We’re a Chinese team specializing in cooling equipment for many years. Our closed cooling towers and evaporative condensers are in use globally, including in India, where the steel industry is vital. We’ve partnered with a major steel plant in Jharkhand, which makes steel bars for construction. Their old cooling system was failing, but our closed cooling towers improved their operations.
Steel manufacturing involves extreme temperatures. Furnaces reach 1500°C, and every step, from molten metal handling to rolling mills and casting, requires substantial cooling. Without effective cooling, machines can overheat, reducing steel quality and production. The Jharkhand plant had an old, open cooling system that leaked, rusted, and broke down, especially during India’s harsh summers and muddy monsoon seasons. Dirty water clogged pipes, raising energy bills and causing a 6% loss in steel quality, disappointing clients in Dubai and Southeast Asia.
The plant’s engineering head reached out to us. We assessed their facility and saw outdated equipment and murky cooling water affecting profits. We proposed our CT-600 closed cooling towers, each providing 600 kW. They are made from stainless steel, ideal for harsh conditions, use a closed-loop system to keep water clean, and feature smart energy-saving controls. The plant liked our solution, crunched the numbers, and we secured the deal.
Our Actions:
– Installed four CT-600 closed cooling towers for cooling rolling mills and casting units.
– Used a glycol-water mix suitable for steel processes.
– Included VFD fans for lower power consumption.
– Connected a PLC system to their control room.
We completed the installation during a scheduled maintenance period to avoid halting furnaces, finishing in 14 days. Our team trained their workers on system maintenance, such as pump checks and filter cleaning. Given India’s challenging water, rich in sediments and minerals, we added a heavy-duty filtration unit to prevent clogs.
Challenges Encountered:
Jharkhand’s heat can soar to 42°C, pushing the towers to work rigorously. We adjusted the fan settings for optimal airflow, maintaining stable temperatures. Monsoons flooded the site with muddy water, so we elevated the tower bases to prevent water damage. Frequent power outages in Jharkhand led us to install backup controls, ensuring uninterrupted operation. Corroded old plant pipes slowed water flow, so we replaced some lines, taking extra time. The plant manager, Mr. Sanjay, supported and understood the necessity of these upgrades.
Feedback from Mr. Sanjay:
Mr. Sanjay, with 15 years of experience running the Jharkhand plant, knows the steel industry thoroughly. Six months post-installation, he shared insights:
“Our old cooling system caused frequent leaks and breakdowns, which hurt production. Your closed cooling towers have significantly improved our operations. Energy costs dropped by 24%, and the fans adjust to save power. We no longer deal with cracked steel, and defects have decreased from 6% to under 1%. Our Dubai clients are satisfied, and orders have increased. Maintenance is straightforward—no rust or scaling. My team manages tower checks every three weeks. We’re producing 20% more steel daily, boosting exports. Your equipment was a worthwhile investment.”
Improvements:
Mr. Sanjay highlighted the plant’s progress. Energy usage decreased, with VFD fans cutting power by almost 25%. Water costs dropped by 18% since closed-loop towers use less water and eliminate contamination. Clean water is crucial for steel production, and our system ensures it, leading to a 20% increase in daily steel output. Plant operations meet the quality standards for Dubai and Southeast Asia, enhancing exports and competitiveness in India’s steel market.
The stainless steel towers withstand Jharkhand’s dusty and humid monsoon air, resisting rust. The PLC system offers real-time monitoring of temperature, pressure, and flow, addressing issues swiftly and minimizing downtime. Mr. Sanjay’s team efficiently handles the system with manuals in Hindi and English, supported by a follow-up visit.
Why It Works in India:
India’s steel industry supports construction, infrastructure, and exports, with plants like Jharkhand running continuously. Effective cooling systems are essential to withstand the intense heat, monsoons, and dust. Our closed cooling towers deliver energy savings, clean water, and increased output, crucial for competing in global markets like Dubai and Southeast Asia that demand high-grade steel.
This project was successful. Mr. Sanjay is satisfied, his team is engaged, and we’re proud that our cooling towers meet the demanding needs of steel production. Beyond steel, other Indian industries like cement and chemicals also require cooling solutions, and we have the right equipment to support them.