Lawrence Mashavave and Chris Buck - Benefits of the Adiabatic Cooling System
| Friday, October 9, 2026 |
| 3:00 PM - 3:30 PM |
| Norfolk Room |
Speaker
Lawrence Mashavave
Foundry Manager
Metso Australia
Benefits of the Adiabatic Cooling System
Synopsis
The installation of the adiabatic cooling system has delivered operational, environmental, and financial benefits compared with the previous cooling towers.
Key Benefits
• The electric motor no longer needs to operate continuously (24 hours a day, 7 days/week), as was previously required to manage Legionella risks. The system now operates only when needed, as the fans are not required to run continuously.
• Water consumption has been reduced by approximately 95% due to the significantly lower cooling water demand. A water savings of approx. 800kL/month
• Chemical treatment and servicing costs have been eliminated. Previously, these expenses averaged approximately $3000.00 per month.
• Routine maintenance associated with chemical dosing equipment has been eliminated, reducing both maintenance costs and production downtime.
• The system has an estimated payback period of approximately 18 months, with substantial ongoing savings from reduced chemical purchases, water testing, maintenance, and operating costs.
• Both the furnace and the shakeout heat exchanger are now cooled using the four-fan adiabatic cooler, replacing the previous cooling towers that required ongoing chemical treatment and maintenance.
• Operating noise is very low, while chemical costs have been virtually eliminated.
• The addition of spray cooling Water is only used during extremely hot summer conditions when the adiabatic spray system is activated, resulting in negligible overall water consumption.
• The system has fewer moving parts, making it simpler, more reliable, and easier to maintain.
Issues Eliminated
The new system has removed several ongoing operational concerns, including:
• Council permitting requirements and inspections.
• Legionella management risks.
• Chemical treatment and dosing equipment maintenance.
• Cleaning and maintenance of cooling tower water basins.
Overall Performance
The adiabatic cooling system has proven to be an excellent solution for foundry induction furnace cooling. It offers outstanding cost effectiveness, environmental benefits, operational simplicity, and reduced maintenance requirements.
Since commissioning, no operational problems have been encountered. The only unexpected outcome has been the system's exceptional efficiency.
Although it is still too early to accurately quantify annual savings, they are expected to be significant. Based on current performance, the installed cost has proven to be well justified, with an anticipated payback period of approximately 18 months.
Key Benefits
• The electric motor no longer needs to operate continuously (24 hours a day, 7 days/week), as was previously required to manage Legionella risks. The system now operates only when needed, as the fans are not required to run continuously.
• Water consumption has been reduced by approximately 95% due to the significantly lower cooling water demand. A water savings of approx. 800kL/month
• Chemical treatment and servicing costs have been eliminated. Previously, these expenses averaged approximately $3000.00 per month.
• Routine maintenance associated with chemical dosing equipment has been eliminated, reducing both maintenance costs and production downtime.
• The system has an estimated payback period of approximately 18 months, with substantial ongoing savings from reduced chemical purchases, water testing, maintenance, and operating costs.
• Both the furnace and the shakeout heat exchanger are now cooled using the four-fan adiabatic cooler, replacing the previous cooling towers that required ongoing chemical treatment and maintenance.
• Operating noise is very low, while chemical costs have been virtually eliminated.
• The addition of spray cooling Water is only used during extremely hot summer conditions when the adiabatic spray system is activated, resulting in negligible overall water consumption.
• The system has fewer moving parts, making it simpler, more reliable, and easier to maintain.
Issues Eliminated
The new system has removed several ongoing operational concerns, including:
• Council permitting requirements and inspections.
• Legionella management risks.
• Chemical treatment and dosing equipment maintenance.
• Cleaning and maintenance of cooling tower water basins.
Overall Performance
The adiabatic cooling system has proven to be an excellent solution for foundry induction furnace cooling. It offers outstanding cost effectiveness, environmental benefits, operational simplicity, and reduced maintenance requirements.
Since commissioning, no operational problems have been encountered. The only unexpected outcome has been the system's exceptional efficiency.
Although it is still too early to accurately quantify annual savings, they are expected to be significant. Based on current performance, the installed cost has proven to be well justified, with an anticipated payback period of approximately 18 months.
Biography
Lawrence Mashavave was born on 28 February 1967 in Kwekwe, Zimbabwe. After completing his education, he began a Foundry Apprenticeship with W.S. Craster Pvt Ltd in 1989 before starting his career with ZISCO Steel where he gained valuable experience in the foundry and steel manufacturing industry.
In 2006, he moved to South Africa, where he worked for Scaw Metals in Benoni until 2008. He then relocated to Australia and joined Weir Minerals Australia, where he spent 13 years before joining Metso Australia in 2021, where he continues to work today.
Alongside his technical career, he also studied Marketing and Communication, enhancing his ability to engage with customers, colleagues, and industry stakeholders. With more than 30 years of experience in the foundry industry, he is passionate about encouraging the next generation to pursue careers in foundries while promoting modern technology and environmentally sustainable manufacturing practices.
Chris Buck
National Sales Manager
Inductotherm Group Australia
Co-presenter
Biography
