In the construction of large volume concrete, pouring of super high-rise buildings, or low-temperature environmental engineering, controlling the internal temperature rise of concrete is the core link to ensure the durability of the structure. Traditional cooling methods such as water pipe circulation and ice water mixing often face problems such as low efficiency, high energy consumption, and poor temperature control accuracy. Plate exchange chillers, with their efficient heat exchange performance and precise temperature control capabilities, have become the preferred technical solution for achieving the goal of "low-temperature molding" in concrete engineering.
Pain points of concrete temperature control and technological breakthroughs in plate exchange chillers
1. Limitations of traditional cooling methods
Natural cooling method: relying on concrete to dissipate heat by itself, it is difficult to meet the strict requirement of internal temperature rise ≤ 25 ℃ for large volume structures (such as bridge piers and nuclear power plant bases);
• Circulating water pipe method: The layout of cooling water pipes is complex, and the cooling water temperature needs to be 5-8 ℃ lower than the concrete outlet temperature, and the circulating energy consumption accounts for more than 40% of the total energy consumption of the system;
Ice water mixing method: The ice making process takes a long time, and the uniformity of the ice particles and concrete mixture is difficult to ensure, which may lead to local supercooling or uneven temperature.
2. Core advantages of plate exchange chillers
The system achieves precise control of cooling water temperature through the collaborative design of "plate heat exchanger+chiller", with key technical features including:
Efficient heat exchange efficiency: optimized design of plate heat exchanger flow channels, with a heat transfer coefficient (K value) of 3500-4500 W/(㎡· K), which is 30% higher than traditional shell and tube heat exchangers;
Dual temperature regulation capability: The cooling side outputs 7 ℃ cooling water (used for cooling the heat exchanger), and the temperature of the water used for concrete mixing can be stabilized at 1-2 ℃;
Modular integrated design: The cooling capacity of a single unit covers 50-1000m ³/h, adapting to diverse needs from small prefabricated components to super high-rise core tube pouring.
System operation process and control logic
[chiller] → refrigerant circulation → cold side of plate exchanger (1 ℃ cooling water)→ Heat exchange → Plate heat exchanger hot side (concrete mixing water)→Temperature detection and PID control→ Mixing plant metering system → Concrete outlet temperature control
Technical difficulties and system optimization path
1. Special challenges of plate exchange units
Scaling and corrosion issues: Calcium and magnesium ions in cooling water are prone to deposit on the heat exchange plates, leading to a decrease in heat transfer efficiency. The solution includes:
Regularly add scale inhibitors;
Using 316L stainless steel plates, the corrosion resistance coefficient is increased by 50%;
Online cleaning device: Regularly rinse the plate side by circulating high-pressure water in reverse (pressure ≥ 3MPa).
Risk of ice crystal blockage at low temperatures: When the cooling water temperature is ≤ 2 ℃, dissolved oxygen in the water precipitates to form ice crystals. The response measures include:
Install magnetizers in the circulation pipeline to reduce the probability of ice crystal formation;
Design a bypass circuit that automatically switches to high temperature difference mode when the temperature is below 3 ℃.
2. Direction of intelligent upgrade
Digital twin system: Build a virtual unit model, simulate heat exchange efficiency and energy consumption in real time under different operating conditions, and optimize operating parameters;
Adaptive load regulation: Based on data such as pouring progress prediction and environmental temperature changes, the power output of the unit is dynamically adjusted to reduce energy consumption fluctuations;
Remote operation and maintenance platform: Implementing status monitoring and fault diagnosis through NB IoT modules to reduce on-site maintenance frequency.
Industry value
1. Deep value of concrete engineering
Quality assurance: The improvement of temperature gradient control accuracy reduces the risk of early shrinkage cracks in concrete by 40%;
• Duration compression: By precise temperature control, the maintenance period can be shortened, and the construction period of a single project can be shortened by 7-10 days;
Green and low-carbon: Compared with traditional cooling tower solutions, plate exchange units can reduce evaporation water loss by 80%, which meets the requirements of "water-saving construction sites".
2. Future direction of technology integration
Integration with the automation system of the mixing plant: realizing the "three in one" intelligent control of concrete temperature, mix proportion, and discharge time;
• Clean energy drive: exploring the use of photovoltaic power generation to power chillers;
Modular mobile unit development: For remote projects, design a sled mounted system that can be quickly disassembled and transported, and complete on-site deployment within 12 hours.
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