HKCI
Seminar
HKCI Seminar
HKCI
Seminar
Hongkong
28 . December 2012
NRKoeling
KoelingBV
BV
NR
Improving Concrete Quality
by cooling,
to prevent damages, complains
and follow-up-costs
NRKoeling
KoelingBV
BV
NR
NR Koeling
BV
NR Koeling BV
Methods of Cooling CONCRETE
- Heat
- Balance
- Chiller plant
- Flake
Ice plant
- Aggregate cooling by ►spraying cold water
- on a special conveyor belt
- inside a special storage silo
- Aggragate
cooling by► blowing cold air into storage silo
- Sand Cooling
by► blowing cold air
- Complete solution
- Configuration of the concrete cooling plant
- Discussion
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Heat - Balance
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Heat Balance
Mix Formula 1 m3 concrete
Mixture
Mass
Temp.
Heatload*
COOLING
Temp.
[ Kcal/hr ]
Heatload*
[ kcal/hr]
1.300 kg
35°C
9.555
Wet-Belt
10°C
9.555
2.730
Sand
900 kg
35°C
6.615
Sand Cooling
15°C
6.615
2.835
Cement
240 kg
55°C
3.168
Cement
55°C
3.168
Water
125 kg
30°C
3.995
65 kg
kg 5°C
Chilled water 125
60 kg -4°C
Flake Ice
750
1.050
Aggregate
Mixer heat
Total
400
2.565 kg 36,9°C
23.733
-4.920
Mixer
400
Temp. After cooling 24,2°C
7,7°C
13,6°C
32,3°C
4.963
8.743
15.568
20.788
* Heatload = mass (kg) x specified heat ( kcal) x temp (°C) = kcal/hr
Concrete temperature
Mixing capacity
Daily production
8°C
220 m³/h
3.100 m³/day
NR Koeling BV
Heat Balance : water + ice
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Heat Balance : water + ice + aggr + sand
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Heat Balance : Cooling Capacities
CHILLED WATER PLANT
Fresh-water supply
Chilled water Flow mixer
Chilled water Flow Flake Ice
Flow
3,5 m³/h 5°C
13,2 m³/h 5°C
16,7 m³/h 5°C
Total Fresh water Flow
Capacity kW
102
384
486
Extra
30%
30%
Cooling Sand
Total sand Heat
Air-losses
Chiller capacity
Capacity kW
133
499
632
10%
990.000 Kcal/h
215.471 Kcal/h
1.402 KW
21,7 m³/h 30°C
Aggregate.1 Air Pre-cooled
Total Aggregate Heat
PRE-COOLING AGGREGATE
Sand cooling
Cooling Sand
Capacity kW
1.402
Aggregate cooling
Aggregate.1 Air Pre-cooled
Aggregate.2 Air Pre-cooled
Aggregate.3 Air Pre-cooled
Capacity kW
774
619
619
Extra
10%
Extra
10%
10%
10%
Air losses
Chiller capacity
Capacity kW
1.542
1.542
Aggregate.2 Air Pre-cooled
Total Aggregate Heat
Capacity kW
851
681
681
2.213
CHILLED WATER PLANT TOTAL CAPACITY KW
Air losses
Chiller capacity
10%
Aggregate.3 Air Pre-cooled
Total Aggregate Heat
3.755
FLAKE ICE PLANT
Total Flake Ice
Flake Ice Rake system
10%
Air losses
Chiller capacity
10%
TOTAL RESULTS
Ton/24Hr
184,8
Extra safety
20%
Capacity
222
70
Ton/24Hr
Ton
COOLING METHODS USED
Chilled water
Aggregate
Sand
Flake ICE
Aggr.hopper
YES
YES
YES
YES
NO
Chilled water plant
5 °C
Chilled water plant sand cooling
Chilled water plant aggregate cooling
Flake Ice plant
Flake Ice rake system capacity
60.500 Kcal/h
774 KW
484.000 Kcal/h
48.400 Kcal/h
619 KW
484.000 Kcal/h
48.400 Kcal/h
619 KW
Concrete temp. :
Concrete production daily
Concrete production hourly
Fresh water flow 30 °C
NR Koeling BV
P.O. Box 95
2920 AB Krimpen a/d IJssel
The Netherlands
Tel. +31(0)180-545111 / Fax +31(0)180-545110
E-mail: info@nrkoeling.nl
Internet: www.nrkoeling.nl
605.000 Kcal/h
7,7°C
3.100 m³/day
220 m³/hr
21,7 m³/h
632
1.542
2.213
4.387
kW
kW
kW
kW
222 Ton/24Hr
70 Ton
NR Koeling BV
Chilled Water
NR Koeling BV
Chilled Water
Large air-cooler chiller plant (Ethiopia)
Small Chiller plant
NR Koeling BV
Water basin
Panama Channel Project
Water cooled chiller unit
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Flake - Ice
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Flake-ICE
Ice makers (NH3)
Cold water: 5°C
Ice
Maker
No1
Ice
Maker
No2
Ice
Maker
No3
Ice
Maker
No4
Bin Cooling
-7°C
Ice
Ice
Ice
Ice
Elevating crew
conveyor
FLAKE ICE
Rake System
Ice
Day-Tank
Isolated Ice storage
Air
Evaporating
condenser
Air
Air
NH3: Liquid +37°C
Compressor
NH3: Suction -34°C
Compressor Unit
Ammonia (NH3)
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Flake-ICE
Ice Maker
Flake Ice Plant
Flake Ice
NR Koeling BV
Flake-ICE
Capacity of the Flake Ice plant for the Panama project
-
Total capacity
330 Ton/24Hr
Number of Ice makers
6 pc
Number of Compressor units
3 pc
Compressor capacity (each)
526 kW
Evaporating temperature
-34°C
Refrigerant
Ammonia
-
Rake system capacity
2x 72 Ton
Volume Isolated Ice storage
900 m3
Number of Day-tanks
4 pc
Number of elevating crew conveyors 2 pc
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Rake system under construction
Rake system under
construction
Flake-ICE
Flake Ice Plant
Tocoma Dam Venezuela
Ice makers installed
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Aggregate
Cooling Concept
Spraying cold water
the aggregates handled on a
special
Conveyor Wet - belt
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Aggregate Wet-Belt
AGGREGATE FROM
STOCK PILE, 28°C
ISOLATING TUNNEL
4°C
WATER SPRAY-SYSTEM
28°C
10°C
RETURN WATER
8°C
WATER COLLECTOR
CONVEYOR BELT
10°C
COLLECTING BASIN
FRESH-WATER 28°C
MIXING BASIN
PUMP
SETTELING BASIN
10°C
4°C
12°C
SEDIMENT
AIR
AIR
AIR
AIR
CHILLER UNIT
AGGREGATE TO
BATCHING PLANT, 10°C
COLD WATER BASIN
4°C
SPRAY
PUMP
PUMP
12°C
4°C
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Diagram showing the cooling effect against time and aggregate size.
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Wet-Belt
Aggregate sprayed
with cold water on a Belt
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Wet-Belt
Tocoma Dam Venezuela
Isolating
Tunnel
Water Spray on belt
Width of belt 1600 mm; v = 0,35 m/s
Spraying with 3° to 4° cold water
At a distance of 20 m the lateral roller
are left out to allow
Wet-Belt under
construction
NR Koeling BV
Conveyor Wet-Belt
Capacity of the WET-BELT for the Panama Canal project
-
Belt lenght
Belt width
Belt capacity
Belt speed
Cooling capacity installed
Water flow
: 220 m
2m
800 Ton / hour
0,3 m/s
5375 kW
500 m3/h
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Aggregate Cooling
Cold Water
Inundation - Sedimentation
into the Silo
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Aggregate hopper cooling
by cold water in Silo
28°C
28°C
4°C
8°C
8°C
7°C
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Technical data
Aggregate capacity*
20
-
800
Ton/hr
Aggregate size
5
-
150
mm
Temperature difference In -Out
0
-
32
K
8
°C
5.000
kW
40
°C
Lowest output temperature
Cooling capacity**
200
-
Outside conditions
Supply voltage
400
-
460
V
Frequency
50
/
60
Hz
Belt length **
10
/
220
m
2
/
15
min
Cooling down time **
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Sedimentation System
Free flow system
water flow ~ 1000 m³/h
Clean
water
Result
Sludge
Aggregate cooling
by
blowing cold air
into storage silo
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Aggregate hopper cooling by cold air
28°C
28°C
9°C
4°C
9°C
-2°C
4°C
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Diagram showing the cooling effect against the remaining time and aggregate size
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Aggregate cooling in Silo
Aggregate cooling by cold air
Sadi Said Marocco
Air-blast unit
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Large aggregate cooling system by cold air with separated storage silos,
(Gibe III Ethiopia)
NR Koeling BV
Capacity:
Aggregate: 700 Ton/Hr
Temp. :29°C  9°C
Refr.cap.: 4.100 kW
Aggregate silo’s for air cooling
Chilled water plant
Large aggregate cooling system by cold air with separated storage
silos, (Gibe III Ethiopia)
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How to cool the Sand
by
ROTATING SAND COOLER
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Sand Cooling
24°C
SAND FROM
STOCKPILE, 28°C
SAND COOLER
Rotating Drum
Air: 2°C
Supply conveyor
COOLED SAND TO
BATCHINGPLANT, 14°C
8°C
Feeding
conveyor
Return AIR : 24°C
Discharge conveyor
Cooling coil
Supply AIR : 2°C
2°C
24°C
Fan
Air-Blast unit
Sand filter
Air
Air
-2°C
4°C
Chiller unit
PUMP
Air
Air
-2°C
4°C
Water/Glycol
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Sand Cooling
Innerview Sand cooler
rotating drum
Sand cooler on job site
Tocoma Dam Venezuela
NR Koeling BV
Sand cooling panama channel project
NR Koeling BV
Sand Cooling
Capacity of the Sand cooler for the Panama project
-
Number of sand coolers
Sand capacity (each)
Diameter of sand cooler
Length
- Cooling capacity installed
2 pc
210 Ton / hour
2500 mm
11.000 mm
2x 775 kW
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Sand cooling Sogamoso Colombia
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Sand Cooling
Rotating drums Sand Cooler
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Complete solution
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General Layout
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General Layout
Inline silo
with
weighing
system
Aggregate
storage
Ice plant
(for safety)
Wet belt
Mixing plant
Sedimentation
Cement and flyash
storage
Chiller plant
Sonla – Dam Vietnam
NR Koeling BV
General layout
Material
storage Sand
Yewa – Dam Myanmar
Sedimentationtanks
Wet belts
Conveying
belts
Materialstorageaggregates
Charging
hopper
Mixing plant
Ice plant
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Configuration
of the
Concrete Cooling Plant
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Selection Criteria
 Concrete temperature at mixer outlet
 Plant Layout
 Energy consumption
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Concrete Temperature
Achievable concrete temperatures
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Plant Combinations
Cooling options
Chilled water
Flake Ice
Aggregate cooling by Water
Aggregate cooling by Air
A
Cooling Plant combinations
B
C
D
E
F
G
H
I
n
n
n
n
n
n
n
n
n
n
n
n
n
n
Result output temp. Concrete (°C)
n
n
n
n
n
n
Sand cooling by Air
n
n
n
34,0 25,3 12,7 13,6 16,5 12,8 13,7
n
n
n
8,0
8,0
8°C Concrete only achievable
with Plant combination H and I
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Energy Consumption (electrical)
Flake Ice uses the most energy
compared to the other methods
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Conclusion
GETTING LOW TEMPETURE CONCRETE
 HEAT-BALANCE
( all relevant data )
 MULTIPLE COOLING SOLUTIONS NEEDED
 SELECT BETWEEN THE AVAILABLE COOLING
METHODS
 OPTIMIZE SELECTED COMBINATIONS
( batching plant supplier, job site…. )
NR Koeling BV
Thanks for your
attention