Annealing Furnace Cooling Project: KEJU Energy-saving Cross Flow Closed Circuit Cooling Tower
May 15, 2026
A heat treatment plant specializing in high-precision component manufacturing. In its core production process, the temperature control accuracy of the annealing furnace directly determines the hardness and toughness of the metal materials. However, with rising summer temperatures, exceeding 38°C in the workshop, the customer's existing open cooling towers experienced a sharp decline in heat dissipation efficiency. This not only caused the annealing furnace to frequently trigger high-temperature alarms and be forced to shut down, severely impacting order delivery cycles, but also increased maintenance burdens and energy costs due to the susceptibility of the open system's water to contamination and severe scaling inside the cooling pipes.
Project Overview
● Industry: Metal Heat Treatment / Machinery Manufacturing
● Application Equipment: Large Mesh Belt Furnace, Annealing Furnace Cooling System
● Core Product: KEJU KBL Series Crossflow Closed Circuit Cooling Tower
● Core Challenges: High summer temperatures leading to furnace temperature runaway, pipe scaling and blockage, and persistently high energy consumption.
Challenges and Tasks
The client urgently needs a highly efficient and stable cooling solution with very clear core requirements:
1. Stability under extreme conditions: The circulating water temperature of the annealing furnace must be precisely controlled within the process requirements even in summer temperatures reaching 40°C, preventing production line shutdowns due to excessively high water temperatures.
2. Prevention of scaling and clogging: Completely eliminate the water pollution problems associated with traditional open-loop cooling systems, protecting the delicate induction coils and piping systems of the annealing furnace, achieving "zero scaling" operation.
3. Energy saving and consumption reduction: The new system must possess excellent energy efficiency to reduce long-term operating costs and meet the transformation needs of green manufacturing.
KEJU COOLING's Solutions
Addressing the client's pain points, the KEJU COOLING technology team, after on-site surveys and heat load calculations, tailored the KBL series crossflow closed-loop cooling tower system, taking the following key actions:
● Adopting a closed-loop dual-circulation design: The internal circulation uses pure water flowing within sealed copper pipes, directly cooling critical parts of the annealing furnace, completely isolating dust and debris, and eliminating the risk of pipe scaling and blockage at the source.
● High-efficiency heat exchange components: The tower body utilizes large-area T2 degreased copper tubes and high-efficiency PVC heat dissipation fillers, combined with a crossflow structure design, greatly increasing the heat exchange area and air contact time, ensuring excellent heat dissipation performance even in extreme high-temperature weather.
● Intelligent frequency conversion control: The system is equipped with a smart control cabinet independently developed by Keju, which can automatically adjust the speed of the fan and water pump according to the real-time outlet water temperature of the annealing furnace. It automatically reduces the frequency under low-load conditions, avoiding the energy waste of traditional equipment that is "overpowered."
● Customized anti-freeze and noise reduction: Considering the characteristics of the winter climate in the customer's location, the coil is equipped with an electric heating anti-freeze device; at the same time, the fan adopts a low-noise design, ensuring that the noise at the plant boundary meets environmental protection standards.
Annealing Furnace Cooling Project Results And Energy-saving Data
After a summer of stable operation, the KEJU crossflow closed-loop cooling tower system delivered significant quantifiable benefits to the client:
● Precise temperature control, zero downtime: Even in extreme weather conditions with ambient temperatures reaching 39°C, the system's outlet water temperature remained stably controlled at 32°C ± 1°C, fully meeting the precision requirements of the annealing furnace. No downtime due to insufficient cooling occurred throughout the summer.
● Significant energy savings: Thanks to the efficient heat exchange of the closed-loop system and intelligent variable frequency technology, the new cooling station reduced overall energy consumption by approximately 30% compared to the old system, significantly reducing the company's electricity costs.
● Zero Maintenance Costs: After one year of operation, a disassembly inspection revealed no scale or rust on the annealing furnace piping and internal tower coils, completely eliminating the need for annual acid cleaning of the pipes and high maintenance and replacement costs.
High Customer Feedback
KEJU's closed-circuit cooling towers not only solved our long-standing problem of production shutdowns due to high temperatures, but their stable performance and energy efficiency far exceeded expectations, making them a truly understanding partner in industrial cooling.
Is your annealing furnace also facing the risk of summer high-temperature shutdowns? Contact KEJU engineers now for a free cooling system selection plan and quote!
