3
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
09
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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
E-mail: [email protected]
www.vipdubai.ae
Qatar (Doha)
KTI Qatar
+974 55 491 286
Saudi Arabia (Dammam,
Jeddah, Riyadh)
KTI Saudi Arabia
+966 3 8144 382
Spain (Saragossa)
Arco Electronica, S.A.
+34 976 81 90 10
Switzerland (Sulgen)
Sauter Plersch AG
+41 71 644 74 00
Turkey (Ankara)
Titan Ltd Sti
+90 312 385 56 08
United Arab Emirates (Dubai)
KTI-Plersch – Dubai Branch
+971 50 4 542186
USA (Newport News, VA)
Liebherr CT
+1 757 928 8547
Brazil (Sao Paulo)
KTI-Plersch do Brasil
+55 12 3126-4095
China (Beijing)
Egypt (Cairo)
India (Chennai)
KTI India
+91 900 3099 404
Iran (Tehran)
Italy (Milano)
KTI Italy
+39 02 75 32 404
Kuwait (Kuwait City)
Gulf Group Co.
+965 1802 803
Oman (Muscat)
Saud Bahwan
Projects & Equipment LLC
+968 24 57 99 01
Portugal
E-mail: [email protected]
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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