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Rethinking maintenance to save millions of liters

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We Don't Have Time

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How a smelter cut its annual water consumption by 45%

Type of energy user: Heavy Industry
Running a world-class copper smelter requires massive cooling power, drawing heavily on local seawater. Instead of waiting for heat exchangers to fail, the Rönnskär plant shifted to a strict, data-driven maintenance plan.
By regularly assessing performance and cleaning equipment before fouling slows it down, they keep the cooling loop running at peak efficiency.
The result is a dramatic drop in the amount of water needed to keep operations stable, slashing annual water consumption by nearly 45% while simultaneously cutting the energy required for water pumping by 15 to 20%.
Other benefits:
  • Higher uptime and process stability: Proactive, condition-based maintenance reduces unplanned downtime and prevents performance degradation, ensuring more consistent cooling and stable smelter operations.
  • Extended equipment lifetime and lower maintenance costs: Regular cleaning and performance optimization minimize wear, fouling, and corrosion, significantly extending heat exchanger lifespan and reducing costly emergency repairs.
  • Improved environmental compliance and risk management: Lower seawater intake and more controlled operations reduce environmental impact and help ensure compliance with increasingly strict water-use and discharge regulations.
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