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
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