A UK aluminium casting facility facing repeated pump failures due to extreme water temperatures, which go up to 87°C, has successfully implemented a custom high-heat pumping solution developed by Wildon UK and KSB, ensuring uninterrupted operations.
In recent times, A UK aluminium ingot supplier encountered recurring pump failures in its casting pit due to excessively high process water temperatures surpassing standard submersible pump thresholds. Recognising the operational risk, the company engaged Wildon UK, which collaborated with KSB to engineer a customised high-performance pumping solution.
The underlying challenge
The casting process demanded the return of cooling water from the pit, where temperatures consistently reached 80°C and occasionally spiked to 87°C, far exceeding the 40°C limit of conventional submersible pumps. Even upgraded models with cooling jackets were failing prematurely due to thermal stress and motor overheating.
Adding to the complexity, the site’s deep wet sound chamber had spatial constraints, necessitating a pump solution that could seamlessly fit within the existing infrastructure and operate independently of the pumped liquid for motor cooling.
Collaboration to the rescue
Wildon UK, in partnership with KSB, developed a bespoke pumping solution to address the site’s demanding operational conditions. The system featured a hydraulic design capable of handling a 36 kW load, along with oversized 70 kW motors specifically chosen to reduce internal heat generation rather than increase power output.
To ensure accurate installation within the site’s spatial constraints, full-scale mock-up testing was conducted before deployment. This custom-engineered approach enabled the pumps to perform reliably in fluid temperatures exceeding twice the industry standard, marking a significant achievement in submersible pump applications.
The result received
Since its installation, the system has demonstrated consistent and reliable performance, with no failures linked to high-temperature process liquid. Any interruptions have been attributed solely to external factors unrelated to the pump design.
This project underscores the importance of customised engineering solutions and close collaboration in addressing complex industrial challenges. For Wildon UK and KSB, it stands as a testament to how strategic design and precise execution can ensure long-term operational reliability in extreme conditions.
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