Ecobat – Lead Battery Plant Cooling Upgrade | Vistech Case Study
Cooling System Upgrade Delivered Within Critical Shutdown Window
Vistech Cooling Systems delivered a turnkey cooling system upgrade for ECOBAT’s battery processing facility in Derbyshire, replacing an ageing cooling tower operating in a highly corrosive environment. The solution centred on the installation of an EWK 1800/09 GRP cooling tower, stainless steel pump, secondary pipework and GRP access platforms, all executed within a tightly controlled 7-day shutdown period.<br />
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The project demonstrates Vistech’s ability to deploy corrosion-resistant, pre-engineered cooling solutions that minimise downtime while improving long-term reliability, efficiency and maintainability in aggressive industrial environments.
The Challenge
ECOBAT operates a battery processing facility characterised by a highly corrosive atmosphere, driven by chemical exposure inherent to lead battery recycling and processing. The existing cooling infrastructure had reached the end of its operational life, presenting risks to reliability, efficiency and ongoing maintenance.
The replacement solution needed to deliver assured cooling capacity while withstanding aggressive environmental conditions without excessive maintenance burden. Materials selection was critical, requiring resistance to corrosion across structural, mechanical and hydraulic components.
A further constraint was the requirement to complete all works within a strictly limited 7-day shutdown window. This imposed significant pressure on programme coordination, installation sequencing and system commissioning, with no tolerance for delays impacting plant restart.
The Solution
Vistech delivered a fully integrated cooling system solution based on a packaged EWK 1800/09 GRP cooling tower, selected for its proven performance in corrosive industrial environments and suitability for rapid installation.
The system was engineered to deliver 6047 kW of heat rejection capacity and incorporated corrosion-resistant materials throughout, combined with prefabricated components to enable efficient installation within the shutdown period.
Key Technical Features:
GRP cooling tower casing and prefabricated GRP access platforms providing long-term corrosion resistance and reduced maintenance requirements
Stainless steel pump and thin-walled stainless steel pipework to ensure durability and rapid onsite welding and installation
High-grade anti-corrosive coating applied to all structural steelwork for additional protection in aggressive atmospheric conditions
22 kW high-efficiency fan motor (IE3 rated) delivering reduced energy consumption and reliable thermal performance
Prefabricated modular components enabling rapid installation and minimised site risk
The installation strategy prioritised speed and coordination, with major components pre-assembled offsite and delivered ready for installation. This approach ensured predictable programme execution and reduced dependency on extended site fabrication.
Scope of Works
Cooling Tower
Design, supply and installation of EWK 1800/09 GRP cooling tower
Pump System
Supply and installation of stainless steel pump
Pipework
Design and installation of thin-walled stainless steel secondary pipework
Access & Safety
GRP access platforms for safe maintenance access
Steelwork
Supply and installation of support steelwork with anti-corrosive coating
Cranage & Installation
Lifting and positioning of assembled tower
Electrical & Controls
Electrical works including fan motor integration and system commissioning
Programme
Day 1–2
Construction and installation of cooling tower
Day 2–4
Electrical works and system integration
Day 5–6
Pipework and pump installation
Day 7
Commissioning and system handover
“ECOBAT expressed satisfaction with the project’s successful delivery, highlighting the efficiency of the installation process and the performance of the onsite team. The rapid execution minimised operational downtime, while the corrosion-resistant system provides long-term reliability in a demanding environment.”
— ECOBAT Project Team