Casthouse Cooling Towers in Iceland
A global metal casting company located in Iceland was installing a new casting line to enhance its aluminium ingot production. The project’s location presented several unique challenges, including a remote site with harsh operational conditions.
Working with SPX Cooling EMEA, the project team determined the right cooling towers for their needs, helping ensure that the casthouse remain online and limit any downtime related to the heat rejection system.
- Remote assembly site: The cooling towers had to be assembled in a laydown area several kilometers from the main plant due to space constraints, and then transported to their final location.
- Harsh environmental conditions: The installation took place in sub-zero temperatures, requiring durable and corrosion-resistant materials.
- High-performance requirements: The cooling system needed to handle a heat load of 35,567 kW, with a flow rate of 1,245 m³/h and operate efficiently at temperatures as low as -25°C.
To meet the client’s demanding requirements, SPX Cooling EMEA provided three Eurovent- and CTI-certified Marley CP Cooling Towers. The solution included:
- Pre-engineered design: The cooling towers were shipped in small, manageable pieces (knocked down), allowing for easy onsite assembly.
- Durable construction: The towers featured S304 stainless steel and fibre-reinforced plastic (FRP) construction, offering excellent corrosion resistance.
- Integrated control system: A full control system was installed to monitor and regulate the towers and pumps, ensuring consistent cold-water temperatures for the quenching process.
To meet the client’s demanding requirements, SPX Cooling EMEA provided three Eurovent- and CTI-certified Marley CP Cooling Towers. The solution included:
- Pre-engineered design: The cooling towers were shipped in small, manageable pieces (knocked down), allowing for easy onsite assembly.
- Durable construction: The towers featured S304 stainless steel and fibre-reinforced plastic (FRP) construction, offering excellent corrosion resistance.
- Integrated control system: A full control system was installed to monitor and regulate the towers and pumps, ensuring consistent cold-water temperatures for the quenching process.
The project was successfully completed in March 2024. Key outcomes included:
- Efficient cooling performance: The system achieved the desired cooling parameters with a cold-water outlet temperature of 25°C, even in sub-zero conditions.
- Reliable operation: The plant has been running commercially for nearly a year with no reported issues.
- Flexibility and scalability: The modular design allowed for adaptable assembly and easy transportation, making the installation efficient and cost-effective.
- Corrosion resistance and longevity: The use of stainless steel and FRP materials provided long-term protection against the harsh Icelandic environment.
With the help of the SPX Cooling EMEA team and Marley-engineered cooling towers, the casthouse can reliably control the heat rejection necessary in their quenching process, even in the Icelandic winter weather. With a legacy of quality engineering and dependable local service, Marley CP Cooling Towers will deliver exceptional performance and reliability for years to come.
Duty Parameters (Total across 3 x Cells)
Flowrate (m3/h): 1,245 m3/h
Hot Water Inlet Temperature (°C): 50
Range (°C): 25
Cold Water Outlet Temperature (°C): 25
Approach (°C): 5.2
Wet Bulb Temperature (°C): 19.8
Heat load (kw/h): 35,567 kW
Marley Representatives: DHD Cooling Ltd
Contractors: ACT – Mechanical Contractor
Electraspec – Electrical Contractor
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"Marley was the brand I learned all about cooling towers from. To this day, we still use Cooling Tower Fundamentals as our reference guide for new engineers joining.”
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