Bronswerk - The solution to all your cooling problems

Fulfilling cooling system capacity specifications without exceeding acceptable noise emission and motor capacity levels can be incredibly difficult. This case study from one of Bronswerk's clients demonstrates the premier standards of its services in the face of such puzzles.

Bronswerk is committed to finding the best solution for its clients' problems. It was once commissioned by engineering agency Jacobs to improve the capacity of two bays of a company's induced draught air cooler.

Never turn down a challenge
Such an improvement was not without challenges, as the improved system would need to comply with the latest specifications and client's requirements. In this case, the client listed the following specifications:

  • 10% increase in cooling capacity
  • 15% extra cooling capacity on top of the increase, if possible, with the lowest possible noise emissions (under 74dB(A)), due to noise restrictions and environmental concerns
  • any extra motor capacity required to be within the limits of the existing cables, which were not being replaced (under 30kW)
  • the material for the housing to be stainless steel standard RVS 316L, due to the corrosive environment
  • all of the above tasks to be carried out within the shortest possible delivery time.


The conundrum
Bronswerk rose to the challenge, its first task being to realise 10% extra cooling capacity, and then yet another 15% extra while maintaining the cooler's current dimensions. This ruled out the option of increasing the bundles, leaving the only possibility to press more air through them. This solution was unacceptable, however: it would require too high an engine capacity (45kW), and the ventilators' noise emissions would far exceed the client's specifications (82dB(A)).

The only real option
Determining the conventional ventilators to be not up to the job, the next step was to examine the alternatives.

Bronswerk considered using Howden's SX ventilators. They too were able to accommodate the 10% extra cooling capacity, but only with noise emissions of 75dB(A) and a motor capacity of 55kW - much too high for the existing cables.

Both scenarios could create the 10% extra cooling capacity, but neither could deliver the 15% extra overcapacity, and perhaps more importantly, noise emissions and motor capacity would be in excess of what had been specified. Bronswerk then considered its own Whizz Wheel cooling system, which it had developed for exactly these types of conditions.

With the Whizz Wheel cooling system, the 10% extra cooling capacity could be created and 5% overcapacity on top of that. This solution would result in noise emissions of just 70dB(A) - 4dB(A) under the specifications - and a motor capacity of just 22kW, which was well within the cables' tolerances.

With the option of using its own Whizz Wheel, Bronswerk was able to satisfy almost all of the client's wishes and requirements, and even completed the project within five months. The desired 15% overcapacity would also have been possible with the Whizz Wheel, but only by compromising on the required motor capacity and noise emissions. However, delighted with the very low noise emissions and motor capacity, the customer subsequently lowered the request for 15% overcapacity to 5%.

The Whizz Wheel cooling system is the perfect solution for situations in which other systems are unable to satisfy all of the customer's requirements.

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The air coolers fitted with the Whizz Wheel cooling system.
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