Latest Design – New Technology
Ice Water & Cold Water Plants for Concrete Cooling
– 4th generation
• Latest compressor technology
• PLC-control with coloured touch screen
Types of Concrete Cooling Plants
Containerized Ice Water Plant – CIWP.4 (4th Generation)
• Stainless steel gauge panel with pressure transducers
Containerized Cold Water Plant – CCWP.4 (4th Generation)
• Inside view of Containerized Ice Water Plant – CIWP.4-128
• Inside view of Containerized Ice Water Plant – CIWP.4-312
• Pressure control valve for freezing protection
• Water flow control
• Electronic expansion valve
There are water chillers available cooling the fresh water from any temperature between +30°C and 45°C down to +5°C. They are called Containerized Cold Water Plants, Type: CCWP.
More efficient for lower concrete temperatures are water chillers cooling the fresh water from any temperature between +30°C and 45°C down to +1°C.
They are called Containerized Ice Water Plants, Type: CIWP and are equipped with special ice bank systems accumulating ice around tube or plate heat exchangers. Up to a daily production of
180 m³ cold water they are installed inside of 20-ft. containers corresponding to a daily concrete production between 1500 and 2200 m³. Up to a daily production of 450 m³ cold water they are installed inside of 40-ft. containers corresponding to a daily concrete production between 3700 and 5500 m² depending on the actual water inlet temperature and the possible addition of water.
All KTI-chillers are highly efficient using three- or four-stage cooling, hot-dipped galvanized evaporative condensers, stainless steel heat exchangers, gauges and panel board and at least two compressors. The power consumption is between 30% and 50% less than conventional water chillers. Each water chiller is equipped with an extra pump for recirculating the cold water inside the tank through the chiller once the tank is full.
Concrete Cooling through CIWP.4
Cooling Stages CIWP.4
First cooling stage
Even under the most severe climatic conditions it is possible to cool water from practically any temperature down to 35°C within an evaporative condenser without the use of a refrigeration compressor. Years of experience with concrete cooling equipment have shown that the water supply to a batching plant can reach temperatures of up to 45°C during the summer especially in the Gulf Countries such as Saudi Arabia, Bahrain, Qatar, the U.A.E., Kuwait, Oman etc.
This water is cooled down within the evaporative condenser to 35°C reducing the actual cooling capacity of the compressors by 25%.
Thus this refrigeration capacity of the first stage is free of charge.
Second cooling stage
Furthermore, it is much more efficient (by 25%) to produce refrigeration capacity at an evaporation temperature of +7°C than at 0°C. Therefore the water is cooled from 35°C down to 12°C in the heat exchanger of the second stage by the first compressor.
Third cooling stage
Then in the 3rd stage the water is cooled from 12°C down to 4°C in the heat exchanger of the third stage by the second compressor.
Fourth cooling stage
Finally in the 4th stage the water is cooled from 4°C down to less than 1°C in our special "ice bank system" by the second or a third compressor, if necessary. This system consists of a water tank in which plate or tube heat exchangers are installed. Around these heat exchangers ice can be accumulated without destroying the system. The water is circulated around these heat exchangers covered slightly with ice. That way the water temperature is between 0°C and 1°C.
Design Conditions (CIWP)
Max. air temperature: 60°C
Wet bulb temperature: 30°C
Water inlet temperature: 45°C
Water outlet temperature: < 1°C
Addition of mixing water: 160 l/m³
Max. air temperature: 60°C
Voltage: 400 V
Wet bulb temperature: 30°C
Phases: 3
Frequency: 50 cycles
Running hrs of batching plant: 12 h/day
Running hrs of ice water plant: 24 h/day
Refrigerant: R 22 or R 404a
Standard Execution (CIWP.4)
• One 20 ft or 40 ft ISO-container, new, painted white, with
air-conditioning, light and aluminum floor
• Two or four semi-hermetic compressors (up to CIWP, 4-128) or screw compressors
• One evaporative condenser with 2-circuits
• Two high efficiency shell & tube evaporators as water chillers
• One ice bank system
• Stainless steel panel with stainless steel gauges and pressure transmitters
• One water pump through chillers to ice water tank
• One water recirculation pump for sub-cooling
• Pressure control valve for freezing protection of evaporator no.2
• Flow control with indication on PLC
• Switch & control board with PLC and Touch Panel visualisation
• Assembly, piping & wiring according to German regulations
• Pressure test in our factory
Design Conditions (CCWP.4)
Maximum air temperature: 60°C
Wet bulb temperature: 30°C
Water inlet temperature: 45°C
Water outlet temperature: < 4°C
Addition of mixing water: 160 l/m³
Maximum air temperature: 60°C
Voltage: 400 V
Wet bulb temperature: 30°C
Phases: 3
Frequency: 50 cycles
Running hrs of batching plant: 12 h/day
Running hrs of ice water plant: 24 h/day
Refrigerant: R22 or R404a
Standard Execution (CCWP.4)
• One 20 ft or 40 ft ISO-container, new, painted white, with
air-conditioning, light and aluminum floor
• Two semi-hermetic piston compressors or screw compressors
• One evaporative condenser with 2-circuits
• Two high efficiency shell & tube evaporators as water chillers
• Stainless steel panel with stainless steel gauges
• Charge with refrigerant
• One water pump through chillers to ice water tank (at site)
• One water recirculation pump for sub- cooling
• Control valve for freezing protection
• Flow control with indication
• Switch & control board with PLC and Touch Panel visualisation
• Assembly, piping & wiring according to German regulations
• Test and adjustment in our factory
Requirements on Site (CCWP.4+CIWP.4)
Water (2 bar pressure) and electric power supply, insulated cold water tank (with piping) and 2 strip foundations. Tanks available in containerized version for 57 m³ or inside prefabricated suppor frames for up to 150 m³.
|
