agglomeration → Precipitation → Drainage

Therefore, the resulting agglomerated/precipitated substances still need to be appropriately managed through the discharge stream.

7.3. Reduced Chemical Storage and Management Requirements

By eliminating the use of water treatment chemicals, the plant may reduce:

• Chemical storage;
• Chemical replenishment;
• Chemical handling;
• Chemical inventory;
• Risks associated with chemical transportation and storage.

7.4. Reduced Risks Associated with Hazardous Chemicals

Reducing chemical consumption may help reduce certain risks related to:

• Chemical exposure;
• Chemical leakage;
• Chemical storage;
• Chemical transportation;
• Chemical handling.

7.5. Reduced Requirements for Industrial Wastewater Treatment

When the amount of chemicals entering the blowdown is reduced, the chemical composition of the discharged water may also be simplified.

However, all wastewater discharge must still comply with the environmental requirements applicable to the plant and local jurisdiction.

8. Applications of ECOION in Cooling Tower Systems

8.1. Cooling Tower Circulating Water

The primary application of ECOION is the treatment of circulating water in Cooling Towers.

The basic process can be described as:

Cooling Tower → Return Water → ECOION → Treated Water → Cooling System

During this process:

• Water is continuously circulated;
• A portion of the water evaporates;
• Make-up water is added;
• ECOION treats the circulating water;
• Blowdown is adjusted according to operating conditions.

8.2. Chiller and Turbo Chiller Systems

Cooling Towers are commonly used in combination with:

• Chillers;
• Turbo Chillers;
• Refrigeration equipment;
• Heat exchangers;
• Compressors.

By maintaining circulating water quality, ECOION can support the maintenance of heat-transfer efficiency in these systems.

8.3. Recirculating Cooling Systems

ECOION may be considered for systems such as:

• Industrial Cooling Towers;
• Chilled-water heat rejection systems;
• Process cooling systems;
• Heat-source cooling systems;
• Industrial heat-exchanger systems.

Equipment selection should be based on circulating flow rate, water quality, and operating load.

8.4. Systems Requiring Scale and Water Quality Control

ECOION is particularly relevant, in terms of its intended application, for plants experiencing:

1. High energy consumption;
2. High chemical treatment costs;
3. Scale formation in heat exchangers;
4. Slime/fouling;
5. Corrosion;
6. High blowdown volume;
7. High water consumption;
8. Difficulty in checking water quality on site.

8.5. Integration into Existing Systems

ECOION can be integrated into existing Cooling Tower systems.

Before implementation, the following should be evaluated:

• Cooling Tower;
• Circulating water flow;
• Make-up water;
• Blowdown;
• Heat exchanger;
• Water chemistry;
• Existing treatment system;
• Electrical power supply;
• Installation space;
• Drainage capability.

9. ECOION – Remote Monitoring and IoT for Cooling Towers

One of the notable features added in the new product material is the capability for remote monitoring of water quality management.

The system can measure and transmit data such as:

• Electrical conductivity
• Electrolytic current
• Alarm information

The data can be transmitted through:

Cooling Tower / ECOION → Control Room / Monitoring Room → Headquarter / Management Company

This allows operators and management personnel to monitor water quality without having to regularly access the installation site directly.

9.1. Electrical Conductivity Monitoring

Electrical conductivity is an important parameter for monitoring the concentration of ions in circulating water.

Conductivity data can be used together with other parameters to evaluate:

• Water quality;
• Concentration conditions;
• Blowdown conditions;
• Abnormal operation.

9.2. Electrolytic Current Monitoring

The electrolytic current is also monitored to evaluate the operating condition of ECOION.

When combined with water-quality data, operators can evaluate the relationship between:

Water Quality ↔ Electrolytic Current ↔ Processing Capacity ↔ Operating Condition

9.3. Alarm and Rapid Response

The remote monitoring system can generate alarms when abnormal conditions are detected.

This helps to:

• Detect abnormalities at an early stage;
• Reduce on-site inspection time;
• Support maintenance;
• Centralize operating data;
• Analyze trends over time.

10. ECOION and the SDGs-Oriented Approach for Industrial Plants

ECOION is not only focused on water treatment but also on optimizing the overall operation of Cooling Tower systems.

Three key factors can be connected:

Water Saving

Reduce blowdown volume when operating conditions permit.

Energy Saving

Control scale to support the maintenance of heat-transfer efficiency.

Chemical Reduction

Reduce dependence on chemical treatment.

When combined with remote monitoring, the system also supports an operating model based on:

Water Treatment + IoT + Energy Management + Environmental Management

This approach is consistent with the trend toward smart industrial systems and SDGs-oriented operations.

11. Conclusion

ECOION by ALPHA TECHNICAL RESEARCH CO., LTD. is a Cooling Tower circulating water treatment solution based on the Advanced Electrolytic Oxidation-Reduction Reaction, using electrical energy and special electrodes to promote electrochemical reactions.

Instead of relying solely on chemicals to control scale and slime, ECOION is designed around the following process:

Electrolysis → Agglomeration → Precipitation → Separation → Drainage

Through this process, components such as Calcium, Silica, and Magnesium can be converted into agglomerated/precipitated forms and removed from the system.

According to the product documentation, ECOION offers several potential benefits:

• Chemical-free water quality management
• Scale control
• Slime control
• Corrosion control support
• Water saving
• Energy saving
• Blowdown reduction
• Reduced chemical handling
• Remote water quality monitoring
• IoT-oriented operation
• Support for equipment service-life extension

In particular, the product documentation presents examples of 35% Calcium hardness reduction, 60% Ionic silica reduction, and a reduction in water consumption from approximately 1,473 m³ to 496 m³ after ECOION implementation. However, these figures should be understood as results/values from the cases presented in the ECOION product documentation, rather than guaranteed performance for every system.

For plants experiencing multiple issues related to scale, slime, corrosion, chemical costs, blowdown, water consumption, and energy consumption, ECOION can be considered as an electrochemical water treatment solution as an alternative or supplement to conventional Chemical Water Treatment.

For proper equipment selection, it is necessary to evaluate the Make-up Water, Circulating Water, Calcium Hardness, Silica, Conductivity, concentration factor, blowdown, circulation flow rate, heat load, and Heat Exchanger condition before designing and implementing the system.