turbomatic presentation

TURBOMATICTM heating system

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Introduction

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Innovative front-runner

• Polarmatic Oy is a leading developer and supplier of…

• Heating,• Cooling,• Automation as well as• Information management & measurement solutions

…for the concrete industry• Polarmatic’s solutions are specifically developed

for the concrete industry• Since the early 1970's the name Polarmatic has • earned itself a strong and dependable reputation

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Innovative front-runner

• The TURBOMATICTM heating system was specifically developed to solve all heating and heat treatment needs in batching plants and precast concrete factories, including:

• Quick melting of ice in aggregates and efficient pre-heating & heating of aggregates

• Curing• Production of all thermal energy (warm water)

needed for process, heating and/or utility purposes

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Total heating system solution…

• The main functions of the TURBOMATIC in the concrete and/or precast concrete production process are:

• thawing of frozen aggregates and pre-heating & heating of aggregates• generation of warm dosing water and/or• generation of warm air, warm water, TURBOsteam or steam for curing

• The TURBOMATIC is also capable of handling all other batching plant and precast concrete factory heating needs (heating options), including:

• heating of concrete batching plant facilities• production of warm wash/fill water for truck mixers etc• heating of precast concrete factory production halls and

facilities (offices, laboratories etc)• heating of other associated production halls and facilities• production of warm utility water

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…specifically for the concrete industry

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Water scalewarm dosing water

Receiving hopper(s)Aggregate ice melting and pre-heating Batching

plant facilities heating

Cold water

Control room

Truck mixer warm water for wash/tank fill

TURBOMATICTM

Aggregate silos Aggregate heating

Production facilitycuring, facility etc heating

Cold water

Aggregate storage (outdoor)Aggregate ice melting

Fuel oil/Natural gas

PLC

Mixer

Curingw/ TURBOsteam

Curingw/ steam

Technical features

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Selection of TURBOMATIC

• The TURBOMATIC is selected based on the following criterias:• Application/purpose of usage (TURBOMATIC model)• Main functions & heating options• Capacity• Fuel• Structure/layout

The TURBOMATIC is always customised to meet customer-specific requirements!

TURBOMATIC

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TURBOMATICModels

Model Application

TURBOMATIC thermal energy unit•minTURBOMATIC•stdTURBOMATIC•maxTURBOMATIC

for all heating and heat treatment needs in batching plants and precast concrete factories

- for moderate climate conditions and lower heating reauirements- for moderate to severe climate conditions- for extreme climate conditions and high, 24/7 heating requirements

TURBOMATIC hot gas generator

for aggregate heating or curing only

TURBOMATIC warm water generator

for generation of warm water only

CUREMATIC for generation of curing-steam in precast concrete factories

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TURBOMATICCapacity

Capacity 300 kW 500 kW 750 kW 1000 kW 1250 kW 1500 kW 2000 kW

TURBOMATIC thermal energy unit- minTURBOMATIC- stdTURBOMATIC- maxTURBOMATIC

x x xx x

xxx

xx

xx

TURBOMATIC hot gas generator x x x x x x

TURBOMATIC warm water generator x x x x x x x

CUREMATIC x x x x

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Main functionsTURBOMATIC thermal energy unit• The main functions of TURBOMATICTM thermal energy unit are:

• Quick melting of ice in aggregates and efficient pre-heating & heating of aggregates,• Generation of warm dosing water

and/or• Generation of TURBOsteam for curing

Cold water

TURBOMATICTM

Water scalewarm dosing water

Cold water


Aggregate silos Aggregate heating

Curing chambersCuring

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Main functionsTURBOMATIC hot gas generator• The main functions of TURBOMATICTM hot gas generator is:

• Quick melting of ice in aggregates and efficient pre-heating & heating of aggregatesor

• Generation of TURBOsteam for curing

Cold water

Aggregate silosAggregate heating



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Main functionsTURBOMATIC warm water generator• The main functions of TURBOMATICTM warm water generator is

production of warm water for heating purposes

Cold water


Production halls, offices etcFacility heating

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Main functionsCUREMATIC• The main functions of the CUREMATICTM is generation of steam for

curing

Cold water


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TURBOMATIC thermal energy unitHeating options for batching plants

Batching plant facilities heating

Cold water

Truck mixer warm water for wash/tank fill

TURBOMATICTM

Production facility, office etcheating


PLC

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TURBOMATIC thermal energy unitHeating options for precast concrete factories

Batching plant facilities heating

Cold water

TURBOMATICTM


Precast concrete mould/ hollow core slab bed heating

Productionhallheating

Office, laboratoryetc. heating

Production facility, office etcheating

TURBOMATICFuel alternatives

• Fuel alternatives are light fuel oil (diesel) or natural gas* • When flexibility is needed the TURBOMATIC can be equipped with

combi-burner, which enables the use of both light fuel oil and natural gas* also other gaseous fuels such as propane

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TURBOMATICFuel oil tank

• The TURBOMATIC can be delivered with a separate oil tank or a fully integrated oil tank located inside the container

Kylmä vesi

Oil tank

PLC

Hot water tank

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TURBOMATIC Layout/Structure

• The TURBOMATIC is available in two structural versions:• container - built in a thermally isolated 6 or 12 m container; weather-proof for outdoor use* • rack - built on a steel frame; for indoor installation

• Factory-finished and test-run (at factory)

• TURBOcontainer color is selected in accordance with customer specifications

note! miniTURBOMATIC w/o insulation

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TURBOMATICControls

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• The batching plant operator is responsible for controlling the TURBOMATIC• The main tasks of the operator is to…

• monitor the aggregate temperatures• add heating to the silos (set time) and heat water (set temperature)• to monitor and control other heating related equipment and systems

• Automated scrubbing of heat transfer surfaces ensures optimum performance and further adds to the ease-of-operation

TURBOMATICControls

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Standards applied in the design and manufacturing:• Safety of Machinery, Basic concepts, SFS-EN ISO 12100-1

general principles for design. Part 1

• Safety of Machinery, Basic concepts, SFS-EN ISO 12100-2

general principles for design. Part 2

• Safety of Machinery, Electrical equipment of SFS-EN 60204-1

machines. Part 1

• Automatic shut-off valves for gas burners SFS-EN 161

and gas appliances

•The TURBOMATIC thermal energy units are manufactured utilizing first rate materials and components which fulfill the requirements of the

• CE norm • EMC-directive in regards to electromagnetical disturbances.

•The design and manufacturing complies with the laws and regulations currently valid in Finland and EU

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TURBOMATICQuality

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note! in Canada CSA and TSSA approvals; in USA UL-approvals

TURBOMATICQuality – Certificates and approvals

Country Certificate/approval Description

FINLAND No. 955/33/2009 Oil equipment installation permitTUKES, safety technology authority

FINLAND No. 1169/343/2009 Natural gas equipment installation permitTUKES, safety technology authority

FINLAND No. 1087/55/2009 Electrical equipment installation permitTUKES, safety technology authority

RUSSIA POCC FI.MP04.B10025 Certificate of conformity / GOST

RUSSIA No. PPC 00-31191 Natural gas certificate

RUSSIA No. 67.CO.01.482.P.001956.09.05 Sanitation permit

BELARUS No. 06-564-2010 Permit for usage

GERMANY Warm Engineering 15.2.2010 Verification of compliance with relevant regulations in Germany

Operating principles

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Innovative TURBOtechnologyTURBOMATIC thermal energy unit

The fast, effective, energy efficient and environmentally friendly operation of the TURBOMATIC thermal energy unit is based on leading the combustion gases to aggregate receiving/storage facilities and/or curing either…

• directly through a TURBOsteam generator (TURBOsteam) and/or • through a heat exchanger located inside the TURBOMATIC’s

hot water tank (TURBOgas)

…thereby transferring the energy contained in the combustion gases to the water in the tank and to the aggregates/for curing – always recovering 100% of the input fuel energy

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TURBOgas/-steam

Dosing water

Heating registers

The heating registers located inside the bins are specifically designed for each bin type & design:• elevation of angle plates• arrangement• number of angle plates - vertical - horizontal• no. of inlets/feeds

Innovative TURBOtechnologyTURBOMATIC thermal energy unit

Water heating

Fast, effective and efficient TURBOMATIC thermal energy unit

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Silo 5

Hot water tank

TURBOgas ≈ 150-200oC

Silo 1Silo 2

Silo 3Silo 4

Cold water

Warm dosing water

TURBOMATICTM

Aggregate heating

Fast, effective and efficient TURBOMATIC thermal energy unit

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Silo 5

Hot water tank

TURBOsteam≈ 250oC

Silo 1Silo 2

Silo 3Silo 4

TURBOMATICTM

Innovative TURBOtechnologyTURBOMATIC hot gas generator

The fast, effective, energy efficient and environmentally friendly operation of the TURBOMATIC hot gas generator is based on leading the combustion gases to aggregate receiving/storage facilities and/or curing…

• directly through a TURBOsteam generator (TURBOsteam)

… to the aggregate silos or curing chambers

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Benefits

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Benefits: superior effectiveness, efficiency and economySingle TURBOMATIC handling all batching plant and precast concrete factory heating requirements…•Increased annual concrete and/or precast concrete production due to superior heating power and/or use of warm concrete•Production of high quality concrete with optimum water-to-cement ratio and temperature and production of high quality pre-cast concrete end-products with hot concrete•Significant savings in fuel consumption – as high as 60-80%•Lowest possible operating costs – no annual inspections, no certified operating personnel, no water treatment chemicals…•Lowest possible maintenance costs – high quality components and equipment•Environmentally friendly•Fully automatic, PC-operated - fast, flexible and reliable; easy-to-operate•Proven solution - with over 30 years of experience and more than 700 units in operation

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Increased productiondue to superior heating power

• The TURBOMATIC’s superior heating power is

due to…• utilisation of all input fuel energy (100% efficiency, “no

chimney”)• actual heating power is significantly, 5-10x, higher than in

traditional heating systems• all input energy can be utilised for aggregate heating and/or

water heating • all heating power is introduced independently into a single silo;

heating times are set flexibly according to need• use of optimum heating media –TURBOgas/-steam: flow rate,

temperature, heat transfer etc (resulting also in an optimum water-to-concrete ratio and thus best possible concrete quality)

• sufficient pressure to ensure efficient penetration and heating (due to the use of a compressor)

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Superior heating powerTestimonials

“Due to superior heating power of the TURBOMATIC it is possible to increase the concrete production as well as in some cases also the production of concrete (end-) products – especially with the use of hot concrete. In some cases it has been possible to double the production with the use of hot concrete”

Tero Kokkonen, Lujabetoni, Finland

“With the cold weather we have had this year we have had major problems in producing concrete for our customers. There are only three plants from which we have been able to deliver under all circumstances…that is where we have our first, second and third TURBOMATIC heating system.

Walter Ritter, Dyckerhoff Beton, Germany

“In January even my competitors in Sofia were buying from me because I was the only one in the whole city who was able to produce (concrete)”

Mr. Nikolov , Hidrobeton, Bulgaria

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Production of high quality concreteat desired temperature

• With the TURBOMATIC it is possible to produce the amount of concrete at the desired temperature with an optimum cement-to-water-ratio under all ambient temperature conditions, even during the coldest of winters due to…

• Superior heating power which ensures capacity and temperature• Optimum heating media (TURBOgas/steam) ensures the quality

of the concrete

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High quality concreteTestimonials

”the heating power of the TURBOMATIC has been such that we have been able to meet the concrete temperature requirement of 20-21oC under all weather (temperature conditions). This was not possible with our old system (and at the same time we have been saving in our fuel oil costs more than 65%)”

Johann Rieber, Dachser, Germany

“With the TURBOMATIC heating system high quality quality concrete and thus high quality end-products can be guaranteed because with the TURBOMATIC heating system the correct water-to-cement ration can always be maintained. In some cases we have also been able to reduce the use of cement in our own production”

Tero Kokkonen, Lujabetoni, Finland

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Superior energy efficiencyand lowest possible fuel consumption

• Utilisation of all input fuel energy (100% efficiency, “no chimney”)• Single unit capable of meeting all heating needs (minimum losses)• No stand-by energy losses and no need for pre-heating – optimised,

flexible, fully automatic operation• Optimum heating media – TURBOgas/-steam (resulting in best possible

concrete quality)• Fuel consumption (up to 60-80% lower); typically…

• TURBOMATIC ~ 1 liter/m3-concrete• Traditional, air or steam based heating system ~ 4 liters/m3-concrete

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Lowest possible fuel consumptionTestimonials

”when comparing the TURBOMATIC to our old steam boilers we found that the annual savings in our fuel consumption was as high as 67%; or in other words a saving of more than 400,000 liters of oil per year. That is 400,000 euros”

Allan Myllyvainio, Strängbetong, Sweden

”with our old boilers the oil consumption used to be 3.5-4 liters per cubic-meter of produced concrete. With the TURBOMATIC it is only 1.2 liters/cubic meter – a saving of 65-70%”

Hans-Jürg Bauer, Salzburger Sand und Kieswerke, Austria

”I hereby confirm that our company Rudus Oy (part of the global CRH Group ) is using TURBOMATIC heating systems in our RMC- and Precast Concrete-plants. We are currently running 32 TURBOMATIC’s (the oldest one is 21 years old ) all over Finland and it’s at the moment the only relevant heating system for our winter conditions. We are still running some old-fashioned heating systems (oil burners/warm air or steam boilers ) but all of them will be replaced by TURBOMATIC’s as soon as possible, because of the extreme energy savings and minimal service requirements. In our winter conditions (-5…-25 oC) the average fuel consumption by the TURBOMATIC is 1liter oil/m3 compacted wet concrete.”

Pasi Korhonen, Rudus, Finland

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References

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References

• Polarmatic has more than 30 years of experience in delivering heating, automation and measurement solutions for the concrete industry…

• with more than 700 TURBOMATIC thermal energy unit deliveries for even the most demanding conditions to…

• all types of concrete batching plants – horizontal, vertical (tower), and mobile –

• precast concrete factories

Selected references

• Asamer-Hufnagl, Austria• Fröschl, Austria• Dyckerhoff, Germany• Berger Bau, Germany• Norbetong (Heidelberg), Norway• UNICON, Norway• SKANSKA, Sweden• Rudus (CRH), Finland• Krost, Russia• OOO Aviakor, Russia• 45 Minutes, Russia• Garantija Stroj, Russia• Gazprom, Russia• Bosta Beton (CRH), Poland• Holcim, Hungary• Hidrobeton, Bulgaria• Tootmisbaas, Estonia• Marcuciai, Lithuania• Alas International, Romania• Beton Provinicial, Canada

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Vladimir Guselnikov, Head Engineer at OOO Aviakor Samara:

“We use the TURBOMATIC for many different purposes: for heating of the aggregates when making concrete, for heating of the hollow core slab beds and turning tables, to produce wash water for truck mixers etc. We are especially pleased with the reliability and superior effectiveness of the system even during the coldest of winters.”

References

Polarmatic”Conqueror of cold climates”

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turbomatic presentation

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