AAPA Technology Tour 18 th June 2012

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1 AAPA Technology Tour 18 th June 2012 RA 100 The new dimension in use of RAP Rolf Jenny Senior Vice President Ammann Group Chairman Ammann Australia Pty. Ltd. 1

2 Road construction in Europe and Australia Europe Many similarities Australia Important differences 1. European market is extremely competitive Coal dust is used as fuel -> big reduction in energy cost High % of recycling -> big reduction in material cost Latest technologies -> reduction in operating cost 2. European Road Construction requires maximum flexibility Asphalt mix are adjusted to all kind of needs (>100 recipes) 3. European environmental standards are different CO, NOX, C, dust ( applicable at all location ). Wet washers/wet scrubbers are impossible to use in Europe 2

3 Sustainable road construction means: Intact living space High Mobility + 3

4 It means also well maintained road network Well maintained roads 4

5 Improvements of construction equipment Speed of Change 1. Environmental Requirements 2. Shift from New Roads to Maintenance 3. Improved Quality Requirement 4. Economical Crisis 5. Competitive Market

6 These methods have gone a long time ago In the Mountains of Nepal in

7 The good old days 7

8 Today s clean asphalt manufacturing 8

9 Shift from new roads to maintenance Total global Asphalt Production Tonnes per year Growth of 4.1% each year 2.2 billion tonnes in ,3 to p.a and Inhabitant Road Maintenance North America 650 Mio. to p.a 5% of the world population using 1/3 of the global prduction Construction of New Road China 440 Mio. tonnes p.a

10 The 3 segments of global road construction markets Total Asphalt Production Maintenance Rural to Paved Road New Road India, South America, Africa Characteristics low investment mobility projects 10

11 The 3 segments of global road construction markets Total Asphalt Production Maintenance Rural to Paved Road New Road Total Asphalt Production Maintenance Rural to Paved Road New Road India, South America, Africa China, Russia, Eastern Europe, Asia Pacific Characteristics low investment mobility projects Characteristics open for new technologies environment coming improved quality 11

12 The 3 segments of global road construction markets Total Asphalt Production New Road Maintenance Rural to Paved Road Total Asphalt Production Maintenance Rural to Paved Road New Road Total Asphalt Production Maintenance New Road India, South America, Africa China, Russia, Eastern Europe, Asia Pacific USA, Western Europe, Australia Characteristics low investment mobility projects Characteristics open for new technologies environment coming improved quality Characteristics environment flexibility quality 12

13 Ammann s answer to the 3 segments Total Asphalt Production Maintenance Rural to Paved Road New Road Total Asphalt Production Maintenance Rural to Paved Road New Road Total Asphalt Production Maintenance New Road EasyBatch Speedy Batch Blackmove 25-60% Recycling % Recycling 13

14 The future is already here Wearing coarse with 92% RECYCLING in Hamburg Germany AC 0/11 Recycling (0/11) 92 % Mineral (8/11) 8 % 14

Strategy: Recycling and Economy of scale Very well sorted Reclaimed Asphalt Consolidation: 100 50 plants High

15 Strategy: Recycling and Economy of scale Very well sorted Reclaimed Asphalt Consolidation: plants High volume production High recycling ratios High flexibility Production: t.p/a Recycling: t.p/a 15

16 Hot and Cold Recycling up to 75% Proven technology (Batch & Conti) 500 Parallel Drums for 60% 1000 Cold Additives for 30% Limitations: Super-heating Emissions RA outlet temperature 16

17 Strategy: 100% Recycling Highly Competitive thanks to RAP High RAP storage volume High flexibility Quality Assured RAP 17

18 RAH 100% Reclaimed Asphalt Hot 100% Ammann developed a new asphalt recycling concept for 0% - 100% reclaimed asphalt

19 World s 1 st Plant Using up to 100% Recycling Asphalt 100% Recycling Device Why up to 100% recycling? Excess of reclaimed asphalt Ecological requirement to preserve natural resources Economical to reuse available material 19

20 100% Recycling Device RA Dryer Process Air Heater Process Air Circulation 20

21 100% recycling device (protected) Raw Gas to Filter (95 ) Heated Reclaimed Asphalt (165 C) Gas Mixing Low ageing of bitumen No radiation heat Soft heat exchange High efficiency Counter flow dryer Process air circulation Low emissions (TOC) Indirectly heated Low temp. heat exchange 21

22 RAH 100% drying drum 22

23 Process air heater 23

24 Treatment of reclaimed asphalt Binder 4,0 % Filler 10,6 % Sand 45,8 % > 2 mm 43,6 % RA 0/22 Screening Binder 5,1 % Filler 12,4 % Sand 52,5 % > 2 mm 35,1 % RA 0/8 RA 8/22 Binder 3,6 % Filler 6,9 % Sand 24,7 % > 2 mm 68,4 % 24

25 Well sorted recycling materials 16/32 8/16 0/8 25

26 Blending of reclaimed asphalt 0/8 8/16 16/32 Scalping screen 26

27 Bitumen characteristics after heating sample A (cold) taken at RA feeder through-put time approx. 10 min. sample B (hot) taken at drum outlet Determination of the parameter in the laboratory: Bitumen content Grading curve to guarantee match of sample A and B Softening point ring & ball R&B Penetration Fraaß breaking point characteristic to evaluate thermal stress of bitumen 27

28 Bitumen characterstics after heating (guide values) Softening point ring & ball: R&B softening point before and after thermal stress of RA R&B (sample cold) 85 R&B (Sample hot) R&B value [ C] ,2 59, , ,4 73,2 76,2 54,6 55,2 64,6 70,2 65,6 v 68 62,4 66,6 60,4 60,4 63,2 60,4 58,4 61 Limit 61, ,6 55, (160 C) 2. (163 C) 3. (164 C) 4. (190 C) 5. (162 C) 6. (155 C) 7. (120 C) 8. (167 C) 9. (170 C) 10. (192 C) 11. (170 C) 12. (145 C) 13. (183 C) Sample No. and RA outlet temperature [ C] 28

29 Bitumen characterstics after heating (guide values) Penetration values: Penetration in 1/10mm before and after thermal stress of RA Pen value [1/10mm] ,2 30,4 15,1 15,5 9,7 11,3 18,8 13, Pen (sample cold) Pen (sample hot) Limit Pen (160 C) 2. (163 C) 3. (164 C) 4. (190 C) 5. (162 C) 6. (155 C) 7. (120 C) 8. (167 C) 9. (170 C) 10. (192 C) 11. (170 C) 12. (145 C) 13. (183 C) Sample No. and RA outlet temperature [ C] 29

30 Intelligent, fully integrated road construction Closing the Loop: from Road to Road High quality, reduced costs and construction time Ecology, Economy, Safety 30

31 AAPA resolution 2011 Australia Leader in Sustainable Road Construction What we take out of the road, we put back! Green Asphalt preferred in tenders Government adopts performance based principles Phase out processes that are not environmentally friendly. 31

32 Leadership in sustainable road construction AAPA Resolution 2011 National and state road authorities Supporting new technologies Road construction companies Investing in new technologies Equipment Manufacturing R&D new technologies 32

33 Thank you very much for your attention Productivity Partnership for a Lifetime 33

Government: - Emissions -Recycling Sustainable Road

34 Drivers for sustainbalbe road construction Tier IV TA Luft Financial: - Lack of Funding - Market competitiveness Government: - Emissions -Recycling Sustainable Road Construction Asphalt back to asphalt Shift of Focus: - From new roads to Maintenance 34

35 kg CO 2 per t of Asphalt 50-25% CO 2 Asphalt Recycling Low Temperature Mix Lower Moisture Cont. Alternative Energies Ecology SW tools, Integrated Constr. 0 Traditional Production New Technology Technologies to come Direct and indirect emissions considered, without transport 35

36 Solar heated bitumen farm 36

37 Global solar radiation Many countries in best solar area 37

38 Wood dust fired burner CO 2 neutral fuel Cost savings 38

39 Wood availability 39

Developments in Asphalt Plant and Equipment. Andreas Biedermann

Developments in Asphalt Plant and Equipment Andreas Biedermann Ammann Group For Internal Use Only 10/29/2013 1 Ammann Technology 10/29/2013 2 Our Planet http://maptd.com/ Low Temperature Asphalt 10/29/2013