1. Project Background
A petrochemical plant located in the Jubail Industrial City of Saudi Arabia (hereinafter “the Plant”) was struggling with its traditional water-based cooling system. In the region’s extreme heat and scarce water conditions, the old cooling towers and circulation pumps suffered frequent over-temperature shutdowns, sand-induced blockages, and accelerated corrosion—resulting in high maintenance costs and operational downtime. Seeking a reliable, low-maintenance solution, the Plant engaged casen to install a stainless-steel air cooled heat exchanger on its rooftop.
2. Installation Site & Environmental Conditions
·Country/City: Jubail Industrial City, Eastern Province, Saudi Arabia
·Location: Unobstructed rooftop of the petrochemical process building
·Climate:Average annual temperature ~40 °C, peak summer temperatures up to 50 °C. Relative humidity below 30% during daytime.Frequent sandstorms and high dust loads
3. Implementation & Results
1.Rapid Delivery & Installation
·Fabrication and delivery completed within 4 weeks of contract award.
·On-site installation and commissioning finished in just 3 days, with zero impact on plant operations.
2.Significant Energy & Water Savings
·Eliminated the need for makeup water, saving approximately 3,000 m³ annually.
·Variable-frequency fan control reduced electrical consumption by about 100,000 kWh per year—cutting overall operating costs by 35%.
3.Precise Temperature Control & High Reliability
·Achieved a stable ΔT of 4 °C ± 0.25 °C between inlet and outlet water temperatures, fully meeting downstream cooling requirements.
·Real-time monitoring of temperature and vibration ensures proactive fault alerts, with unplanned shutdowns dropping below 0.3%.
4.Durable, Corrosion-Resistant Design
·Constructed entirely from 316L stainless steel with a specialized sand-blasted finish, providing exceptional resistance against sand abrasion and salt corrosion.
·Modular fan units and accessible maintenance walkways enable annual servicing in under 16 hours.
4. Client Testimonial
“casen’s air-cooled heat exchanger has performed flawlessly under intense heat and sandstorms. It not only stabilized our cooling process but also drastically reduced our dependence on scarce water resources and cut energy costs significantly.”
—— Jubail Plant Maintenance Head Mohammed Al-Fahad
For technical inquiries or collaboration opportunities, please contact casen!
