Challenge/Solution Case Study:

Correcting Overheating of Large Rectifier Unit for a Primary Aluminum Manufacturer

Result

EFI Group was able to determine the root cause of overheating for two large rectifier units, develop a comprehensive solution, compile the required equipment specifications and obtain detailed quotes from several vendors for equipment that would allow the rectifiers to operate at maximum capacity.

Challenge

The processing of aluminum requires a large amount of DC electrical current. In large rectifier units that generate large amounts of waste heat during the process, electricity is transformed from Alternating Current (AC) to Direct Current (DC). Two of the client’s rectifiers could not run at maximum ratings without overheating, reducing the amount of aluminum the plant could produce.

Solution

Since the rectifiers’ installation in 2003, the company had made several attempts to improve function with little success.

After reviewing the historical data and the available equipment documents, plus gathering empirical data from field measurements, EFI Group was able to calculate actual heat load at maximum rated current.

Calculations showed that the original and replacement heat exchangers were too small to remove enough heat and, under worst-case conditions, to run the rectifier at its full rated current. EFI Group then contacted several heat exchanger manufacturers to obtain detailed quotations on replacement units.

Deliverables

Heat transfer calculations detailing the actual heat load at the heat exchanger.
Cost estimate detailing multiple heat exchanger options.
Recommendations on which heat exchanger would best suit the application.
Preliminary general arrangement showing placement of the new heat exchangers.

We hired EFI Group to help us figure out a project and scope it, and I felt confident they would keep a keen eye on it. They had to deliver quickly and they did it well. They are especially good at project management when you don’t have the resources to do it internally. Reliability is the word I would use to describe EFI Group.

— Coatings Industry Professional

EFI Group is timely. We’ve had a lot of situations when we’ve been in a time crunch and they’ve responded very quickly. They are detail oriented and efficient. They’re a good group of people who also have a lot of strength in pre-engineering — the thought process to get to preliminary design and making sure we’ve investigated all the potential asks of a project to ensure we didn’t miss anything. They have great attention to detail up front which is very important to any project because having that detail-oriented deep dive into the pre-engineering phase sets the stage for the success of the rest of the project, making the process smoother and making it much easier to keep the project on schedule and on budget.

— Mike Quigley, Engineering & Maintenance Manager, Food Industry

I’ve worked with EFI Group for a while, so I know they have a good, knowledgeable staff. We know we’re going to get the results from them we expect. From my interactions with all the different EFI team members I’ve worked with, I know they have knowledge across many industries. Equally, I never have to follow up with EFI Group and, in some cases, they keep me on track.

— Ryan Fredsall, General Manager, Pacer Minerals LLC

We view EFI Group as a team that can dimensionalize our capability to execute projects. We can articulate what it is we want to do and they can take that input and run with it without much intervention from us. They’re able to move a project along independently and only engage us when it’s time to bring us up to speed or get more input to drive a project to conclusion. That’s one of the reasons I view them as an excellent contractor.

— Environmental Engineering Industry Professional

EFI Group has good engineers and good customer service. We know when we get an EFI engineer on a project, we’re going to a get a good job from them and it’s been a productive relationship for both of us — I genuinely like the people.

— Corporate Director, Project Management in Food & Flavors Industry

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Challenge/Solution Case Study:

Correcting Overheating of Large Rectifier Unit for a Primary Aluminum Manufacturer

Result

Challenge

Solution

Deliverables

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