NR Koeling BV - Hong Kong Concrete Institute

NR Koeling BV



NR Koeling
BV


HKCI
Seminar

HKCI Seminar

Hongkong



28 .
December

2012

NR Koeling
BV

HKCI Seminar

NR Koeling BV




NR Koeling
BV

NR Koeling
BV



NR Koeling BV


I
mproving Concrete Quality



by cooling,



to prevent damages, complains



and follow
-
up
-
costs

NR Koeling BV

-

Sand Cooling by
►

blowing cold air

NR Koeling BV

-

Aggregate cooling by
►
spraying cold water

-

Configuration of the concrete cooling plant

-

Flake Ice plant



-

Chiller plant

-

Complete solution


-

on a special conveyor belt


-

inside a special storage silo


-

Aggragate cooling by
►

blowing cold air into storage silo

-

Discussion


-

Heat

-

Balance

Methods of Cooling CONCRETE

Heat
-

Balance

NR Koeling BV


Heat Balance

Mixture

Mass

Temp.

Heatload
*

COOLING


Temp.

Heatload
*

[

Kcal/
hr

]

[ kcal/
hr
]

Aggregate

1.300 kg

35
°
C

9.555

Sand


900 kg

35
°
C

6.615

Cement


240 kg

55
°
C

3.168

Water


125 kg

30
°
C

3.995

Mixer heat

400

Total

2.565 kg

23.733

36,9
°
C

Wet
-
Belt


Temp. After cooling

Mix
F
ormula

1 m
3

concrete

Cement 55
°
C 3.168


Mixer 400

*
Heatload

=
mass

(kg) x
specified

heat ( kcal) x temp (
°
C) = kcal/
hr


6.615



1.050

NR Koeling BV

Sand
Cooling

Chilled

water

Flake

Ice

125 kg 5
°
C



9.555


20.788


32,3
°
C


60 kg
-
4
°
C

65 kg 5
°
C


24,2
°
C




-
4.920



15.568



750



8.743


10
°
C 2.730



4.963



13,6
°
C



7,7
°
C


15
°
C 2.835

Concrete temperature

8
°
C

Mixing capacity


220 m³/h

Daily production


3.100 m³/day

NR Koeling BV


Heat Balance : water + ice

NR Koeling BV


Heat Balance : water + ice +
aggr

+
sand

NR Koeling BV


Heat Balance :
Cooling

Capacities

Cooling Sand
Fresh-water supply
Capacity kW
Extra
Capacity kW
Total sand Heat
990.000
Kcal/h
Chilled water Flow mixer
3,5
m³/h 5°C
102
30%
133
Air-losses
10%
215.471
Kcal/h
Chilled water Flow Flake Ice
13,2
m³/h 5°C
384
30%
499
Chiller capacity
1.402
KW
16,7
m³/h 5°C
486
632
Total Fresh water Flow
21,7
m³/h 30°C
Aggregate.1 Air Pre-cooled
Total Aggregate Heat
605.000
Kcal/h
Air losses
10%
60.500
Kcal/h
Sand cooling
Capacity kW
Extra
Capacity kW
Chiller capacity
774
KW
Cooling Sand
1.402
10%
1.542
1.542
Aggregate.2 Air Pre-cooled
Total Aggregate Heat
484.000
Kcal/h
Aggregate cooling
Capacity kW
Extra
Capacity kW
Air losses
10%
48.400
Kcal/h
Aggregate.1 Air Pre-cooled
774
10%
851
Chiller capacity
619
KW
Aggregate.2 Air Pre-cooled
619
10%
681
Aggregate.3 Air Pre-cooled
619
10%
681
Aggregate.3 Air Pre-cooled
2.213
Total Aggregate Heat
484.000
Kcal/h
CHILLED WATER PLANT TOTAL CAPACITY KW
3.755
Air losses
10%
48.400
Kcal/h
Chiller capacity
619
KW
Ton/24Hr
Extra safety
Capacity
Concrete production daily
3.100
m³/day
Total Flake Ice
184,8
20%
222
Ton/24Hr
Concrete production hourly
220
m³/hr
Flake Ice Rake system
70
Ton
Fresh water flow 30 °C
21,7
m³/h
Chilled water plant 5 °C
632
kW
NR Koeling BV
Chilled water plant sand cooling
1.542
kW
P.O. Box 95
Chilled water plant aggregate cooling
2.213
kW
2920 AB Krimpen a/d IJssel
Chilled water
YES
4.387
kW
The Netherlands
Aggregate
YES
Tel. +31(0)180-545111 / Fax +31(0)180-545110
Sand
YES
E-mail: info@nrkoeling.nl
Flake ICE
YES
Flake Ice plant
222
Ton/24Hr
Internet: www.nrkoeling.nl
Aggr.hopper
NO
Flake Ice rake system capacity
70
Ton
TOTAL RESULTS Concrete temp. :
7,7°C
COOLING METHODS USED
CHILLED WATER PLANT
Flow
PRE-COOLING AGGREGATE
FLAKE ICE PLANT
NR Koeling BV

Chilled

Water

NR Koeling BV

Chilled

Water


Large

air
-
cooler

chiller

plant (
Ethiopia
)


Small

Chiller

plant

NR Koeling BV

Panama Channel Project

Water
cooled

chiller

unit

Water
basin

NR Koeling BV

Flake

-

Ice

Flake
-
ICE

Cold water: 5
°
C

Ice

Ice

Ice

Ice

Ice
Maker

N
o
1

Ice
Maker

N
o
2

Ice
Maker

N
o
3

Ice
Maker

N
o
4

Compressor Unit

Ammonia (NH3)

Ice

makers (NH3)

Isolated

Ice

storage

Elevating

crew
conveyor

Day
-
Tank

Compressor

Evaporating
condenser

Air

Air

Air

NH3: Suction
-
34
°
C

NH3: Liquid +37
°
C

Ice

Bin
Cooling

-
7
°
C

FLAKE ICE

Rake System

NR Koeling BV

Flake
-
ICE

Flake

Ice

Plant

Ice Maker

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 m
3

-

Number of Day
-
tanks



4 pc

-

Number of elevating crew conveyors 2 pc

NR Koeling BV

Flake
-
ICE

Flake Ice Plant

Rake system under
construction

Ice

makers
installed

NR Koeling BV

Tocoma

Dam Venezuela

Rake
system

under

construction

NR Koeling BV

Aggregate

Cooling Concept



Spraying cold water

the aggregates handled on a
special

Conveyor Wet
-

belt

Aggregate

Wet
-
Belt

WATER SPRAY
-
SYSTEM

4
°
C

8
°
C

4
°
C

10
°
C

4
°
C

4
°
C

12
°
C

12
°
C

ISOLATING TUNNEL

CONVEYOR BELT

COLLECTING BASIN

CHILLER UNIT

SETTELING BASIN


MIXING BASIN

COLD WATER BASIN

SPRAY
PUMP

PUMP

AGGREGATE TO

BATCHING PLANT,
10
°
C

WATER COLLECTOR

FRESH
-
WATER
28
°
C

AGGREGATE FROM

STOCK PILE,
28
°
C

AIR

AIR

AIR

AIR

28
°
C

10
°
C

PUMP

10
°
C

RETURN WATER

SEDIMENT

NR Koeling BV

NR Koeling BV




Diagram showing the cooling effect against time and aggregate size.

NR Koeling BV

Aggregate sprayed


with cold water on a Belt


Wet
-
Belt

Wet
-
Belt

Isolating
Tunnel

Water Spray on belt

Wet
-
Belt under
construction

NR Koeling BV

Tocoma

Dam Venezuela

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

Conveyor Wet
-
Belt

Capacity of the
WET
-
BELT
for the Panama
Canal project

-

Belt
lenght



: 220 m

-

Belt
width




2 m

-

Belt
capacity





800 Ton /
hour

-

Belt speed




0,3 m/s

-

Cooling

capacity

installed

5375 kW

-

Water
flow





500 m
3
/h

NR Koeling BV

NR Koeling BV

Aggregate Cooling


Cold Water

Inundation
-

Sedimentation

i
nto the Silo

Aggregate hopper
cooling


by
cold

water in Silo

NR Koeling BV

28
°
C

4
°
C

8
°
C

28
°
C

8
°
C

7
°
C

NR Koeling BV

Technical data











Aggregate capacity*



20

-

800

Ton/hr

Aggregate size




5

-

150

mm

Temperature difference In
-
Out



0

-

32

K

Lowest output temperature







8

°
C

Cooling capacity**



200

-

5.000

kW

Outside conditions







40

°
C

Supply voltage



400

-

460

V

Frequency



50

/

60

Hz

Belt length **

10

/

220

m

Cooling down time **




2

/

15

min

Free flow system

water flow ~ 1000 m³/h


Sedimentation System

Result

Sludge

Clean

water

NR Koeling BV

Aggregate cooling

by

blowing cold air

into storage silo

Aggregate hopper cooling by cold air

NR Koeling BV

28
°
C

9
°
C

28
°
C

4
°
C


-
2
°
C

4
°
C

9
°
C

NR Koeling BV

Diagram showing the cooling effect against the remaining time and aggregate size

Aggregate cooling in Silo

Aggregate cooling by cold air

Air
-
blast

unit

NR Koeling BV

Sadi Said
Marocco

NR Koeling BV

Large

aggregate

cooling

system by
cold

air
with

separated

storage

silos
,

(
Gibe

III
Ethiopia
)

NR Koeling BV

Large
aggregate

cooling

system by
cold

air
with

separated

storage
silos
, (
Gibe

III Ethiopia)

Aggregate silo’s for air cooling

Chilled water plant

Capacity
:

Aggregate
: 700 Ton/
Hr

Temp. :29
°
C


9
°
C

Refr.cap
.: 4.100 kW

NR Koeling BV

How

to

cool
the

Sand

by


ROTATING SAND COOLER

Sand Cooling

COOLED SAND TO

BATCHINGPLANT,
14
°
C

SAND FROM

STOCKPILE,
28
°
C

Sand

filter

PUMP

SAND COOLER

Chiller

unit

Air
-
Blast

unit

4
°
C

-
2
°
C

-
2
°
C

4
°
C

Supply AIR :

Air:

Return AIR :



Air

Air

Air

Air

Fan


Cooling

coil

2
°
C

24
°
C

Water/Glycol

Rotating Drum

Supply conveyor

Discharge conveyor

Feeding
conveyor

2
°
C

24
°
C

24
°
C

2
°
C

8
°
C

NR Koeling BV

Sand Cooling

Innerview Sand cooler
rotating drum

Sand cooler on job site

NR Koeling BV

Tocoma

Dam Venezuela

NR Koeling BV


Sand
cooling

panama

channel

project


Sand Cooling

Capacity

of the
Sand

cooler

for

the Panama project

-

Number of sand coolers



2 pc


-

Sand capacity (each)



210 Ton / hour

-

Diameter of sand cooler


2500 mm

-

Length



11.000 mm


-

Cooling capacity installed

2x 775 kW


NR Koeling BV


Sand
cooling

Sogamoso

Colombia

NR Koeling BV



Sand
Cooling


NR Koeling BV

Rotating

drums Sand
Cooler

NR Koeling BV

Complete solution

NR Koeling BV

General Layout

General Layout

Aggregate


storage


Wet belt

Sedimentation

Inline silo

with

weighing

system

Ice plant

(for safety)

Mixing plant

Cement and fly
-
ash

storage

Chiller

plant

Sonla

–

Dam Vietnam

NR Koeling BV

General
layout


Material
storage Sand

Wet belts

Sedimentation
-
tanks

Mixing plant

Ice plant

Materialstorage
-
aggregates

Charging

hopper

Conveying
belts

Yewa

–

Dam Myanmar

NR Koeling BV

NR Koeling BV

Configuration


of the

Concrete

Cooling

Plant

NR Koeling BV


Concrete temperature at mixer outlet



Plant Layout



Energy consumption


Selection

Criteria

NR Koeling BV


Concrete Temperature

Achievable concrete temperatures

NR Koeling BV


Plant
Combinations

8
°
C Concrete only achievable

with Plant combination H and I



Cooling options

Cooling Plant combinations

A

B

C

D

E

F

G

H

I

Chilled water

n

n

n

n

n

n

n

n

n

Flake Ice



„

n

n

n



?

„

n

Aggregate cooling by Water



?

„



?

„



„



Aggregate cooling by Air



?

?

„



?

„



„

Sand cooling by Air



?

?

?

„

n

n

n

n

Result output temp. Concrete (
°
C)

34,0

25,3

12,7

13,6

16,5

12,8

13,7

8,0

8,0


Energy

C
onsumption

(
electrical
)

NR Koeling BV

Flake Ice uses the most energy

compared to the other methods

NR Koeling BV


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…. )






Thanks

for

your



attention