1. HKCI Seminar HKCI Seminar HKCI Seminar Hongkong 28 . December 2012
NR Koeling BV
NR Koeling BV
NR Koeling BV

2. Improving Concrete Quality to prevent damages, complains
by cooling,
to prevent damages, complains
and follow-up-costs
Introduction
Dear Comitee,… thanks that you give me the possibility to say something about the concrete quality and temperature.
Dear Ladies and Gentleman
In 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 27°C.
On the dams should be the temperature between 12°C and 16°C. – 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.
NR Koeling BV
NR Koeling BV
NR Koeling BV
NR Koeling BV

3. NR Koeling BV

4. Methods of Cooling CONCRETE
- Heat - Balance
Chiller plant
Flake Ice plant
Aggregate cooling by ►spraying cold water
- on a special conveyor belt
- inside a special storage silo
- Aggragate cooling by► blowing cold air into storage silo
Sand Cooling by► blowing cold air
Complete solution
Configuration of the concrete cooling plant
NR Koeling BV
- Discussion

5. Heat - Balance
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6. Heat Balance NR Koeling BV Mixture Mass Temp. Heatload* COOLING
Mix Formula 1 m3 concrete
Mixture
Mass
Temp.
Heatload*
COOLING
[ Kcal/hr ]
[ kcal/hr]
Aggregate
1.300 kg
35°C
9.555
Sand
900 kg
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
Wet-Belt
10°C
9.555
Sand Cooling
15°C
6.615
Cement °C
Chilled water
125 kg 5°C
65 kg 5°C
1.050
750
Flake Ice
60 kg -4°C
-4.920
Mixer
36,9°C
Temp. After cooling
13,6°C
7,7°C
24,2°C
32,3°C
15.568
4.963
8.743
20.788
* Heatload = mass (kg) x specified heat ( kcal) x temp (°C) = kcal/hr
Concrete temperature 8°C
Mixing capacity 220 m³/h
Daily production m³/day
NR Koeling BV

7. Heat Balance : water + ice
NR Koeling BV

8. Heat Balance : water + ice + aggr + sand
NR Koeling BV

9. Heat Balance : Cooling Capacities
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10. Chilled Water
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11. Chilled Water NR Koeling BV Large air-cooler chiller plant (Ethiopia)
Small Chiller plant
NR Koeling BV

12. NR Koeling BV Panama Channel Project Water basin
Water cooled chiller unit
NR Koeling BV

13. Flake - Ice
NR Koeling BV

14. Elevating crew conveyor
Flake-ICE
Ice makers (NH3)
Cold water: 5°C
Ice Maker
No1
Ice Maker
No2
Ice Maker
No3
Ice Maker
No4
Bin Cooling
Ice
Ice
Ice
Ice
-7°C
Elevating crew conveyor
FLAKE ICE
Rake System
Ice
Day-Tank
Isolated Ice storage
NH3: Liquid +37°C
Air
Air
Evaporating condenser
NH3: Suction -34°C
Compressor
Compressor Unit
Ammonia (NH3)
Air
NR Koeling BV

15. Flake-ICE
Ice Maker
Flake Ice Plant
Flake Ice
NR Koeling BV

16. Flake-ICE NR Koeling BV
Capacity of the Flake Ice plant for the Panama project
Total capacity Ton/24Hr
Number of Ice makers pc
Number of Compressor units pc
Compressor capacity (each) kW
Evaporating temperature °C
Refrigerant Ammonia
Rake system capacity 2x 72 Ton
Volume Isolated Ice storage m3
Number of Day-tanks pc
Number of elevating crew conveyors 2 pc
NR Koeling BV

17. Flake-ICE NR Koeling BV Rake system under construction
Flake Ice Plant
Tocoma Dam Venezuela
Ice makers installed
NR Koeling BV

18. the aggregates handled on a special
Cooling Concept
Spraying cold water
the aggregates handled on a special
Conveyor Wet - belt
NR Koeling BV

19. Aggregate Wet-Belt NR Koeling BV AGGREGATE FROM STOCK PILE, 28°C
ISOLATING TUNNEL
4°C
WATER SPRAY-SYSTEM
28°C
10°C
RETURN WATER
WATER COLLECTOR
8°C
CONVEYOR BELT
AGGREGATE TO
BATCHING PLANT, 10°C
10°C
FRESH-WATER 28°C
COLLECTING BASIN
MIXING BASIN
PUMP
4°C
4°C
SETTELING BASIN
10°C
12°C
SEDIMENT
SPRAYPUMP
COLD WATER BASIN
CHILLER UNIT
PUMP
AIR
AIR
AIR
AIR
12°C
4°C
NR Koeling BV

20. Diagram showing the cooling effect against time and aggregate size.
NR Koeling BV

21. with cold water on a Belt
Wet-Belt
Aggregate sprayed
with cold water on a Belt
NR Koeling BV

22. Wet-Belt Tocoma Dam Venezuela NR Koeling BV Isolating Tunnel
Water Spray on belt
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
Wet-Belt under construction
NR Koeling BV

23. Conveyor Wet-Belt NR Koeling BV
Capacity of the WET-BELT for the Panama Canal project
Belt lenght : 220 m
Belt width m
Belt capacity Ton / hour
Belt speed ,3 m/s
Cooling capacity installed 5375 kW
Water flow m3/h
NR Koeling BV

24. Inundation - Sedimentation
Aggregate Cooling
Cold Water
Inundation - Sedimentation
into the Silo
NR Koeling BV

25. Aggregate hopper cooling by cold water in Silo
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26. NR Koeling BV Technical data Aggregate capacity* 20 - 800 Ton/hr
Aggregate capacity* 20 -
800
Ton/hr
Aggregate size 5
150 mm
Temperature difference In -Out 32 K
Lowest output temperature 8 °C
Cooling capacity**
200
5.000 kW
Outside conditions 40
Supply voltage
400
460 V
Frequency 50 / 60 Hz
Belt length ** 10
220 m
Cooling down time **  2 15
min
NR Koeling BV

27. Sedimentation System Free flow system water flow ~ 1000 m³/h
Clean water
Result
Sludge

28. Aggregate cooling by blowing cold air into storage silo
NR Koeling BV

29. Aggregate hopper cooling by cold air
NR Koeling BV

30. Diagram showing the cooling effect against the remaining time and aggregate size
NR Koeling BV

31. Aggregate cooling in Silo
Aggregate cooling by cold air
Sadi Said Marocco
NR Koeling BV
Air-blast unit

32. Large aggregate cooling system by cold air with separated storage silos,
(Gibe III Ethiopia)
NR Koeling BV

33. NR Koeling BV Aggregate silo’s for air cooling Chilled water plant
Capacity:
Aggregate: 700 Ton/Hr
Temp. :29°C  9°C
Refr.cap.: kW
Aggregate silo’s for air cooling
Chilled water plant
Large aggregate cooling system by cold air with separated storage silos, (Gibe III Ethiopia)
NR Koeling BV

34. How to cool the Sand by ROTATING SAND COOLER
NR Koeling BV

35. Sand Cooling NR Koeling BV SAND COOLER SAND FROM STOCKPILE, 28°C
Rotating Drum
Air:
2°C
Supply conveyor
COOLED SAND TO
BATCHINGPLANT, 14°C
Feeding conveyor
8°C
Return AIR :
24°C
Discharge conveyor
Cooling coil
Supply AIR :
2°C
2°C
24°C
Fan
Air-Blast unit
Sand filter
-2°C
4°C
Air
Air
Chiller unit
PUMP
Air
Air
-2°C
4°C
Water/Glycol
NR Koeling BV

36. Sand Cooling NR Koeling BV Innerview Sand cooler rotating drum
Sand cooler on job site
Tocoma Dam Venezuela
NR Koeling BV

37. NR Koeling BV
Sand cooling panama channel project

38. Sand Cooling NR Koeling BV
Capacity of the Sand cooler for the Panama project
Number of sand coolers pc
Sand capacity (each) Ton / hour
Diameter of sand cooler mm
Length mm
Cooling capacity installed 2x 775 kW
NR Koeling BV

39. Sand cooling Sogamoso Colombia
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40. Sand Cooling
Rotating drums Sand Cooler
NR Koeling BV

41. Complete solution
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42. NR Koeling BV
General Layout

43. General Layout Sonla – Dam Vietnam Inline silo with weighing system
Aggregate storage
Ice plant (for safety)
Wet belt
Mixing plant
Sedimentation
Cement and fly-ash storage
Chiller plant
Sonla – Dam Vietnam

44. NR Koeling BV

45. General layout Yewa – Dam Myanmar Mixing plant Ice plant
Sedimentation-tanks
Material storage Sand
Wet belts
Materialstorage-aggregates
Conveying belts
Charging hopper

46. NR Koeling BV

47. Concrete Cooling Plant
Configuration
of the
Concrete Cooling Plant
NR Koeling BV

48. Selection Criteria Concrete temperature at mixer outlet Plant Layout
Energy consumption
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49. Achievable concrete temperatures
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50. Plant Combinations 8°C Concrete only achievable
Cooling options
Cooling Plant combinations A B C D E F G H I
Chilled water n
Flake Ice
Aggregate cooling by Water
Aggregate cooling by Air
Sand cooling by Air
Result output temp. Concrete (°C)
34,0
25,3
12,7
13,6
16,5
12,8
13,7
8,0
8°C Concrete only achievable
with Plant combination H and I
NR Koeling BV

51. Multiple cooling combination needed
Plant Combinations
Multiple cooling combination needed
to achieve 8°C Concrete
NR Koeling BV

52. Flake Ice uses the most energy compared to the other methods
Energy Consumption (electrical)
Flake Ice uses the most energy
compared to the other methods
NR Koeling BV

53. 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…. )
NR Koeling BV

54. Thanks for your
attention
谢谢！ 2