Concrete Cooling through Flake Ice Plants

From the cold water tank the water is delivered partly directly to the scale of the batching plant and partly to the flake ice plants. KTI flake ice plants are installed inside of 40-ft. containers. The sizes vary from 20 to 100 tons daily capacity per unit.
Modular flake ice plants (consisting of 2 containers) can be manufactured up to a size of 200 tons per day. All flake ice plants are equipped with ice makers with non-rotating drums avoiding the danger of leakage through a shaft-seal.
The flake ice is removed by ice removal tools on the inside of the drum. The optimum ice thickness is 1.5 mm which guarantees the highest possible output and the shortest possible mixing and melting time inside the mixer. The flake ice is sub-cooled to approx. - 7°C thus remaining cisp during storage and transportation.


Containerized Flake Ice Plants (FLIP) for Tropical Conditions

About Flake Ice

Flake Ice is small ice in flat pieces.
It is used in concrete cooling, cooling seafood, in meat processing and in a whole range of industrial processes. The most important application of KTI-Flake Ice Plants is in the concrete cooling industry, where flake ice is used to control the concrete temperature, particularly in hot climates.
Slightly sub-cooled (-7°C) Flake Ice is also a dry ice, which means that the latent heat, the principal source of the cooling energy is 100 % available.
Due to the dryness, the cooling input of Flake Ice can be accurately calculated and its effects on the mixtures temperature are quickly apparent.
Flake Ice is free flowing, its flakes do not stick together nor do they form blocks. Therefore it is easy to store and to handle.
Due to the above features and because of its moderate production costs – compared to most of the other kinds of ice – Flake Ice is used in large quantities in many industrial (e.g. concrete cooling) and food processes.


Flake Ice Production

To begin the ice making process, water is pumped from a recirculating water tank to the top of the rotor. It is then distributed to the freezing surface where it freezes immediately. After subcooling the ice is sheared from the surface by the ice removal tools and it falls out of the bottom of the ice maker. Any water that does not freeze returns to the water tank for recirculation.


Further Applications of Flake Ice

• Fishing/aqua-culture industry
• Produce industry
• Chemical field
• Concrete Cooling
• Poultry industry
• Meat processing
• Dairy industry
• Energy conservation
• Baking industry


Options (on Request)

• Semi-hermetic piston or screw compressors
• Stainless steel ice maker
• 60 cycles design
• Combinations with water chillers within the machinery container


Accessories and Additional Equipment

• Containerized Ice Storages (MIS) for 18 and 23 tons
• Mobile Ice Storages (MIS) for 40, 50, 60, 75 and 90 tons
• Ice Storages (IS) up to 200 tons
  (All ice storages are equipped with optimized air-circulation systems
   and automatic ice rake.)
• Ice delivery (screw and belt conveyors and blowing systems)
• Weighing systems
• Intermediate holding hoppers (day tanks)
• Prefabricated steel frames for the support of the Containerized and
   Mobile Ice Storages with and without integrated and insulated cold
   water tank
• Prefabricated steel frames for the support of the Containerized and
   Mobile Ice Storages with integrated ice weighing and ice blowing
   sytems
• Containerized Cold or Ice Water Plants (CCWP or CIWP)



KTI’s unique modular design for concrete cooling makes it possible that the installation of the ice plants, ice storage, delivery and weighing systems including start-up is finished within a few days.


Standard Execution

• One new ISO-container, painted white with air-conditioning, light and   aluminum floor
• Piston or screw compressors
• Electric motors – IP 55 – insulation class F
• One evaporative condenser
• One or two ice makers with level control
• Automatic oil return system
• Flow control with indication to ice maker
• Switch & control board for fully automatic operation
• Stainless steel panel with stainless steel gauges
• Assembly, piping & wiring according to German regulations
• Adjustment in our factory


The latest Generation of Operation and visualized Control of KTI-Plants

KTI always is attempt to design reliable high quality plants. The new Generation of KTI-Flake Ice Plants and KTI-Ice Storages with discharge system is equipped with a high quality reliable Siemens S7-300 PLC and a Touch Panel.
KTI realizes a visualization and developed a very comfortable operation system of the plant.

Downlaod PDF (330 KB)


The latest Generation of Visual Display and Controls of KTI-Plants

Continuous improvements and developments are a buzz word in KTI which lead us to the design of reliable and user friendly high quality plants. The new generation of KTI - Ice Plants and KTI – Chiller Plants1 are equipped with a high quality reliable Siemens S7 PLC system.
KTI designed and developed a new visual display which is a self explaining, comfortable and reliable way to operate Ice plants and Chiller plants by touch panel.

Downlaod PDF (412 KB)


Requirements on Site

• Water (2 bar pressure, 5°C)
• electric power supply
• adequate foundations


Design Conditions

Max. air temperature: 60°C
Wet bulb temperature: 30°C
Water inlet temperature: 5°C
Ice outlet temperature: -7°C
Refrigerant: ozone-friendly freon or ammonia
Voltage: 400 V
Phases: 3
Frequency: 50 cycles
Running hours flake ice plant: 24 h


KTI Design for Concrete Cooling Industry

For many years KTI has designed and produced Containerized Flake Ice Plants which have been operating throughout the world under the most extreme climatic conditions – to the fullest satisfaction of our customers. Plants with daily capacities from 10 to 100 tons per unit are available either as plug-in or split units with water cooled or with evaporative condensers.


First Class Components

North Star Flake Ice Maker

Versatile
Makes ice from fresh water, seawater or other liquids (orange juice, blood etc.). Uses ammonia or ozone-friendly refrigerant. Approved for food processing plants. Carbon or stainless steel freezing surface.

Economical
Produces more ice than any other ice maker using an equally rated compressor. Operates continuously with no defrost cycles. Makes the coldest ice with better cooling power than any other ice maker. Reduces refrigeration losses with insulated fiberglass enclosure.
Converts all water to ice without water loss. Saves space with compact design. Requires minimal maintenance.

Dependable
Designed with only one major moving part and no refrigerant seals. Built for industrial use with high quality heavyduty parts.

Faster cooling and mixing
North Star Flake Ice provides more than 1750 m2 of cooling surface per ton compared to 400 to 1000 m2 of other types of ice.

Greater product protection
North Star Flake Ice stays dry, packs well and cushions products against damage.

Compressors
The heart of each ice plant are either BITZER or SABROE compressors (piston or screw).
Both compressors have proved their superiority in countless applications throughout the world setting the standard in terms of performance and durability.
From 31 tons/day production capacity onwards 2 or more screw compressors are installed with a motor size of 55 kW and 84 kW for each compressor, which is a big advantage during start-up (low start-up current) and increases the reliability of each plant.

Gauge and control panel
The panel itself and the big diameter gauges for suction, discharge and oil pressure are all made in stainless steel assuring the best visibility of the plant performance and longest life expectancy.

Switch and control board
The switch and control board withall its starters, timers, contactors, fuses etc. is tropical-insulated. It is both manufacturedand wired strictly
accordingto German Regulations (VDE) and equipped with the best electrical components available in the market. Furthermore it is equipped with all lights necessary for the indication of normal operation and of possible disturbances.