Concrete Cooling - Hansa Industrieanlagen

v3.1 – 042006
Concrete Cooling
Cooling
Modular Concrete Cooling Systems
Water Chillers
Iced Water Chillers
Flake Ice Plants
Ice Storage Systems
Ice Conveying Systems
Dam Projects
Hansa Industrieanlagen GmbH
P.O.Box 1203
D-89250 Senden/Germany
Tel.: +49 (0)7307/9717-0
Fax: +49 (0)7307/9717-21
mail@hansa-industrieanlagen.de
www.hansa-industrieanlagen.de

Finding the Finding perfect the technical perfect technical solution for solution your specific for your requirements
specific requirements
Consulting, Computation, Design
Every concrete batching plant has it’s very own demand for
refrigeration, depending on the local ambient temperatures, quality
of water, production hours and many other operating
characteristics. Our consulting engineers will find out the perfect
solution for your project. First of all, please fill in the attached
questionnaire that will enable us to make a first computation of
the cooling requirement. After that we will contact you to discuss
the technical specification.
Step by Step
Depending on the required cooling demand, one of the following
refrigeration plants or combinations of them will be the best
solution:
cooling plant cooling media
A) chilled water plants water +4°C
B) iced water plants water +1°C
D) flake ice machines ice –5°C
E) aggregate cooling systems
All components of our concrete cooling plants (water chillers, ice
machines, ice storage, conveying systems) come in containerized
and/or modular design. They can easily be extended and are
prefabricated and mobile to a high extend.
The following pages will introduce you to the technique, the pros &
cons and the range of application of these machines. Pictures and
technical drawings will give you a first impression of the reliability
and quality of our refrigeration plants. For more detailed questions
please do not hesitate to contact us
The Refrigerants
Engineering
Besides the widely used CFC or HCFC-refrigerants, especially
larger refrigeration machines are preferably equipped with
Ammonia, which is a natural and very economical refrigerant and
allows for highest COP-values (Coefficient of Performance)

Cooling of batching water – Pre-Cooling of water for Ice production – Aggregate Cooling
Containerized concrete cooling plant in Saudi Arabia
Flowing Diagram of a containerized chilled water plant
Water Chillers
Inside view of containerized water chiller with ice plant 24to
Containerized Water Chillers
Our containerized water chilling units
are working with one, two or three step
chilling systems, depending on water
inlet temperature and specific conditions
of your project.
Independently working cooling circuits
with one or more evaporators (chillers)
will cool down the batching water to
+3°C (TIWK CA-System) or approx.
+4°C (HI CWP-System).
The whole cooling system is built in a
20’ or 40’ container, with doors, ventilation
and light. The chillers are
equipped with air cooled-, water
cooled- or evaporative condensers.
For buffering the chilled water, which is
produced during the night time, a
chilled water buffer tank (simple earth
tank or containerized tank) should be
installed locally. The stored water is recirculated
through the chiller in order to
compensate heat up in the buffer tank.
Containerized water Chillers are available
from 20kW to 1500kW / unit.
Range of application
Chilled water systems are used
A) in case of small or medium
cooling demand, whenever
medium concrete temperatures are
sufficient or gravel, cement and
admixtures are already at lower
temperatures.
B) for pre-chilling the water and 1 st
step cooling, when Flake Ice
Machines are used additionally.

Cooling of Batching water
Containerized Iced Water
Chillers
The containerized iced water
chillers produce Iced water of
below +1°C. In these systems
the pre-cooled batching water
is streaming over the frosted
surface of a plate evaporator
system.
The whole system can be built
into a container, with door,
ventilation and light. The
chillers are equipped with air
cooled-, water cooled- or
evaporative condensers.
Range of application
Iced water systems +1°C are
mostly used
in case of small or medium
cooling demand. These
systems are very economical
if the reduction of the water
temperature to +1°C helps to
avoid ice application.
Iced Water Chillers
Flowing Diagram of a containerized iced water plant with two step prechilling
of the batching water
Containerized Iced water plant with buffer tank

Highly effective cooling
motor
distributor
steel cylinder
(double wall)
rotating scraper
insulated cylinder
water pump
Fully Containerized Ice Plant (15to/day)
Flake Ice Plants
Containerized Flake Ice Machines
Flake Ice is the ideal cooling media,
whenever a large cooling potential is
needed. The dry and slightly subcooled
flake ice has a cooling capacity
of more than 80 kcal/kg (this
is 20 to 70% higher than of wet ice).
With its large surface and little
thickness it melts very fast during the
mixing process.
It is very easy to store and to
handle, as it doesn’t stick together
when stored at minus temperatures.
Each Ice generator has a capacity of
5 to 50 tons of ice/day. They can be
combined in modules in order to
achieve even higher ice production
per ice plant.
Each 10kg of ice will cool down 1m³
approximately by -1°K.
Flake ice is produced inside a double
wall steel cylinder. Water is pumped
into the top of the distributors and
flows over the cold inner surface. A
scraper is flaking the ice off.
Range of application
Flake Ice is used in case of medium
and large cooling demand,
whenever low concrete temperatures
have to be granted even during the
very hot periods of the day.
For best quality concrete even at high
temperatures of cement, gravels and
admixtures.
The Flake Ice Plants are usually
combined with a chilled water plant.

Reliable systems for ice storage, ice extraction and ice conveying
For economical reasons ice making
plant usually are designed for operation
of 24 hours/day. This means that the
overnight-production needs to be stored
in an ice storage silo.
A) Orbital Ice Silos
Orbital ice Silos are available for
capacities of up to 25to. Orbital silos
stand for high storage quality, due to the
FIFO (first in – first out) principle.
Discharge and dosing are done by a
rotating screw extractor.
All parts of the orbital silos, which are in
contact with the ice are made of stainless
steel or polyester.
B) Rake Systems
Ice Silos with Rake Systems are available
as containerized Version (Storage
capacity 20 or 40to) or as Modular Rake
Systems which are set up in a locally
erected cold store room (up to 200to).
B) Non-Automatic Silos
A low cost, simple solution can be
realized by using a container silo without
rake. The ice is stored in a refrigerated
and well insulated container, which can
be placed under the ice generators.
Ice conveyors
Depending on the type of mixing plant,
the distance from silo to mixer and other
parameters, belt, screw or air
conveyors combined with different types
of ice scales can be used.
Please contact us to find out which is
the best ice storage and delivery
system for your project.
Ice Storage
Ice Extraction
Ice Conveying
Tonnes of Ice
25
20
15
10
required size of the ice silo
ice stockage
in the silo
working hours
Production (20to/24h)
5
0
safety stock (2to)
0 5 10
hours per day
15 20
A)
Orbital ice silo for small
and medium ice
storage volume
Consumption (20to/10h)
B) ice plant 40to/day with modular rake silo system 100to
C)
Non-automatic
simple ice silo
24

Combination of aggregate cooling / ice addition / water cooling
Ice Silo 150to and Ice Plant 120to/day for Dam Project
Water Chiller with Q=3.0MW with water storage basin
Pre-Cooling of aggregates in a pre-cooling silo.
Ice
Aggregates +6°C
+6°C
+6°C
Inline Silo
Wet Belt
Dewatering
Dam Projects
+3°C Water
+3°C Water
The right choice
Cooling
Cooling
Silo
Silo
Silo
Stock Pile
There is no application where the concrete
temperature crucial than with mass concrete,
especially on dam projects.
Depending on the type of dam and on which
type of concrete (RCC/CVC) is utilized, the
allowable concrete temperature in the mixer
varies between about +18°C and +6°C.
Combination of Cooling Systems
HANSA INDUSTRIEANLAGEN has realized and
designed concrete cooling systems for RCC
and CVC dams for concrete temperatures as
low as +6°C.
Usually dam projects always require precooling
systems for the coarse aggregates. The
aggregates are usually cooled down by means
of water or air either in a pre-cooling silo or on
a wet-belt (depending on required
temperature). For pre-cooling of gravel the
right know how is very important in order to
guarantee constant aggregate temperature
and low moisture at the entrance to the
working silos. Reliability, Flexibility, Energy
Efficiency and Environmental Protection are
main duties of modern Concrete Cooling
Systems
For low concrete temperature also flake ice will
be added to the mixer. HANSA supplies the full
range from ice plants, to ice conveying, ice
weighing and ice storage systems in many
types of sized and technologies.
In 2003 to 2005 two of the major dam
projects in South East Asia chose HANSA for
concrete cooling.

Ice
Aggregates +5°C
+5°C
+5°C
+1°C Water
Inline Silo
Dewatering
Wet Belt
+3°C Water
Dam Projects
Stock Pile
Containerized Water Chillers Q=4.5MW (600m³/hr water) Wet Belt (150mtr) for Aggregate Cooling
Wet Belt for Aggregate Cooling (inside view) Containerized Ice Plant 120to/day and Ice Silo 100to
Ice Distribution, Day Tank, Ice Weigher Ice Distribution, Day Tank, Ice Weigher