Transforming Industrial Equipment and Processes into Intelligent, Monitorable, and Analyzable Systems

Smart Transformation of Industries and Mining

Project Title

Cooling electric motors used in industrial pumping systems can have a significant impact on equipment reliability and service life, while also consuming considerable amounts of water. In this project, the existing cooling system was replaced with a closed-loop cooling system combined with water hardness control, enabling the reuse of cooling water. This approach reduced water consumption while protecting the pump coils against scaling and improving equipment efficiency, particularly in water-stressed industrial environments.

The project was designed and implemented to optimize the cooling system of TECO electric motors used in return-water pumps at Unit 75 of the Sarcheshmeh Copper Complex. The solution was based on a closed-loop cooling circuit and a cooling tower to provide the required cooling load while allowing the cooling water to continuously circulate without the need for a constant supply of fresh water. Based on the design calculations, an 80-ton refrigeration capacity cooling tower was selected to meet the cooling requirements of 13 pumps under peak operating conditions.

Optimization and Intelligent Control of TECO Motor Cooling Systems in the Copper Industry
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Project Description​​​​​​​

●  Design and implementation of a closed-loop cooling system for TECO electric pumps
●  Design and installation of an 80-ton refrigeration capacity cooling tower
●  Cooling-fluid circulation using two high-pressure pumps
●  Design and implementation of a water softening and scale-control system to protect pump coils
●  Implementation of a smart control system based on PLC and inverter technology
●  96% reduction in cooling water consumption compared with the existing system
●  Reduced risk of scaling and performance degradation in cooling coils
●  Improved system operation and reduced maintenance requirements
●  Successful implementation and operation of the system at Sarcheshmeh Copper Complex

Project Outputs

Two high-pressure pumps, each with a flow rate of 30 m³/h and a head of 66 m, were used to circulate the cooling fluid and maintain pressure balance throughout the piping network. An automatic water softener with a capacity of 300,000 grains was also installed to reduce water hardness and prevent scale formation, particularly inside the pump cooling coils. The system was controlled and monitored using a PLC, inverter, and smart control panel, providing both automatic and manual control for more stable operation and optimized equipment management.

تبدیل تجهیزات و فرآیندهای صنعتی به سیستم های قابل پایش، تحلیل و تصمیم گیری هوشمند.

تبدیل تجهیزات و فرآیندهای صنعتی به سیستم های قابل پایش، تحلیل و تصمیم گیری هوشمند.