10 Things to Consider When Using Water as a Heat Transfer Fluid

Water is often the first choice as a heat transfer fluid – and for good reason. It’s cheap, readily available, non-toxic, and has excellent thermal performance. But before committing to water for your chiller or closed-loop cooling system, it’s important to understand the limitations and risks that come with it. Here are 10 key things to consider when using water as your heat transfer medium:

1. Thermal Performance and Cost

Water’s high specific heat capacity makes it one of the most efficient heat transfer fluids available. It can absorb and transfer more heat than almost any alternative fluid at a lower cost. Combine this with its low viscosity (which makes it easy to pump), and it’s easy to see why water is the default choice in many applications.

2. Water Quality Matters

The quality of the water you put into your system directly affects performance and longevity. Tap water often contains minerals and chemicals that can cause scaling, corrosion, and bacterial growth. Ideally, water should meet the following parameters:

Calcium < 50 ppm
Magnesium < 50 ppm
Total Hardness < 100 ppm
Chlorine/Sulphate < 25 ppm
Conductivity < 20 µS/cm
pH 6.5-7.5

 

If your water doesn’t meet these limits, you risk damaging components and clogging flow paths.

3. Use of RO or Deionised Water

If your facility’s tap water is too hard or too impure, you may need to use filtered, reverse osmosis (RO), or deionised (DI) water. These systems remove most dissolved minerals and ionic contaminants, delivering ultra-pure water ideal for sensitive systems. For chillers with inline deionisation systems, you can achieve higher resistivity levels, ideal for laboratory and semiconductor applications.

4. Material Compatibility with DI Water

While DI water is chemically “clean”, it’s also aggressive. Its low ionic content makes it highly reactive with metals and plastics. To avoid corrosion and leaching, ensure all wetted components (especially pipework) are made from stainless steel or plastics like ABS. Brass, copper, and mild steel are not suitable.

5. Risk of Corrosion and Scale

Even within acceptable hardness levels, minerals can precipitate out of solution, especially as water is heated and cooled repeatedly. These deposits form scale, reducing thermal performance and causing localised overheating. Untreated water can also promote galvanic corrosion in systems with dissimilar metals.

6. Potential for Biological Contamination

Water is a perfect environment for bacteria and algae if left untreated. These microorganisms can form biofilms inside tubing and heat exchangers, restricting flow, damaging pumps, and reducing heat transfer efficiency. For closed-loop systems, regular water treatment and system flushing are essential.

7. Temperature Range Limitations

Water freezes at 0°C and boils at 100°C under atmospheric pressure. If your application operates below +6ׄ°C or above +90°C, water alone won’t be sufficient. In cold environments, you’ll need antifreeze protection. For high temperatures, pressurised systems or alternative fluids like glycol may be necessary to prevent boiling.

8. When to Use Additives

In some cases, pure water may not offer enough protection. Corrosion inhibitors and biocides can be added to help to stabilise the fluid and extend system life. Alternatively, a pre-mixed glycol/water solution may be a better fit – especially in outdoor or low-temperature conditions. Just keep in mind that additives usually reduce the thermal performance of the fluid.

9. System and Pump Design Considerations

Thanks to its low viscosity, water can be moved efficiently with centrifugal pumps. However, if fouling occurs (from scale, bacteria, or rust), system resistance increases, making flow rates drop. It’s important to match pump performance with expected operating conditions – and to include filtration if your water quality isn’t ideal.

10. Ongoing Monitoring and Maintenance

Even if your water starts off clean, it won’t stay that way forever. Regular maintenance is essential. This includes:

  1. Testing conductivity and pH
  2. Monitoring resistivity (if using DI water)
  3. Replacing filters
  4. Servicing inline deionisers
  5. Checking antifreeze protection (if used)
  6. Flushing and refilling systems annually or as needed

 

Preventative maintenance helps to catch small issues before they result in expensive downtime or component failures.

Water can be one of the best fluids for heat transfer – if it’s treated properly. At Applied Thermal Control, we offer expert guidance on fluid selection and system design to ensure long-term efficiency and reliability. If you’re unsure about the best fluid for your application, or need help monitoring your existing system, our team is here to help.

Got questions about water quality or treatment options? Get in touch with us today or visit our FAQs page for more details.