Torraval Cooling has upgraded the cooling system at the Zabalgarbi plant. This project has been a key component in industrial sustainability, focusing on optimizing energy recovery and reducing environmental impact. Thanks to our technology, the cooling tower is designed to improve the plant’s operational efficiency, ensuring optimal performance.
THE COOLING NEED
Over 20 years ago, Torraval installed the cooling towers for Zabalgarbi’s production process. Now, Zabalgarbi has decided to carry out an upgrade to improve the efficiency of these cooling towers, extend their service life, and optimize their performance.
THE COOLING SOLUTION
In order to extend the operational life of the towers and ensure efficient maintenance in the years to come, Torraval proposed a redesign based on replacing the metal structure with one made of pultrusion material, eliminating the risks of corrosion.
After several years of use, cooling towers require an upgrade to their internal parts to continue meeting the thermal program for which they were designed.
Updated components in the cooling tower:
- Internal parts of the tower: fill, drift eliminator, collectors, water distribution pipes, and nozzles.
- Structure: both the main structure and the supports for the fill or pipes, as well as all metal inserts in the concrete. The bolts are replaced with AISI 316 grade stainless steel.
- The enclosures are fully renewed, including the perimeter enclosure, removable panels, walkable roofs, wind screens, and deflectors.
Reused components:
- Motors, gearboxes, transmissions, fans, and coupling guards.
Additionally, access to the towers has been improved with the installation of access ladders, internal maintenance platforms, perimeter railings, and manholes.
Most importantly, the 2 towers with 3 cells each have been transformed into 6 individual cooling towers, capable of operating independently according to the plant’s needs.
COOLING SYSTEM UPGRADE PROJECT – THE CHALLENGE
The cooling system upgrade project at the Zabalgarbi plant presents several key challenges. The first and most important is meeting the established deadlines, which are essential to ensure the plant’s operational continuity without compromising its performance. Additionally, it is crucial to maintain or improve the cooling towers’ performance, certified through thorough performance tests to ensure the system’s optimization.
Another critical challenge is ensuring accessibility to key points of the towers for long-term maintenance, guaranteeing safe and efficient operation. Lastly, the towers’ durability is essential, requiring high-quality and corrosion-resistant materials to withstand the plant’s demanding operational conditions.
Due to the project’s magnitude and complexity, the upgrade will be carried out in two phases: the first in June 2024 and the second throughout 2025, ensuring a smooth transition while minimizing disruptions to the plant.
The upgrade of the Zabalgarbi cooling system has brought numerous benefits to the plant, improving both its performance and long-term sustainability. With a high-performance system, built using durable and corrosion-resistant materials, the plant has achieved maximum efficiency. Additionally, the tower was custom-designed to meet the client’s specific needs.
The project also prioritized safety and accessibility, ensuring easier and safer maintenance. Finally, the installation and commissioning were completed on time, meeting the agreed-upon performance tests and thermal program, reinforcing Torraval’s commitment to operational excellence and customer satisfaction.
