Supplemental cooling supports steel production at a Pennsylvania facility

Client: Steel manufacturing facility
Location: Braddock, PA
Sector: Manufacturing

Overview

The challenge

A steel facility in Braddock, PA, needed process water cooled from 135°F to below 90°F for their degas process, but their existing system only reached 107°F

The solution

We engineered a temporary cooling system with cooling towers, shell-and-tube heat exchangers, and pumping equipment that worked alongside their existing infrastructure

The impact

Our supplemental cooling approach delivered the process temperature they needed while keeping steel production running

6,000GPM CAPACITY

2,000GPM DIVERTED

45°FTEMPERATURE DROP

Working together

A steel facility in Braddock, PA, needed process water cooled from 135°F to below 90°F for their degas process, but their existing system only reached 107°F. Permanent changes would require months of planning and major investment. We engineered temporary cooling towers, heat exchangers, and pumps that diverted 2,000 GPM through a dedicated loop, blending cooled water back into their system to achieve target temperatures while maintaining production.

We engineered a temporary cooling system with cooling towers, shell-and-tube heat exchangers, and pumping equipment that worked alongside their existing infrastructure to deliver the temperature drop they needed. We configured the system to divert about 2,000 GPM of their total process flow through a dedicated cooling loop. Hot water entered our temporary system at 135°F and came out at 90°F using our supplemental cooling towers, then we blended that cooled water back into their existing system. The result was a mixed outlet temperature below 90°F with minimal operational disruption and no permanent modifications required.

Our supplemental cooling approach delivered the process temperature they needed while keeping steel production running. Instead of a large-scale permanent installation, they got temporary cooling capacity deployed quickly and aligned with their operational timeline. The solution gave them flexibility to meet immediate requirements while buying time to evaluate future infrastructure decisions. By working with their existing plant assets and adding only what was needed, we reduced complexity. We supplemented rather than replaced their system, so they could hit their targets while maintaining operational flexibility and avoiding major capital pressure.

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