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 3
kg CO 2 per tonne of asphalt CO 2 Emission per Tonne of Asphalt 20 15 10 Indirect Emissions Production of raw materials and energy 30 kg CO 2 Direct Emissions On the Mixing Plant 20 kg CO 2 Total 50 kg CO 2 5 0 Aggregates Bitumen Electricity Model calculation, Transport not considered Ammann Technology Bitumen Storage Logistics Dryer 10/29/2013 4
Prices Since 2005: Bitumen +200% 400% 300% 200% 100% 0% 1998 2000 2003 2006 2008 2011 Bitumen Price (Germany) Asphalt Cement (New Jersey) 2012 Ammann Technology 10/29/2013 5
Road Construction - Keeping the Asphalt in the Road The Stadium - Where it all comes together 29/10/2013 6
GBP per ton of asphalt (material only) Cost Benefits from Recycling Asphalt (RA) 50 40 30-15 GBP/ton Estimated costs 20 10 0 No RA 30% RA 60% RA 90% RA Bitumen Aggregates RA RA Analysis 1 500 000 GBP less material costs per year The Stadium - Where it all comes together 29/10/2013 7
as1 Reclaimed Auftragsverwaltungs- Asphalt Valueable und Dispositionssysteme Resource Grain size-sorted reclaimed asphalt 0/8 8/16 16/32 Scalping screen Homogenous stockpile The Stadium - Where it all comes together 29/10/2013 8
Different Techniques To Keep the Asphalt in the Road parallel drum dedicated counter flow drum in elevator in drying drum in pug mill 0% 25% 50% 75% 100% Possible Ratio of Reclaimed Asphalt The Stadium - Where it all comes together 29/10/2013 9
RAH 50 Combined Asphalt Recycling - North-East Italy Example RAH 50: RAP-cold feed in dryer drum Retrofit on CB 210 First Installation: 3rd may 2010 Plant with existing cold recycling line The Stadium - Where it all comes together 29/10/2013 10
RAH 50 Gentle Heating of Reclaimed Asphalt Reclaimed Asphalt (RA) Hot Mix of RA and Virgin Aggregates Virgin Aggregates The Stadium - Where it all comes together 29/10/2013 11
Merging of Reclaimed Asphalt (RA) & Virgin Aggregates RA Overheated edges Virgin Aggregates Merging blades Mix of RA & Virgin Aggregates The Stadium - Where it all comes together 29/10/2013 12
RAH50 Retrofit and New Installation CB 210 with RAH50 CB 150 with RAH50 Retrofit in Cyprus Retrofit in Israel The Stadium - Where it all comes together 29/10/2013 13
Rejuvenating Reclaimed Bitumen http://www.comedix.de The Stadium - Where it all comes together 29.10.2013 14
Goals of Using Additives Low viscosity of binder during asphalt production Lower stiffness during compaction Higher stiffness at high service temperatures Lower stiffness and faster relaxation at low service temperatures Reduce fumes from bitumen Reduce or improve foaming Rejuvenate bitumen Reduce sticking in plant Substitute a portion of the bitumen Improve adhesion and/or coating Colorize binder Additive Ammann Group, Andreas Biedermann 10/29/2013 15
Working With The Magical Essence Mixing Dosing Addition Storage / Reaction Heating / Melting www.nk-rock-city.de Additive Ammann Group, Andreas Biedermann 10/29/2013 16
Dope Addition System Standard Configuration: 12 l/min 3 tons of asphalt with 5% bitumen Into Bitumen Stream / Scale Additive Ammann Group, Andreas Biedermann 10/29/2013 17
Process Oil Addition Continuous or batch-wise addition Heated system Addition Points: RA drum RA chute / silo Mixer Additive Ammann Group, Andreas Biedermann 10/29/2013 18
Bitumen Modification Plant - Moditek Additive Ammann Group, Andreas Biedermann 10/29/2013 19
Varying the Addition of Reclaimed Asphalt The Stadium - Where it all comes together 29/10/2013 20
Dynamic RA Addition Optimal Use of Recycling Adjust RA ratio continuously Adapt mixing curve to lab results Optimal use of RA during start-up The Stadium - Where it all comes together 29/10/2013 21
Documented Quality Protocols Statistics & listings as1 control system, 2012 www.ammann-group.com 29.10.2013 22
Integrated Quality Control Reports VM GBS_13. + 14.10.2011 /ASW 23
Peak Load Management for cost saving Unit price [kwh] + Power peaks cost money Savings up to 30% Peak load price [kw]
Sample planning and taking Asphalt plant as1 reports that a sample is due as1 Software Module for Production Sample Scheduling Result Sample Laboratory Conformity verification Ammann as1 Production Sample Scheduling module 29.10.2013 25
Knowing the Process - Online How economically and ecologically am I currently operating my plant? Cost saving: > 10% The Stadium - Where it all comes together 29/10/2013 26
Planning of maintenance interval Don t wait until it breaks Zeitlicher Intervall Time interval Ereignisbasiert Event driven as1 control system, 2012 www.ammann-group.com 29.10.2013 27
Energy Consumption per ton asphalt Low Temperature Highest Quality with Lowest Energy Foam Zeolithes Additives HMA 1.5 kg Oil Heating & Drying 0 C 50 C 100 C 150 C Cold Asphalt Half Warm Asphalt 115 C 180 C Warm Asphalt Hot Asphalt Technology Trend = Lower Temperatures 200 C The Stadium - Where it all comes together 29/10/2013 28
Low Temperature: On Plant and On Construction Site! Temperature Reduction On Plant On Job Site Foam Based ++ ++ Wax Based + (+) Zeolithes + ++ The Stadium - Where it all comes together 29/10/2013 29
Ammann Foam Generator Basic Principle Foaming water 2-4% of bitumen (0.1-0.2% of asphalt) Static Mixer Hot Bitumen High pressure (water & bitumen) Foam outlet Foamed bitumen Mixer Adapted cycle The Stadium - Where it all comes together 29/10/2013 30
Bitumen Foaming + + = Hot Bitumen 160 C Cold Water 2-4% Fine Distribution Bitumen Foam 1 litre 0.03 litre 20 litres 5 % of asphalt 0.15% of asphalt water: <0.05% of asphalt The Stadium - Where it all comes together 29/10/2013 31
Switzerland Foam Bitumen - AC T 22 N - 2011 Hot Mix Asphalt Foam Asphalt (115 C) Same crew, same plant, same equipment About 50% RA (cold and warm addition) Equal number of roller passes The Stadium - Where it all comes together 29/10/2013 32
Why Ammann Foam? Low Running Costs Energy savings, lower emissions on site No license fees Use ordinary bitumen, no additives required Aggregates > 2mm Foamed Bitumen Aggregates < 2mm Filler E.g. Cold Recycling Mixing Discharge Phase 1 Phase 2 10 20 30 40 50 60 0 70 Time [s] Recommended Values. Individual times depending on specific installation and materials. Low Investment Use existing bitumen pipes Flexibility If desired, add additives in binder scale Continuous and batch mixing plants The Stadium - Where it all comes together 29/10/2013 33
The Stadium Where it all comes together Keeping asphalt in the road. Gently adjust RA addition. Know the process - Online! Low Temperature Asphalt Highest quality lowest energy The Stadium - Where it all comes together 29/10/2013 34
Productivity Partnership for a Lifetime www.ammann-group.com Ammann Group For Internal Use Only 10/29/2013 35