Extreme heat, no failures: KSB pumps in casting pit
When a UK aluminium ingot supplier faced repeated pump failures in their casting pit, they turned to Wildon UK, who delivered a custom-engineered solution using KSB pumps. The result? A custom-engineered pumping system that has operated reliably for over six years despite handling process water at temperatures exceeding 87°C, more than double the standard pump limit.
When a UK aluminium ingot supplier faced repeated pump failures in their casting pit, they turned to Wildon UK, who delivered a custom-engineered solution using KSB pumps. The result? A custom-engineered pumping system that has operated reliably for over six years despite handling process water at temperatures exceeding 87°C, more than double the standard pump limit.
The project:
Cooling water return in extreme conditions
- Recirculation of cooling water around the site’s towers
- Return of high-temperature water from the casting pit
The challenge:
High temperatures and tight spaces
The solution:
Engineered by Wildon UK using KSB pumps
- 3x KSB KRTF 150-401/A954WNG-S submersible motor pumps, handling 80°C return water from the casting pit, a first of its kind for KSB UK
- 6x KSB KRTF 150-401/504UG-S IE3 submersible motor pumps, handling 22°C cooling water recirculation
- Hydraulic design: the pump was designed to absorb 36 kW of hydraulic load
- Oversized motor: a 70 kW motor was selected, not for power, but to minimise internal heat generation. This ensured the motor windings remained within safe limits without relying on the process water for cooling and also prevented the motor heating the surrounding media/process water
- Mock-up testing: A full-scale wooden model of the pump was built to verify fit during a scheduled shutdown. This ensured seamless installation in the confined wet well
This approach allowed the pump to operate reliably in fluid temperatures more than twice the industry norm, a rare achievement in submersible pump applications.
Data | Facts | Figures
- 3x Amarex KRTF 150-401/A954WNG-S
- 6x Amarex KRTF 150-401/504UG-S with IE3 motors
Used products
Amarex KRT
Horizontal or vertical single-stage submersible motor pump in close-coupled design, with various next-generation impeller types, for wet or dry installation, stationary or transportable version, with energy-saving motor and models for use in potentially explosive atmospheres.