Project Basic Information

Equipment Type: Cooling Tower

Medium: Water

Quantity: 2 Units

Project Description

This project delivers a complete cooling system supporting a local an Eastern European country foundry enterprise, with sets of  industrial cooling towers put into service on site. The units undertake circulating water cooling and heat dissipation for melting furnaces, casting cooling sections, heat treatment processes and hydraulic systems on the casting production line. Fully tailored to an Eastern European country’s temperate continental climate featuring long frigid winters, drastic temperature swings between summer and winter, and permafrost in partial regions, all design, manufacturing and acceptance procedures fully comply with an Eastern European country industrial safety codes, casting industry cooling standards and strict anti-freezing specifications. Equipped with enhanced heat exchange structure, low-temperature startup anti-freezing protection system, long-term anti-corrosion technology and variable-frequency energy-saving control system, the equipment comprehensively addresses common industry pain points including pipeline freezing and blockage in winter, structural fatigue caused by extreme temperature difference and heat exchange efficiency decline under low ambient temperature. It ensures year-round uninterrupted stable operation of casting lines, improves casting quality and cuts comprehensive energy consumption and maintenance costs of the plant.

Stable Operation:  Cooling Tower for Casting Production in an Eastern European country

Situation

An Eastern European country ranks as a key global power in casting and metallurgy industries, with its casting sector underpinning core fields including automobile manufacturing, heavy machinery, oil & gas equipment and military production. During continuous casting production, electric melting furnaces, casting lines, heat treatment furnaces and hydraulic units generate massive waste heat, which requires stable and uninterrupted circulating water cooling to sustain normal equipment operation and guarantee casting quality. 

Most regions of an Eastern European country feature continental climate with long freezing winters; extreme temperature can drop to -40~-50℃ in certain areas, and the annual temperature difference exceeds 70℃. Severe cold brings multiple operational risks to outdoor cooling equipment: circulating water tends to freeze easily, resulting in pipeline rupture and fill damage; drastic temperature fluctuation leads to repeated thermal expansion and contraction of tower metal structures, generating intense structural stress; road de-icing salt in winter and industrial dust in workshops accelerate equipment corrosion. Meanwhile, temperature can exceed 30℃ in many an Eastern European country regions in summer, so cooling towers must maintain stable heat dissipation under all-year working conditions. Besides, industrial power grids in an Eastern European country suffer severe voltage fluctuation, setting higher standards for the stability of electrical control systems. Conventional cooling towers suffer weak anti-freezing capacity, startup failure under low temperature and sharp fluctuation of heat exchange efficiency with temperature change, which form the core challenges of this project.

The client SERGEY** is a professional local an Eastern European country foundry enterprise. For its newly expanded casting production line, the factory requires supporting cooling systems with strict mandatory standards on cold-region reliability, anti-freezing performance and year-round operational stability.

Task

The project adopts a parallel scheme of cooling towers to cover all process cooling loads of the casting workshop. The equipment must adapt to an Eastern European country’s cold-region environment and on-site production conditions, with five core challenges listed below:

• Low-temperature anti-freezing and startup guarantee for cold regions: The minimum winter temperature in an Eastern European country falls below -40℃, bringing severe risks of freezing, blockage and rupture to cooling tower water circulation systems and outdoor pipelines. The equipment must be equipped with a complete anti-freezing protection system to prevent pipeline freezing and cracking during shutdown, enable rapid system recovery upon low-temperature restart, and avoid full-line production suspension caused by freezing damage.

• Long-term structural stability under extreme temperature difference: With annual temperature difference over 70℃, tower bodies, metal pipes and heat exchange fills bear alternating thermal expansion and contraction stress continuously. Low-temperature resistant special materials and optimized anti-fatigue structural design are required to eliminate structural deformation, weld cracking and fill embrittlement damage under low temperature.

• High-precision water temperature control for casting processes: Melting, casting and heat treatment procedures are extremely sensitive to cooling water temperature fluctuation; unbalanced water temperature will directly alter metallographic structure and dimensional accuracy of castings. The cooling system shall maintain constant outlet water temperature all year round to meet differentiated cooling requirements of multiple casting processes.

• Adaptation to power grid fluctuation & reliable electrical safety: The electrical system shall adapt to voltage fluctuation in an Eastern European country industrial zones for continuous stable control; fan and water pump motors adopt wide-temperature low-temperature resistant configuration to realize normal startup and operation under subzero extreme cold.

• Intelligent coordinated operation of dual parallel units: Two cooling towers are arranged centrally with uniform distribution of air volume, water pressure and circulating water flow and automatic dynamic load balance. Maintenance or shutdown of one single unit will not interfere with the whole cooling system, satisfying the 24-hour continuous production demand of the foundry.

Action

The professional heat exchange solution technical team of Shandong Casen Heat Transfer (CasenHeatTransfer) customized an integrated complete set solution of 2  cooling towers targeting an Eastern European country’s cold-region climate and exclusive casting process demands, tackling all working condition difficulties item by item. Casen heat transfer products have been exported to more than 30 countries and regions worldwide. In 2025, the official an Eastern European country Representative Office was established in Moscow to provide rapid localized technical service and after-sales support for local clients.

• Integrated design of cold-region anti-freezing & low-temperature startup The whole water circulation system of cooling towers is fully wrapped with electric tracing heat insulation to isolate freezing damage during low-temperature shutdown. Independent anti-freezing structures are applied to water collecting trays and outdoor pipelines, equipped with fully automatic temperature-controlled heating modules which activate anti-freezing heating protection automatically when ambient temperature drops below the threshold. Fans and water pump motors are filled with special low-temperature resistant lubricating grease and matched with low-temperature resistant insulating materials to achieve smooth startup and operation under extreme -40℃ low temperature. Low-temperature special structural steel is adopted for tower main bodies, and modified anti-embrittlement materials are used for heat exchange fills to avoid cracking failure under extreme cold.

• Enhanced heat exchange structure adapting to full-year wide temperature working conditions The heat exchange area of tower fills is expanded, internal air ducts and large-flow uniform water distribution structures are optimized to improve gas-liquid contact heat exchange efficiency and guarantee heat dissipation performance in hot summer. Fans are equipped with variable frequency speed control systems to adjust rotation speed automatically in real time based on ambient temperature and return water temperature, reducing power consumption for energy saving in cold seasons and stabilizing water temperature in hot periods to accurately meet temperature control standards of each casting process.

• Low-temperature resistant raw materials & optimized anti-fatigue structure Low-temperature pressure-bearing steel is adopted for tower frames and metal pipelines. Core load-bearing structures pass thermal stress simulation verification under extreme temperature difference with sufficient safety margin reserved. Modified anti-embrittlement polymer materials are selected for fills to maintain stable mechanical strength and heat exchange performance under low temperature. All connecting fasteners are made of low-temperature stainless steel to prevent bolt loosening and leakage caused by temperature shrinkage.

• Full-equipment anti-corrosion & weather resistance protection system The overall hot-dip galvanizing anti-corrosion treatment is conducted on equipment frames and metal pipelines, with an outer weather-resistant protective coating for double-layer protection against industrial corrosion in workshops and erosion of winter de-icing salt, greatly extending the service life of outdoor equipment in cold regions.

• Customized electrical system for local conditions Voltage stabilizing modules are built into electrical control cabinets to buffer voltage fluctuation of local power grids. Full sets of motors and electrical control components adopt wide-temperature anti-freezing models to ensure long-term uninterrupted stable operation of electrical systems under extreme cold.

• Intelligent parallel linkage control system for dual units Central main pipe layout is adopted for two cooling towers, with balance pressure stabilizing pipelines added to main pipes to equalize water pressure and circulating water volume of each tower. A integrated intelligent central control system is matched to realize synchronous startup & shutdown of dual units, intelligent load distribution, real-time online monitoring of operating parameters and remote fault alarm push. Operation and maintenance staff can conduct centralized unified management to cut labor maintenance costs and guarantee uninterrupted continuous production of casting lines.

Result

The sets of cooling towers have completed complete machine installation, commissioning and grid-connected production at the an Eastern European country foundry, with all full-working-condition operating indicators meeting design standards. Six core achievements are delivered by the project:

• Excellent anti-freezing performance in cold regions: The equipment has fully passed the test of severe an Eastern European country winters. No freezing or pipeline rupture failure occurs to the water circulation system under extreme -40℃ low temperature; electric tracing temperature control modules respond sensitively with smooth low-temperature restart, realizing uninterrupted winter production of the factory all year round.

• Stable and reliable structure under extreme temperature difference: No structural deformation or weld cracking occurs to tower bodies under circulating working conditions with annual temperature difference over 70℃; fills maintain stable mechanical strength and heat exchange efficiency under extreme cold, fully meeting standards with the low-temperature material selection scheme.

• Accurate and stable water temperature control for casting processes: Outlet water temperature under all-year working conditions is stably locked within the design range, perfectly matching differentiated cooling demands of multiple procedures including melting, casting and heat treatment. Consistent metallographic structure and dimensional accuracy of castings significantly improve finished product yield.

• Outstanding weather resistance and anti-corrosion performance: The equipment withstands the composite corrosive environment of industrial dust and de-icing salt in an Eastern European country for long-term operation, with long-term stable anti-corrosion effect of metal components and greatly extended overall service life.

• Remarkable energy & water saving benefits: The variable frequency speed regulation system dynamically adjusts operating power based on ambient temperature, achieving obvious reduction of comprehensive energy consumption compared with traditional fixed-frequency cooling towers. Equipped with high-efficiency water collection and water-saving structures, wind-induced water loss is far below local environmental control limits, continuously lowering plant production water consumption and long-term operation costs.

• Safe and stable operation of dual parallel units: Automatic balanced load distribution is realized between two parallel cooling towers with fast response of the intelligent linkage system and stable long-term continuous operation, fully satisfying the strict requirements of uninterrupted continuous production for foundry plants.

Quantifiable Core KPI Metrics

• Delivery Outcome: cooling towers fully completed installation, commissioning and grid-connected operation

• Low-temperature Startup Performance: Complete machine normal startup under extreme -40℃ ambient temperature, zero freezing failure of water circulation system

• Comprehensive Power Saving Index: Supporting variable frequency control system, comprehensive energy consumption of the whole cooling system reduced by ≥15%

• Extreme Operating Temperature Range: Stable operation within full temperature range of -40℃~+35℃, heat exchange efficiency fully consistent with design parameters

• Water Saving Quantitative Index: Equipped with high-efficiency water collectors, wind-induced water loss rate ≤0.015%, sharp reduction of production water consumption

• System Continuous Operation Reliability: Real-time monitoring via intelligent central control + remote fault alarm, dual units serve as mutual standby, annual continuous operation rate of the system ≥99%

• Compliance Certification: All equipment passed local an Eastern European country industrial equipment safety acceptance, complying with mandatory standards of local power grid and cold-region climate

Replicable Promotion Value & Project Highlights

• Standardized Cooling Solutions for Foundry & Metallurgy in an Eastern European country and Cold Regions A standardized complete anti-freezing cooling tower solution is developed targeting process cooling demands and frigid environments of casting, metallurgy and heavy machinery manufacturing industries in cold belt countries including an Eastern European country, Kazakhstan and Mongolia, which can be rapidly replicated and implemented in various industrial cooling projects with identical climate.

• Integrated Complete Anti-freezing Technology for Cold-region Cooling Towers The combined anti-freezing system integrating electric tracing heat insulation, intelligent temperature-controlled heating, low-temperature resistant special steel and anti-embrittlement fills can be mass applied to all outdoor industrial cooling equipment in frigid regions worldwide such as Northeast China, an Eastern European country, Northern Europe and Canada.

• Anti-fatigue Structural Design Scheme for Ultra-large Temperature Difference The low-temperature resistant structural steel + stress optimization design adapting to continental climate with annual temperature difference over 70℃ can be promoted to outdoor complete industrial equipment projects in high-latitude cold regions worldwide with drastic temperature swing.

• All-year Accurate Temperature Control Complete Technology for Foundry Industry The all-weather constant temperature cooling system developed for temperature-sensitive casting procedures including melting, casting and heat treatment can be horizontally replicated to upstream and downstream manufacturing industries such as metallurgy, forging, heat treatment and die casting.

• General Variable Frequency Energy-saving Technology for Cold Regions The intelligent variable frequency speed regulation system for cooling tower fans adjusts output power adaptively with ambient temperature to greatly cut energy consumption in cold seasons, suitable for wide-scale promotion in all cold-region industrial cooling scenarios globally.

• Complete Intelligent Co-control Technology for Multiple Parallel Towers The complete system with shared main pipe optimization, automatic load balance and remote online monitoring for two or more cooling towers is applicable to centralized circulating cooling projects of large processing plants and industrial parks.