Heat Balance

NR Koeling BVNR Koeling BV HKCI SeminarHKCI Seminar

Hongkong 28 . December 2012

NR Koeling BVHKCI Seminar1

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NR Koeling BVImproving Concrete Quality

by cooling,

to prevent damages, complains and follow-up-costsIntroductionDear Comitee, thanks that you give me the possibility to say something about the concrete quality and temperature.Dear Ladies and GentlemanIn the past nobody takes care about the concrete quality. On the one hand cement was saved and on the other hand the concrete temperature was neglected.If you travel with open eyes through the world, you will see, the most of the sanitations and repair works are concrete constructions ( bridges, roads, dams, buildings.). For this reason the concrete temperature becomes ever more important and gains very strongly significance.The regulations and standards in Europe means, that the concrete temperature at the job site are not over 27C.On the dams should be the temperature between 12C and 16C. As you know all, the Three Georges Dam has in the meantime over 100 large cracks; up to 100m long and 2m wide.- not the best solution for dams. The reason I will explain you later on.

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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 CONCRETEHeat - Balance

NR Koeling BV Heat BalanceMixtureMassTemp.Heatload*COOLING Temp.Heatload*[ Kcal/hr ][ kcal/hr]Aggregate1.300 kg35C9.555 Sand 900 kg35C6.615Cement 240 kg55C3.168Water 125 kg30C3.995Mixer heat400Total2.565 kg23.73336,9CWet-Belt Temp. After coolingMix Formula 1 m3 concreteCement 55C 3.168 Mixer 400* Heatload = mass (kg) x specified heat ( kcal) x temp (C) = kcal/hr 6.615 1.050

NR Koeling BVSand CoolingChilled waterFlake Ice125 kg 5C 9.555 20.788 32,3C 60 kg -4C 65 kg 5C 24,2C -4.920 15.568 750 8.743 10C 2.730 4.963 13,6C 7,7C 15C 2.835Concrete temperature8CMixing capacity220 m/hDaily production3.100 m/day6

NR Koeling BV Heat Balance : water + ice7

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Heat Balance : water + ice + aggr + sand

NR Koeling BV Heat Balance : Cooling Capacities

NR Koeling BVChilled Water

NR Koeling BV

Chilled Water

Large air-cooler chiller plant (Ethiopia)

Small Chiller plant

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Panama Channel ProjectWater cooled chiller unitWater basin

NR Koeling BVFlake - Ice

Flake-ICE

Cold water: 5CIceIceIceIceIce MakerNo1Ice MakerNo2Ice MakerNo3Ice MakerNo4Compressor UnitAmmonia (NH3)Ice makers (NH3)Isolated Ice storageElevating crew conveyorDay-TankCompressorEvaporating condenserAirAirAirNH3: Suction -34CNH3: Liquid +37CIce

Bin Cooling-7CFLAKE ICERake System

NR Koeling BVFlake-ICE

Flake Ice Plant

Ice MakerFlake Ice

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Flake-ICECapacity of the Flake Ice plant for the Panama project Total capacity330 Ton/24Hr Number of Ice makers 6 pc Number of Compressor units 3 pc Compressor capacity (each) 526 kW Evaporating temperature -34C Refrigerant Ammonia Rake system capacity2x 72 Ton Volume Isolated Ice storage 900 m3 Number of Day-tanks 4 pc Number of elevating crew conveyors 2 pc

NR Koeling BVFlake-ICE

Flake Ice PlantRake system under constructionIce makers installed

NR Koeling BVTocoma Dam VenezuelaRake system under construction

NR Koeling BVAggregate Cooling Concept

Spraying cold water the aggregates handled on a special Conveyor Wet - belt

Aggregate Wet-Belt

WATER SPRAY-SYSTEM4C8C4C10C4C4C12C12CISOLATING TUNNELCONVEYOR BELTCOLLECTING BASINCHILLER UNITSETTELING BASIN MIXING BASINCOLD WATER BASINSPRAYPUMPPUMPAGGREGATE TOBATCHING PLANT, 10CWATER COLLECTORFRESH-WATER 28CAGGREGATE FROMSTOCK PILE, 28CAIRAIRAIRAIR28C10CPUMP10CRETURN WATERSEDIMENT

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NR Koeling BV

Diagram showing the cooling effect against time and aggregate size.

NR Koeling BVAggregate sprayed with cold water on a Belt Wet-Belt

Wet-Belt

Isolating TunnelWater Spray on beltWet-Belt under construction

NR Koeling BVTocoma 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 allowConveyor Wet-BeltCapacity 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 installed5375 kW Water flow 500 m3/h

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NR Koeling BVAggregate Cooling Cold Water Inundation - Sedimentationinto the Silo Aggregate hopper cooling by cold water in Silo

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28C4C8C28C8C7C

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Technical dataAggregate capacity*20-800Ton/hrAggregate size 5-150mmTemperature difference In -Out0-32KLowest output temperature8CCooling capacity**200-5.000kWOutside conditions40CSupply voltage400-460VFrequency50/60HzBelt length **10/220mCooling down time **2/15min

Free flow system water flow ~ 1000 m/h

Sedimentation SystemResultSludgeCleanwater

NR Koeling BVAggregate coolingby blowing cold airinto storage siloAggregate hopper cooling by cold air

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28C9C28C4C -2C4C9C

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Diagram showing the cooling effect against the remaining time and aggregate sizeAggregate cooling in Silo

Aggregate cooling by cold airAir-blast unit

NR Koeling BVSadi Said Marocco

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Large aggregate cooling system by cold air with separated storage silos,(Gibe III Ethiopia)

NR Koeling BVLarge aggregate cooling system by cold air with separated storage silos, (Gibe III Ethiopia)

Aggregate silos for air coolingChilled water plantCapacity: Aggregate: 700 Ton/HrTemp. :29C 9CRefr.cap.: 4.100 kW

NR Koeling BVHow to cool the Sand by ROTATING SAND COOLER

Sand Cooling

COOLED SAND TOBATCHINGPLANT, 14CSAND FROM STOCKPILE, 28CSand filterPUMPSAND COOLERChiller unitAir-Blast unit4C-2C-2C4CSupply AIR :Air: Return AIR : AirAirAirAirFan Cooling coil2C24CWater/GlycolRotating DrumSupply conveyorDischarge conveyorFeeding conveyor2C24C24C2C8C

NR Koeling BVSand Cooling

Innerview Sand cooler rotating drumSand cooler on job site

NR Koeling BVTocoma Dam Venezuela

NR Koeling BV

Sand cooling panama channel project Sand CoolingCapacity of the Sand cooler for the Panama project Number of sand coolers 2 pc Sand capacity (each) 210 Ton / hour Diameter of sand cooler2500 mm Length 11.000 mm

Cooling capacity installed2x 775 kW

NR Koeling BV Sand cooling Sogamoso Colombia

NR Koeling BV Sand Cooling

NR Koeling BVRotating drums Sand Cooler

NR Koeling BVComplete solution

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General LayoutGeneral Layout

Aggregate storage Wet beltSedimentationInline silowithweighingsystemIce plant(for safety)Mixing plantCement and fly-ashstorageChiller plantSonla Dam Vietnam

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General layout Material storage SandWet beltsSedimentation-tanksMixing plantIce plantMaterialstorage-aggregatesCharging hopperConveying beltsYewa Dam Myanmar

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NR Koeling BVConfiguration of theConcrete Cooling Plant

NR Koeling BVConcrete temperature at mixer outlet

Plant Layout

Energy consumption Selection Criteria

NR Koeling BV Concrete TemperatureAchievable concrete temperatures

NR Koeling BV Plant Combinations8C Concrete only achievablewith Plant combination H and ICooling optionsCooling Plant combinationsABCDEFGHIChilled waternnnnnnnnnFlake IcennnnnnAggregate cooling by WaternnnAggregate cooling by AirnnnSand cooling by AirnnnnnResult output temp. Concrete (C)34,025,312,713,616,512,813,78,08,050

NR Koeling BV Plant Combinations

Multiple cooling combination needed to achieve 8C Concrete Energy Consumption (electrical)

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Flake Ice uses the most energy compared to the other methods

NR Koeling BV ConclusionGETTING 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 2