Call us: +27 10 140 0870 (SA) | +1 (904) 749 4352 (International)
[email protected]
Watercare InnovationsWatercare InnovationsWatercare InnovationsWatercare Innovations
  • Home
  • About Us
    • Company Overview
    • Industries We Serve
    • Safety, Health, Environment and Quality Commitment
    • B-BBEE Accredited
    • Corporate Social Investment
  • Our Expertise
    • Water Treatment Chemicals & Services
    • Process Technology
      • Water Treatment Plants
      • Metal and Reagent Recovery Plants
      • Gold Recovery Process
      • Integrated Mine Water Management Systems
    • Industrial Water Equipment
    • Case Studies
  • Our Capabilities
  • Blog
  • Opportunities
    • Careers
    • Partnerships
  • Contact Us

How to decrease aluminium reworks through optimising cooling water quality

NextPrevious
aluminium quality

How to decrease aluminium reworks through optimising cooling water quality

By Wendy Losper | Blog, Case Studies | Comments are Closed | 10 May, 2022 | 0

The success of aluminium casting depends on the implementation of accurate temperature control through the smelting and casting process. The dissipation of heat must be uniform at all points of the final product.

Temperature control is achieved through the application of water, which influences the aluminium material structure, the microstructure and the surface of the metal. The quality of the cooling water directly affects the quality of the cast aluminium.

The water is required to have consistent conductivity between 1 800 and 2 000 µS/cm (TDS 1 260 – 1 400 mg/l) and chlorides approximating 600 mg/l. Metal cracking results when the conductivity is out of range.

When Watercare Innovations was given the opportunity to manage the cooling water quality at an aluminium smelter, the client was experiencing product cracking and rejection directly resulting from the sub-optimal cooling stage of manufacture. White deposits were forming on the finished metal surface, negatively impacting the market value of the product.

We worked with the client’s technical team to improve the quality of the water used to cool the aluminium moulds and reduce the incidents of product rejection.

Visible difference in cooling water quality

Before cooling system water management
After cooling system water management

Real-time remote monitoring to manage cooling water treatment

The cooling water system is 1,3 ML. At the time that we took over the control of the system, the TDS was in excess of 8 000 mg/l and chlorides were over 1 000 mg/l. The water was treated with chlorine gas for microbial control.

Before implementing the water treatment programme, our team physically cleaned the hot and cold wells, as well as the cooling tower sump and other retention dams.

A fully automated conductivity controller was installed and linked to WaterBizz, Watercare Innovations’ in-house IT platform. This enabled remote, real-time monitoring of the water’s pH and conductivity by both our site representative and the customer.

Both Watercare Innovations and the customer communicate daily on the observed trends. Immediate corrective action is implemented when the parameters are out of specification.

Chemical treatment programme to control cooling water quality

The chemical water treatment programme incorporates our antiscalant CT 9190 and a microbial control programme incorporating a combination of oxidising and non-oxidising biocides together with a bio-dispersant.

An immediate improvement in the consistency of the water quality and, consequently, aluminium product quality, was achieved just by improving conductivity control.

The antiscalant dispersed inorganic deposits formed in the cooling tower, improving the cooling efficiency across the tower and reducing operational costs associated with cast cooling. The consistency of the aluminium product quality improved significantly with reduced product reworks and rejection.

Our biocide treatment programme has proven to be more cost-effective than the continuous application of chlorine gas, even though it is more complex in terms of the product combination. The combination of products and optimum dosage regime has reduced the microbial counts of the cooling water, contributing to improved water quality.

Less downtime and improved product quality

In conclusion, optimally managing the cooling water quality to the plant’s required specifications has decreased the level of production downtime and maintenance, and improved the consistency of the cast aluminium product quality. The customer has realised an improved market value for their product and significant operational cost savings.

Looking to improve cooling water quality at your plant? Speak to us!




    No tags.

    Wendy Losper

    More posts by Wendy Losper

    Related Post

    • How a PGM mine’s environmental sustainability framework fosters water repurposing and recycling

      By Wendy Losper | Comments are Closed

      Water security is a key operational risk facing the mining industry. Many mines are in water-scarce regions. Mining operations use large amounts of water in mineral extraction, ventilation, and cooling activities. The security of theRead more

    • A holistic approach to mine-to-mill operations is required to address the challenges of "smart mining"

      The role of effective solid liquid separation in mine design

      By Wendy Losper | Comments are Closed

      “Smart mines” of the future need to address many challenges. These include safer mining, greener mining, increased ore recovery, reducing the impact of waste rock, issues surrounding the lack of specialised personnel, sustainable mining, andRead more

    • There are many surface-water colours depending on the dissolved and suspended impurities that may be organic or inorganic in nature.

      Coping with colour in water treatment: how colour is removed and its impact on water quality

      By Wendy Losper | Comments are Closed

      It may be true that colour in water is harmless when the water is utilised for human consumption, however, it is certainly unappealing. Colour in our water does matter when it comes to drinking it,Read more

    • reverse osmosis and green energy production

      How reverse osmosis sets in motion green hydrogen production

      By Wendy Losper | Comments are Closed

      South Africa is shaping up to become a world leader in green hydrogen technology within the next five years. Clean energy technologies, including renewable energy and their deployment, is central to the country’s efforts toRead more

    • Watercare Innovations at Electra Mining Africa (with photo gallery)

      By Wendy Losper | Comments are Closed

      2020 came and went leaving behind fundamental shifts in thinking and doing. Our business was not exempt. The flexibility of work location and changes in modes of communication were two of the most fundamental shiftsRead more

    NextPrevious

    Recent Posts

    • How a PGM mine’s environmental sustainability framework fosters water repurposing and recycling
    • The role of effective solid liquid separation in mine design
    • Coping with colour in water treatment: how colour is removed and its impact on water quality
    • How reverse osmosis sets in motion green hydrogen production
    • Watercare Innovations at Electra Mining Africa (with photo gallery)

    Yes!

    At Watercare Innovations water treatment is more than just chemical treatment. Innovation that improves water and energy efficiencies, as well as productivity, is what sets us apart as a water treatment company.

    • About Us
    • Our Expertise
    • Our Capabilities
    • Case Studies
    • Contact Us
    • Downloads & Resources
    • Privacy & Cookie Policy
    Copyright 2021 Watercare Innovations | Designed By Select Web | All Rights Reserved
    • Home
    • About Us
      • Company Overview
      • Industries We Serve
      • Safety, Health, Environment and Quality Commitment
      • B-BBEE Accredited
      • Corporate Social Investment
    • Our Expertise
      • Water Treatment Chemicals & Services
      • Process Technology
        • Water Treatment Plants
        • Metal and Reagent Recovery Plants
        • Gold Recovery Process
        • Integrated Mine Water Management Systems
      • Industrial Water Equipment
      • Case Studies
    • Our Capabilities
    • Blog
    • Opportunities
      • Careers
      • Partnerships
    • Contact Us
    Watercare Innovations

    WhatsApp us