Introduction
DHD was engaged to design and install a cutting-edge cooling system for a new billet casting line at a leading aluminium casting facility.
The project required an advanced variable load and flow system to provide efficient cooling for a diverse range of aluminium products in a state-of-the-art facility.
The Challenge
Design a modular cooling system that could be pre-assembled offsite and transported to its final location.
Ensure the system functions effectively in subzero temperatures while offering flexibility to meet varying cooling demands.
Develop a comprehensive control system to monitor and regulate multiple pumped circuits, manage water levels, and maintain a fixed design water temperature for consistency.
The Solution
DHD implemented a high-performance cooling system featuring:
A stainless-steel framed, GRP-cased modular cooling tower designed for easy transportation and installation.
A custom-built control system to optimise water flow and cooling fan performance for maximum efficiency.
Pre-assembly of the cooling towers at a remote site, reducing on-site congestion and allowing other construction work to proceed simultaneously.
Safe access platforms for simplified long-term maintenance.
The Benefits
By partnering with ACT and SPX, DHD successfully delivered and installed three large cooling tower cells efficiently, ensuring minimal disruption to the project timeline. Additionally, through collaboration with Electraspec, DHD developed a modular control system to seamlessly manage the entire cold-end process, offering:
Operational Flexibility: Adaptive controls to accommodate a wide range of cooling needs.
Seamless Commissioning: System readiness at every stage to meet operational deadlines.
Ongoing Support: From initial planning to final implementation, DHD remained committed to helping the client achieve their project goals.
This innovative cooling solution ensured a smooth transition to commercial operation, demonstrating DHD’s expertise in delivering reliable and efficient cooling systems for aluminium casthouse applications.
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