Concrete Cooling with Ice Water & Cold Water
General Features
Our latest (4th generation) containerized chillers – type CIWP.4 – are specially designed for cooling the mixing water for batching plants from 45°C down to less than 1°C (higher inlet temperatures are possible upon request). Using evaporative condensers and a 4-stage cooling system these new containerized chillers are superior to any common water chiller available in the world.
Reasons for Concrete Cooling through Ice Water & Cold Water Plants
And these are the reasons:
An evaporative condensing system is superior to common air-cooled systems due to considerable differences in condensing pressures and temperatures. Furthermore, our system guarantees the automatic elutriation of the condenser with its self-cleaning effect. All our condensers are fully hot-dipped galvanised, thus ensuring the longest possible life expectancy.
Compressors
We use semi-hermetic compressors made by “BITZER”, the world famous German manufacturer, to make sure that our customers not only get one of the most reliable compressors in the world but also receive proper service and spare parts everywhere and at any given time.
Gauge and Control Panel
The panel itself and the big diameter gauges for suction, discharge and oil pressure are all made of stainless steel assuring best visibility of the plant performance and longest life expectancy.
Switch and Control Board
The switch and control board of all KTI-Chiller plants is equipped with a high quality reliable PLC System. We designed and developed a new visual display which is a self explaining, comfortable and reliable way to operate Ice Plants and Water Chillers by a touch panel. It is both manufactured strictly according to German Regulations (VDE) and equipped with the best electrical components available in the market. The panel board is designed for tropical use.
Touch Panel
The installed Touch Panel indicates all Alarm messages and provides a HELP option for easy troubleshooting. More over all pressure settings and temperature settings are done at the panel. All six relevant water temperatures, and the water flow rate are indicated in the Touch Panel. The water level in the cold water tank is adjustable and indicated at the panel.
The PLC is equipped with an ethernet network interface to realize a remote control of the plant.
Cold Water Pump
The water pump which is pumping the water from the evaporative condenser through the 3 chillers to the cold water tank is included in our scope of delivery.
Sub-cooling (Recirculation Pump)
Our containerized ice water plants are equipped with sub-cooling facilities. That means that the water inside the cold water tank is recirculated through the 3rd and 4th stage after it has reached its upper limit. That way, we guarantee that the water inside the cold water tank always has the lowest possible temperature. The required sub-cooling pump is included.
Container Assembly
Our chillers are assembled in our new and latest installation facilities by the most experienced refrigeration technicians inside of a 20-ft or 40-ft container. This container is painted white on the inside and outside and equipped with lighting and an air-conditioning unit. Therefore the doors of the container can be kept closed. This avoids that dust and humidity enter the machinery container.
We use brand-new containers only. The floor of the container inside is layed with chequered aluminum sheets, to avoid rust build-up on the floor.
The ice water plant is assembled, piped, wired and pressure tested completely in our factory, prior to shipment.
Plug-in Units
Once power and water have been connected, the plant is ready for operation. All safety and control devices are properly adjusted so that the installation of the plant can be done within one day including commissioning. The same applies for the dismantling of the plant.
Just connect our plant to the water and power supply as well as to the insulated cold water tank on site and the plant isready to run.
This is also very important for contractors who are changing their site quite frequently.
Power Savings
Compared to conventional air-cooled water chillers (which are actually designed for air-conditioning purposes only) KTI Ice Water Plants have a lowerpower consumption of up to 55%.
Lower Concrete Mixing Temperature
With 1°C water the lowest possible concrete temperature (approx. 30°C depending on the aggregates) can be achieved by means of ice water. Lower temperatures are only possible by adding Flake Ice to the mixer. For indication, any 4 degree lower water temperature improves the concrete temperature by 1 degree.
Ideal Supplement to Flake Ice Plants
The Containerized Ice Water Plants of KTI – CIWP – are actually a must before a flake ice machine is considered for concrete cooling. It is always recommended to cool down all water for the batching plant as low as possible in order to get the best possible performance of the Flake Ice Plant installed eventually at a later stage. Compared to a Flake Ice Plant, an Ice Water Plant with the same refrigeration capacity costs only 25%. This illustrates the effectiveness and importance of a KTI Ice Water Plant.
Extremely effective supplement: Prefabricated insulated Cold Water Tanks from 57 m³ to 150 m³.
Prefabricated Cold Water Tanks
A full range of perfectly insulated cold water tanks is available, ideally suited for the support of chillers or ice storages with flake ice plants. The necessary stairways and platforms are available in galvanized execution.
• Containerized Cold Water Tank – insulated – 57 m³; chillers to be
installed on top
• Insulated cold water tank – 150 m³ – inside steel frame for support of
chillers or ice storage and flake ice plant
