Concrete Cooling Systems -...

01.09.2012

Concrete Cooling Systems

Worldwide # 1 in

con

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Concrete Mixing Temperatureas function of water temperature and addition of ice respectively

0 °C45 5 01525

Water temperature [°C]

35

0 80 100 150 1701306040

Flake Ice [kg/m3]

Ice Water [l/m3]

20

170 90 70 20 040110130150

10 °C

20 °C

30 °C

40 °C

50 °C 50 °C

0 °C

10 °C

20 °C

30 °C

40 °C

Cooling with

Chilled Water only

Cooling with

Flake Ice and Ice Water

Temp. before mixing 49 °C

+ 70 kg Flake Ice

+ 100 l Ice Water

= Mixing temperature 29 °C

Temp. before mixing 49 °C

+ 170 l Ice Water 1 °C

= Mixing temperature 37 °C

CementDune sand Washed sand Aggregates 10mm Aggregates 20mm Water

380 kg/m3230 kg/m3 665 kg/m3 230 kg/m3 690 kg/m3

170 kg/m345 °C 75 °C

75 °C

75 °C

45 °C 45 °C 45 °C

35 °C 35 °C 35 °C 35 °C

25 °C

1% moisture 2% moisture

25 °C 25 °C 25 °C

Assumption of mix design for calculation

Supplying temperature-controlled con-

crete for any major construction site is

a must all over the world. The develop-

ment of the strength in concrete is

accompanied by evolution of heat as

the cement cures and hardens (heat of

hydration). In small structures this phe-

nomenon is not of importance, but very

significant in mass concrete, for

instance for dam projects. The heat of

hydration raises the temperature during

the curing process by up to 25° caus ing

an increase of volume. After the curing

the concrete cools down, again reduc-

ing its volume and thus naturally

causing cracks eventually. Therefore

the initial pouring temperature should

be lowered so much that the maximum

temperature during the curing process

does not ex ceed a certain tempe rature

determined by the consultants.

Temperature-Controlled Concrete Although the required pouring tempera-

tures of the concrete vary from site to

site and from country to country (from

+7 °C to max. 30 °C) there is al ways a

requirement for a sophisticated refrig-

eration system.

As the initial and the running costs for

such a refrigeration system are quite

high (they even can be higher than the

ones of the concrete batching plant

it self), it is essential for the contractor

to have an optimised system installed.

25 K 35 K 42 K11 KCIWP

Cold/Ice Water

(+1°C)

FLIP

Flake Ice

(- 7°C)

CACS-w/a

Aggregate Cooling

(+10°C)

SC

Sand Cooling

(+25°C)

9 kWh/m³

19 kWh/m³

32 kWh/m³

26.7 kWh/m³

0.69 kWh/m³

Qo = Δt · 0.69 kWh/m³ K

Δt

General Cooling Requirements

How it all began ...

In 1923 Richard Plersch sen. began

with the design and manufacturing

of components and plants for the

refrigeration industry. His son Richard

Plersch II continued the tradition and

established the global reputation of

PLERSCH products.

Today, the company is run by Rupert

Plersch in the third generation. As

managing director he keeps the family

tradition and philosophy alive. In a well-

founded entrepreneurial spirit he has

established KTI-Plersch Kältetechnik

GmbH and in the last 25 years the

company has become a leading refrig-

eration contractor worldwide. PLERSCH

products stand for first-class, cutting

edge refrigeration plants of top quality

made in Germany. Since 1986 more

than 2,500 cooling plants have been

sold and installed worldwide. In addi-

tion to the production of turnkey solu-

tions for the concrete cooling industry,

the sale of components and spare

parts as well as service and consulta-

tion are KTI core business areas.

... and where we are today

KTI-Plersch Kältetechnik GmbH is a

dynamic and innovative German refrig-

eration contractor specializing in con-

crete cooling and special equipment.

In the past 25 years KTI-Plersch

Kältetechnik GmbH has set new stan-

dards for block ice plants and flake ice

plants as well as for fully automatic ice

storage and delivery systems.

At company headquarters in Balzheim,

ice plants and cooling systems are

developed, designed and manufactured

to meet the most diverse needs of KTI

customers worldwide.

KTI is a solution finder: the main goal

is to provide the very best solutions to

the concrete cooling industry. KTI cool-

ing solutions always consider customer

needs and requirements.

KTI means responsibility, know-how,

expertise, three generations of experi-

ence, innovation, team spirit, and deep

personal commitment by the Plersch

family and the employees. We work

hand in hand. This approach has made

us what we are today:

• A successful international company

• An innovative company with a

solution oriented service mentality

• A customer-centered provider

• A reliable partner for customers,

employees, suppliers and business

partners

Responsibility

KTI is well aware that its products

use natural resources and consume

energy. The KTI concept offers custom-

ers the possibility to produce ice with

the lowest consumption of energy.

Production of ice can also take place

during the night and stored under safe

conditions. With the KTI multistage

cooler, the customer sees up to a 50%

reduction of energy consumption com-

pared to conventional water chillers.

KTI Facts & Milestones

1994 Opening of new production facili-

ties in Balzheim

2000 Cooperation and sales agency

contract with VIP Various Ice

Products, Dubai, to manu facture

mobile ice storages

2002 Construction of new office

buildings and assembly hall in

Balzheim

2003 Opening of additional assembly

hall and comprehensive staff

facilities in Balzheim

2006 KTI Qatar opens offices in Doha

2006 KTI Saudi Arabia establishes

offices in Dammam, Jeddah and

Riyadh

2007 Construction of additional

production facility in Balzheim

2008 KTI-Plersch – Dubai Branch opens

2010 KTI-Plersch do Brasil

(Sao Paulo) established

2010 KTI India opens offices

2010 Founding of Sauter Plersch AG

2012 Extension of office and produc-

tion facility Balzheim

KTI Agencies and Registered Offices

In addition to its branches and offices,

KTI has agencies all over the world:

Brazil (Sao Paulo), KTI do Brasil

China (Beijing)

Egypt (Cairo)

India (Chennai), KTI India

Iran (Tehran)

Italy (Milano), KTI Italy

Kuwait, Gulf Group

Oman (Muscat), Bahwan Engineering

Qatar (Doha), KTI Qatar

Saudi Arabia (Dammam, Jeddah,

Riyadh), KTI Saudi

Spain (Sargagossa), Arco Electronica, S.A.

Switzerland (Sulgen), Sauter Plersch AG

Turkey (Ankara), Titan Makina Ltd

USA (Newport News, VA), Liebherr CT.

Starting in the early years with a

regional emphasis on the Middle East,

KTI is operating today on an interna-

tional level, providing mass concrete

solutions where required independent of

climate zone and continent.

The Company

4 5

Ice Water and Cold Water Plants

Containerized Ice Water Plant – CIWP.4 (4th Generation)

Containerized Cold Water Plant – CCWP.4 (4th Generation)

Ice Water and Cold Water Plants

• Up to 55% less power consumption

compared to air cooled systems due to

the use of evaporative condensers

• Cold water production from 45°C down to

less than 1°C

• 4 stage cooling system (cooling tower

effect, 2 stages shell & tube evaporator,

ice bank)

• High quality semi hermetic screw

compressors

• PLC controlled with touch panel for

operation

• Compact containerized design

• Plug-in unit: Just water supply and power

supply to be connected

• Product range from 32 m³ to 450 m³/day

available

• Subcooling facility to maintain the

temperature inside the cold water tank

Prefabricated Cold Water Tanks

• Range of cold water tanks from 58 m³

to 150 m³

• Prefabricated and insulated

• Including support for discharge screw

conveyors or pumps

• Support base for chillers or ice plants

Inside view of containerized

ice water plant – CIWP.4-312

Electronic expansion valve

Inside view of containerized

ice water plant – CIWP.4-128

High-efficiency copper-coil heat exchanger

for ice bank system (4th stage)

Evaporative condenser inside

CIWP.4 (1st stage cooling)

High efficiency shell & tube

evaporators (insulated) –

2nd & 3rd stage cooling

Water flow control

Containerized cold water tank – insulated – 58 m³;

chillers to be installed on top

Complete setup with water chiller, cold water tank,

flake ice plant and ice storage

Pressure control valve for

freezing protection

High-tech semi-hermetic screw

compressors made by BITZER

Insulated cold water tank – 150 m³ – inside steel frame for support

of chillers or ice storage and flake ice plant

6 7

Benefits of Flake Ice

• Fastest melting time of flake ice

compared to any other ice

• Shortest mixing time as flake ice melts

rapidly

• Longer lifespan of the batching plant

equipment and cost saving due to the

short mixing times

• The cooling energy is 100% or even

higher as the flake ice is sub-cooled

(–7°C)

• Due to the dryness, the cooling input of

flake ice can be accurately calculated and

its effects on the mixture’s temperature

is quickly apparent

• Flakes remain crisp and do not stick

together nor do they form blocks

• Flakes are free flowing

• Easy to be stored and leveled inside a

refrigerated ice storage with a fully

automatic ice rake system

• Easy to transport via screw conveyors or

blowing system

• No defrost losses as subcooled flake ice

is sheared from the freezing surface by

the ice removal tools

Ice maker (inside view)

Stainless steel gauge panel with

pressure transducers

Electrical switchboard with PLC control and touch panel for indication of

ice level and all other relevant plant performance values Ice outlet of discharge screw

Prefabricated ice storages Flake ice maker

Inside view machinery container

Arabian Cement, Saudi Arabia 4x FLIP 86; 2x MIS 75 for

up to 4500 m³/day concrete production

Jirau Dam, Brazil

2 Collapsible ice storages

MIS 75 with 2 flake ice

plants (FLIP 150)

installed in Subansiri

dam project, India

Flake ice

Flake Ice PlantsPrefabricated and Mobile

8 9

Ice Storages

Transportable &

Semi-Automatic

• Automatic loading

• Manual discharge

• Insulated ice storage

with cooling room

• Mobile 40ft container

• Integrated discharge

screw conveyors

• Power generator

optional

Fully Automatic

• Mobile ice storages for 19 to 90 tons

• Integrated ice rake for automatic ice discharge

• Patented air circulation and room cooling system

Ice rake drive unit with flexible slip clutch

Inside view MIS 26 sa Transportable ice storage in Portugal

2x FLIP 280, MIS 200

Collapsible ice storage MIS 75 under production

Inside view MIS.4 - 60

Back view MIS.4 - 75

Dubai Airport – 280 tons ice production

per day with 250 tons ice storage

assembled in UAE

10 11

Ice Delivery SystemsWeighing & Dosing

• Ice delivery screw conveyors for a

efficient and fast delivery

• Hot dipped galvanized screw conveyors

• Double discharge screw conveyor

for simultaneous ice delivery to

2 different locations

• Blowing system for ice delivery

especially long-distance

• Exact dosing of ice by integrated

weighing system

• Pneumatic ice delivery

• Ice delivery screw conveyors

Ice discharge and delivery screw with

metering hopper Galvanized screw conveyor

Metering hopper

Weighing screw conveyor for pneumatic ice delivery with rotary valve

Flake ice plant with fully automatic ice storage and

pneumatic ice delivery system to two locations

Blowing station

under construction

Blower system for pneumatic ice delivery to three locations Cyclone receiver Diverter valve

Ice weighing hopper

Blower outlet

Loading for transportation

Double screw conveyor – galvanised

12 13

Falling film evaporator Stainless steel heat exchanger plates

Water chillers for aggregate cooling

in flooded silos

Screw compressor unit for aggregate cooling

200 t Flake ice plant, Jirau Dam, Brazil

Wet belt for aggregate cooling

Water chiller for aggregate cooling

and flooded belt conveyors

Air cooling unit for aggregate cooling

Dam Projects & Mass Concrete Aggregate Cooling for Dam Projects

• Wet belt cooling by ice water and silo

cooling by flooding with ice water

- Ice water chiller for wet belt cooling

producing water of less than 1°C

- Falling film evaporator insensitive

against mud and scale

- Evaporator easy to clean during

operation

- Falling film evaporator made of

stainless steel

- High efficiency due to an excellent

heat transfer between water and

aggregates

- Environment friendly refrigerant:

ammonia

- Latest screw compressor units

• Aggregate cooling by air

• Post cooling of concrete after pouring

• Sand cooling equipment

• Turnkey design

• Containerized plants to achieve the

shortest installation time

• Multiple reusability

14 15

Qatar

Dubai – UAE

Germany

Brazil

Saudi Arabia

India

KTI Service and SalesTurnkey Installation

Our Strengths

• Dedicated to customer care

• Regular service points in Dubai, Qatar, Saudi Arabia,

Germany, Brazil

• Highly qualified teams of service technicians and engineers

• Efficient fleet of fully equipped service cars

• KTI owned spare parts storage warehouses in Doha,

Riyadh, Jeddah, Dammam and Sao Paulo

• Central location of KTI warehouse in UAE

(Dubai Industrial City)

• 24/7 availability

• KTI training center in Dubai

• Training of service staff and customer personnel by

German engineers according to German regulations

Your Benefits

• KTI service mentality

• German quality standard

• Enhanced reliability

• Optimized running costs

• Longer life expectancy

• Minimized breakdowns

• 100% spare parts availability

• Permanent service availability

• On-site training of staff at large construction sites

• Service contracts

KTI is customer-service centered. To guarantee

KTI customers the smooth and reliable operation of each

plant, KTI employs highly qualified teams of engineers and

service technicians worldwide. Working very closely with the

KTI overseas offices, agencies and branches, they provide

a unique after-sales customer service and support

KTI customers all the year round, everywhere in the world.

KTI Turnkey Installations

KTI provides simple and highly cost efficient solutions.

They require • no extra underground water tank

• no separate support construction

• no additional engineering and design work.

The modular systems of KTI are set up within the shortest

possible time.

It takes • one day for the chillers

• two days for the flake ice plant with water

tank, ice storage, platforms and stairways

• two to three days for outside piping, cabling

and installation of the ice delivery system.

With proper site preparation a com plete concrete cooling

system will be in operation within one week.

Step 5Installation of the platforms and stairways – all hot dipped galvanised – for easy access to the plants. All platforms and stairways are bolted to the frames and can be dismantled and re-assembled for future installations.

Step 4

Installation of flake ice plant (e.g. FLIP 42 – with a daily capacity of 42 tons per day)

Step 3Installation of 2nd frame with insulated ice storage for 75 tons flake ice including fully automatic ice rake and delivery system

Step 2A

Installation of bottom frame with insulated water tank holding 150,000 liters of water

Step 1

Empty space with concrete foundation 8 x 16 m

Step 2BInstallation of intermediate frame with ladders and platforms to adapt the height of the ice discharge outlet corresponding to the batching plant

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KTI Agencies and Registered Offices

KTI-Plersch Kältetechnik GmbH

Carl-Otto-Weg 14/2

D-88481 Balzheim

Germany

Tel.: +49/7347/9572-0

Fax: +49/7347/9572-22

E-mail: [email protected]

www.kti-plersch.com

Scan QR code with your mobile

device to view our website:

www.kti-plersch.com

VIP – Various Ice Products Sales Representative –

Middle East for KTI-Plersch

P.O.Box 17618 (Jebel Ali Free Zone)

Dubai, United Arab Emirates

Tel.: +971/4/8809666

Fax: +971/4/8809966

Mobile: +971/50/4560414


www.vipdubai.ae

Qatar (Doha)

KTI Qatar

+974 55 491 286

[email protected]

Saudi Arabia (Dammam,

Jeddah, Riyadh)

KTI Saudi Arabia

+966 3 8144 382

[email protected]

Spain (Saragossa)

Arco Electronica, S.A.

+34 976 81 90 10

[email protected]

Switzerland (Sulgen)

Sauter Plersch AG

+41 71 644 74 00

[email protected]

Turkey (Ankara)

Titan Ltd Sti

+90 312 385 56 08

[email protected]

United Arab Emirates (Dubai)

KTI-Plersch – Dubai Branch

+971 50 4 542186

[email protected]

USA (Newport News, VA)

Liebherr CT

+1 757 928 8547

[email protected]

Brazil (Sao Paulo)

KTI-Plersch do Brasil

+55 12 3126-4095

[email protected]

China (Beijing)

[email protected]

Egypt (Cairo)

[email protected]

India (Chennai)

KTI India

+91 900 3099 404

[email protected]

Iran (Tehran)

[email protected]

Italy (Milano)

KTI Italy

+39 02 75 32 404

[email protected]

Kuwait (Kuwait City)

Gulf Group Co.

+965 1802 803

[email protected]

Oman (Muscat)

Saud Bahwan

Projects & Equipment LLC

+968 24 57 99 01

[email protected]

Portugal


Cairo

Tehran

Ankara

Jeddah

DohaDammam

Dubai

Muscat

Kuwait

Riyadh

VIP

KTI

KTI

KTIKTI

KTI

KTI

Headquarters

KTI-Plersch do Brasil

KTI Saudi ArabiaKTI-Plersch – Dubai Branch

KTI India

KTI Qatar

KTI Saudi Arabia KTI

Agencies

KTI offices and branches

Installations

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