The Situation
The operators of a major steel manufacturing Hot Mill site in South Wales contacted their local HAYLEY DEXIS team and challenged them to assist with reducing energy consumption and costs.
The focus area of this would be the slab sprayer area where the steel is reheated and temperatures exceed 1250°C, before the steel is coiled.
The Solution
A HAYLEY DEXIS Sales Engineer, along with a member of the HAYLEY 247 DEXIS Pump Services team visited the facility to understand the use of pumping equipment and to identify potential areas where energy efficiency could be improved. Three cooling water return pumps were chosen for specialist refurbishment treatment that would include a coating of Belzona 1341 and new sets of wear rings for each asset.
"A TOTAL EFFICIENCY GAIN OF 18% WAS ACHIEVED FOR THE THREE PUMPS"
The Result
The pumps, running 24/7/365 and performing an essential role in the mill’s slab sprayer area, were sent to HAYLEY 247 DEXIS’ main workshop in Dudley, West Midlands, where they were subjected to a full refurbishment on a priority basis.
Due to the fact that the pumps were 20+ years old with no refurbishment jobs being conducted on them in the past 5 years, the calculated efficiency gain achieved by the HAYLEY 247 DEXIS pump refurbishment was 10%.
The Belzona 1341 coating, applied to the pumps internals was calculated to improve the overall hydraulic efficiency by 8%. This meant that a total efficiency gain of 18% was achieved for the three pumps, representing a total cost-saving of £521,526 per year for the customer.