The project demanded more than just cooling power. The customer required a system that could mitigate the heat island effect within a compact footprint, reduce on-site complexity, and be delivered within an accelerated timeframe of six months. Kelvion met the brief – and more.

“This project showcases what Kelvion does best,” said Björn Stemmann, VP Global Solution Engineering Data Centre at Kelvion. “We combine proven technology, fast execution and smart design to solve complex cooling challenges at scale – without compromise.”

Engineered for High-Density AI Workloads
Kelvion’s modular cooling solution has been specifically engineered to meet the thermal demands of high-density artificial intelligence applications. The design incorporates site-erected GigaBays – large-scale Air Fin Coolers – which are equipped with Kelvion’s adiabatic fogging system to enhance cooling performance. Key features include:

• GigaBay configuration with large fans and high-pressure fogging systems
• Low-maintenance needs, optimised for uptime and long-term performance
• Water-saving operation compared to conventional wet cooling tower systems

Conventional dry or hybrid cooling methods would have required significantly more space, as well as introducing unnecessary complexity in terms of piping and wiring. However, Kelvion’s modular approach, based on tried-and-tested design blocks, allowed for a streamlined, semi-customised solution, helping to minimise risk and reduce costs.

The project also includes six CCDU skids – five with a capacity of 9+ MW each and one with a capacity of 4+ MW – enabling centralised control of the liquid cooling infrastructure. These units enhance system efficiency, simplify monitoring, and support future scalability.

“Understanding our customers’ processes in depth is one of our top priorities. For this project, we collaborated closely with the customer, providing comprehensive technical guidance and tailoring the solution to meet all their requirements. This is how we initially delivered the AFCs, and how we later identified the need for Centralised Coolant Distribution Units through our process insight - including the reliable design and precise selection of the GPHEs integrated into the CCDU. This is a great example of our holistic approach to developing scalable, customised solutions,” said Franz Löhrke, Solution Designer GSE Data Centre at Kelvion.

Manufacturing for this project is led by Kelvion’s facility in Catoosa, USA, ensuring proximity and speed. On-site support and project management were critical success factors, with Kelvion working closely with the engineering team of the customer and EPC partners to align all disciplines.

Powering the Future of AI
Placed in 2025, the order reflects the AI customer’s trust in Kelvion’s ability to deliver large-scale cooling infrastructure on a tight schedule. It also highlights the growing demand for thermal management solutions that are technically advanced, practical and sustainable, and built for tomorrow’s data centre landscape. As artificial intelligence continues to drive exponential growth in data centre capacity, Kelvion remains a committed partner, engineering intelligent cooling systems that transform complexity into clarity.