Project Overview
In the dry and hot Middle Eastern environment, commercial concrete mixing plants of large capacity required an efficient cooling system to create quality concrete. In a region where ambient temperatures regularly exceed 40°C (104°F), the project required a robust system to maintain concrete mix temperatures in an ideal range and prevent premature setting. To counter these challenges, the ZNX-1180 evaporative condenser with a nominal cooling capacity of 1180 kW was selected as a major item in the plant’s cooling system.
The Challenge
The production of commercial concrete (ready-mix concrete) within hot climates is extremely challenging. Ambient high temperatures can potentially increase the temperature of the concrete mixture, thereby causing fast hydration, reduced workability, and compromised strength. The system required an evaporative cooling system capable of supplying chilled water around 1-5°C (34-41°F) to chill the aggregates and mix water so that the final temperature of the concrete mix is below 18°C (65°F). The system also required being energy-efficient, effective, and robust enough to operate for extended periods in a harsh desert environment.
The Solution: ZNX-1180 Evaporative Condenser
The ZNX-1180 is the evaporative condenser of choice for its high efficiency and suitability for hot, dry climates. The innovative cooling device employs evaporative cooling technology to deliver stunning reductions in temperature with lower energy expenditure than traditional air-cooled systems. The key benefits of the ZNX-1180 include:
- High Cooling Capacity: With a nominal capacity of 1180 kW, the unit is well positioned to handle the cooling demands of large-scale concrete production.
- Energy Efficiency: The three-stage cooling cycle of the evaporative condenser reduces power usage by up to 30% compared to conventional water chillers.
- Strong Design: Built with hot-dipped galvanized steel and stainless steel heat exchangers, the ZNX-1180 is designed to resist the corrosive nature of the desert climate and deliver long-term performance.
- Uninterrupted Operation: The system is designed with automated controls and sensors, facilitating smooth integration into operations of the concrete plant and uninterrupted operation.
The ZNX-1180 was integrated into a chilled water plant, supplying cold water to chill aggregates and mix water. The system supplemented insulated cold water storage tanks to maintain steady low temperatures, maintaining the concrete to strict quality levels for large-scale infrastructure projects, including highway development and commercial building developments.
Implementation
Installation of the ZNX-1180 evaporative condenser was completed within one week with its modular, containerized design requiring only compacted soil foundation and 50-ton crane for installation. The cooling system of the plant was prepared for the high concrete production rate of 200 cubic meters per hour. The ZNX-1180 was supplemented with a flake ice plant to attain further cooling efficiency at extreme summer conditions, granting precise temperature control of the concrete mixture.
Automation features of the system, including temperature controllers and sensors, allowed real-time monitoring and regulation, minimizing energy waste and offering optimum efficiency. The low-noise feature and enclosed design of the evaporative condenser also minimized environmental pressure, in harmony with the project’s sustainability ideals.
Results
The ZNX-1180 evaporative condenser installation delivered outstanding performance:
- Uniform Concrete Quality: The system provided uniform mix temperatures below 18°C (65°F), which guaranteed high-grade workability and strength of concrete for critical infrastructure projects.
- Power Savings: The energy-efficient architecture of the ZNX-1180 saved approximately 30% of power compared to traditional cooling, lowering operational costs.
- Reliability Under Extreme Conditions: The rugged construction and high-quality materials ensured uninterrupted operation even in hot weather conditions.
- Environmental Benefits: The system’s low usage of water and the ability to reduce noise caused environmentally friendly operations, with compliance to local environmental standards.
Conclusion
The ZNX-1180 evaporative condenser was the ideal solution for the Middle East commercial concrete mixing plant project. Its huge capacity, energy-efficient, and long lifespan addressed the issues of producing high-quality concrete in a hot and arid environment. This successful experience is proof of the ZNX-1180’s ability to meet large-scale construction projects with cost-saving and environmentally friendly cooling solutions.
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