How to be smart about your cooling system performance

- with a game-changing solution for achieving significant capacity improvements

Here’s a fact: the efficiency of your industrial plant’s cooling system directly affects your productivity and bottom line!

For a large industrial plant, the circulation of cooling water consumes a significant amount of energy.

The Industrial Cooling Water Solution lets you analyse your cooling water systems, identify potential for improvements and achieve energy savings by a substantial margin.

It also provides a solid assessment of the return on investment.


Inefficient cooling water flow in a large industry affects production processes and impacts your bottom line. Imagine using a digital and innovative solution that reveals the full potential of your cooling water systems performance, leading to:

Improved productivity

Debottlenecking the system and optimising flows will ensure full utilisation of your cooling capacity.

Increased cooling capacity

Increased cooling water flow can have a huge impact on your productivity on a hot day.

Increased process safety

Optimised water flows through heat exchangers will help maintain desired heat transfer efficiency.

Major cost savings

Our hydraulic simulation model demonstrated potential energy savings of EUR 700,000 per year (23% reduction) in a 30-year-old cooling system – after making recommended changes of the piping layout.

“Today, the hydraulic conditions in these systems are poorly understood, and we believe that cooling of installations worth billions should aspire for more. We are looking at cooling system optimisation from a new angle. For example, a recent hydraulic study on a large industrial cooling system has revealed potential to increase cooling water flow by 18% at the same pumping costs. This extra flow allows the system to reject 9% more heat at the same hot water temperature, which would have increased by 1.2°C without the hydraulic improvements.”

Jan Krejcik
Sales Executive
DHI Group

How it works

The Industrial Cooling Water Solution gives you the flexibility of going ahead with – or stopping at – any of these three stages:

Stage 1:
Identifying potential for improvement

We first develop a simplified hydraulic simulation model based on your existing data (such as log sheets, process diagrams or CAD drawings) to quickly identify potential for improvement.

You might discover, for example, that you have a 20% potential gain in pumping efficiency or 15% in cooling capacity increase based on total system analysis.

Stage 2:
Getting a full cost-benefit analysis

Once the potential is identified, you may choose to move on to Stage 2, where we develop a calibrated model based on field measurements. We execute an in-depth analysis of system performance, develop a list of practical enhancement measures and provide a cost-benefit analysis.

The developed simulation model tool is also yours to use in your daily operations, and can help you determine the effects of closing a valve or adding a pump, for example.

Stage 3:
Implementing an online solution

This longer-term strategy includes an automated online solution. The system makes simulations based on data from sensors, and based on the targets, optimises water flows in real-time.

This ultimate solution will allow you to utilise the full potential of your cooling system.

Other benefits

A hydraulic analysis can also be applied to other water networks within an industrial plant. Other advantages:

Improved safety

During a fire emergency, knowing how and where to direct water – in the shortest time possible – is crucial. Being well-prepared with a fire water system analysis could spare you the worry of facing potentially catastrophic consequences in a crisis situation.

Reduced risk of equipment damage

Pressure surge can damage vital equipment such as pipes, pumps and valves. With a pressure surge analysis, you can ensure asset safety and help avoid costly replacements as well as production interruptions.

Better maintenance

Monitoring of critical heat exchange parameters over time will reveal the trends in heat transfer efficiency. This will enable timely planning and correct focus of cleaning operations.

Want to know the cost-savings potential of your cooling water systems? Then get in touch with our experts right here!

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