Tag Archives: bitumen water emulsion

bitumen water emulsion

It is well known that investment into maintenance and servicing of roads in the West is several times that of the eastern countries and the nations of the former USSR. For example, a nation with the best and most expensive roads, Germany, spends around US$ 3.9 million per 1 kilometer of highway, which in Russia the cost of making the same road time is about US$ 1.3 million, and US$ 1.12 million in China.

Where does the wide difference come from, if road construction materials compliant with the western standards are all purchased in the world market?

The secrets of German roads – emulsifield bitumen and traction

It is well known that investment into maintenance and servicing of roads in the West is several times that of the eastern countries and the nations of the former USSR. For example, a nation with the best and most expensive roads, Germany, spends around US$ 3.9 million per 1 kilometer of highway, which in Russia the cost of making the same road time is about US$ 1.3 million, and US$ 1.12 million in China.

Where does the wide difference come from, if road construction materials compliant with the western standards are all purchased in the world market?

Beside the fact that Germany, being the example of construction quality regulations, makes multilayered road pavement with support, drain, damping and super-strong asphalt, the country uses only the highest quality of the best grades. E.g. bitumen emulsions, a material which reinforces each of the possible layers of the new road and increases the quality of the product has not only be known but used for 70 years.

Bitumen emulsion, however, may be compared to bitumen, which is sometimes referred to as tar, as blended fuel with source material. Bitumen is not soluble in water. However, in the process of mixing it with water with addition of certain stabilizers, acids, solvents, emulsifiers and heat, the result is a substance many times more durable, reliable and reasonable to use, that the original.

Bitumen emulsion is better not only due to high efficiency and wide scope of application, but also due to direct savings.

First, coming back to paving bitumen emulsions, it should be noted that the whole process of building quality roads is based on the use of bitumen blends, not just heated tar. Each layer of the road is treated by bitumen emulsions. They are used in the process of asphalt laying, added to gravel and aggregate, used for preparation of tack coat, saturation of asphalt top layer, road repairs etc.

Apart from their use in road construction, bitumen emulsions are used to protect buildings from water, as well as for roofing construction and repairs.

UVB type bitumen emulsion preparation systems with production capacity ranging from 1 to 10 cubic meter per hour are in demand in the international market of advanced machinery. This plants are designed for production of various types of bitumen emulsions: anionic, which are mixed with materials of alkaline nature, and the versatile cationic emulsions which can interact both with acids and alkalis.

The process of bitumen emulsion production is a complicated and innovative process. There are several differences from the simple neat bitumen, which characterize emulsions as a better and more efficient material.

Here are some of the advantages and economic opportunities when using bitumen emulsions in construction.

The first and the most obvious difference is the need to heat bitumen before operation, whereas bitumen emulsion is used without prior heating, which saves on heating equipment maintenance costs.

Another advantage is the presence of water blended with bitumen. Absence of organic solvents reduces the risk of fire in the closed premises of construction companies and the toxic hazard for the people working with emulsions in poorly ventilated rooms.

The presence of water also promotes better adhesion of asphalt pavement. When water from the bitumen emulsion saturates the asphalt and then evaporates, layers become tightly connected, much tighter than with tar alone.

Water based materials are recognized as more environmentally friendly by the international expert institutions. The use of such materials reduces the emission of hazardous substances into the atmosphere and consequently eliminates the risk of environmental violations and the resulting fines for the companies.

In this article the question is posed: what it is that makes our roads expensive. It seems, the raw materials and substances which local companies use for road construction,  are compliant with the international quality standards. Our manufacturers of construction equipment, material and even plant for production of protective materials, such as bitumen emulsions, offer advanced products on par and in many cases better than the imported ones.

Therefore, if possible, there should be savings on construction materials, development of the existing components for better road quality, use of own machinery for production of such materials, which are most compliant with the international standards and individual calculation for a given project.

Asphalt Bitumen emulsion plant type UVB-1 (containerized) (production capacity 10 m³/h)

Bitumen emulsion plant UVB-1 is designed to produce bituminous emulsions of anionic and cationic type:

  • to prepare old road base for asphalt-concrete;
  • to prepare cold asphalt-concrete mixtures;
  • for surface treatment of roads;
  • for making thin protective coatings;
  • for patch road repairs;
  • to ensure water-tightness of buildings and other constructions;
  • for construction and repairing of soft roofs. 

Details:

1

General information

2

Technical data

3

Technical description of the equipment

4

Principle of operation

5

Recommended scheme of installation

6

Commercial information

Asphalt bitumen emulsion plant UVB-1 Asphalt bitumen emulsion plant GlobeCore UVB-1 in the container

General view of the bitumen emulsion plant

1. GENERAL INFORMATION

Bitumen emulsions are heterogeneous two-phase systems consisting of two immiscible liquids. The bitumen is dispersed throughout the continuous water phase as minute particles typically 0.1-5 µm in diameter, as an oil in water emulsion.

Bitumen-water emulsions must break in a controlled manner upon laying with the mineral aggregate. The efficiency of the breaking process is strongly influenced by the surface characteristics of the aggregate substrate and the properties of the bitumen emulsion. GlobeCore™ Bitumen Emulsion Plants allow to produce bitumen emulsions formulated to obtain optimal emulsion stability and also to provide adequate mixing/breaking rates when mixed with mineral aggregates.

Specialized usage of asphalt emulsion plant

GlobeCore™ Bitumen Emulsion Plants is especially designed to fulfill the requirements of the specialized contractor/producer wishing to produce volumes of emulsion for tack coat and/or pot- hole patching mainly for in-house use. This means that the production capacity as well as the features and level of control of the plant have been purposely chosen to provide an economically feasible production units with the right quality performance for this production situation.

Bitumen emulsion plant production quality

Main components of Bitumen Emulsion Plant are three static mixers and colloid mill especially designed and optimized for bitumen emulsion. Together they produce a fine and narrow particle size distribution, which builds viscosity and improves storage stability. The mill is furnished with frequency control for speed variability. This enables adoption of the emulsion characteristics and improves the quality of emulsion produced with various bitumen types. The complete mill is made in stainless steel with the shaft, the rotor and the stator in an extra high quality alloy.

Easy operation

The complete plant is mounted on one space saving frame laid-out for easy access to control devices and process supervision. The electrical controls are collected in one control panel also mounted on the frame and from this panel the plant is operated.

Operational reliability

Only high quality components and materials are used to ensure best possible operational reliability and a long technical life. The water-phase pipe system like the colloid mill is made in stainless steel to guarantee corrosion resistance.

The plant is laid-out for easy access to all components and electrical wiring. Comprehensive Manuals go with the Plant and include process and electrical schematics, maintenance and service instructions and technical data for the various components and systems.

Fast and straightforward installation

The Plant is fully assembled with all equipment mounted on one space saving frame. The plant is tested and calibrated at factory before delivery. The local commissioning takes normally less than three working days provided other equipment; tanks, etc are installed.

2. TECHNICAL DATA

Parameters

Values

1

Capacity, t/h

8

2

Water consumption, m³/h

5…7

3

Additives consumption, l/h

50…350

4

Bitumen consumption, m³ /h

10,5

5

Acid consumption, l/h

50…150

6

Emulsifier consumption, l/h

50

7

Bitumen input pressure, MPa

0,2

8

Bitumen mixer pressure, MPa

1,4

9

Liquid mixer pressure, MPa

0,2

10

Bitumen input temperature, ºC

140…160

11

Water input temperature, ºC

40…60

12

Emulsion maximum raise height, m

10

13

Power consumption, kW

46,6

14

Voltage, ~50 Hz, three phases

380

15

Dimensions, mm:

length:

width:

height:

6100

4270

2810

16

Weight, kg

4355

2.  TECHNICAL DESCRIPTION OF THE EQUIPMENT.

Bitumen emulsion plant UVB-1 is designed to produce bituminous emulsions of anionic and cationic type:

  • to prepare old road base for asphalt-concrete;
  • to prepare cold asphalt-concrete mixtures;
  • for surface treatment of roads;
  • for making thin protective coatings;
  • for patch road repairs;
  • to ensure water-tightness of buildings and other constructions;
  • for construction and repairing of soft roofs. 

Asphalt Emulsion block consists:

  1. 1 – Bitumen pump type DC-180
  2. Type – gear pump, capacity – 500 L/min, working pressure – 0,59 MPa (kg/cm²),max. bitumen temperature -180°C, max safe revolutions rate – 480 rpm, weight – 320 kg
  3. 2 – Colloid mill GlobeCore®
  4. Viscosity – 400 – 1.500mPa s (cP), Design pressure-8 bar, design temperature-200°C, operating suction pressure – 0.3 bar minimum, operating pressure expected – 1,5 to 2,5 bar, operating temperature, expected – 95 to 180 °C, seal flushing liquid – water.
  5. 3 – Hydrodynamic mixer
  6. Three-stage mixers with valves and piping.
  7. 4 – Additives mixer
  8. 5- Bitumen pump drive
  9. Three-phase asynchronous motor 5A 160 M4 (power 18,5 kW, 1500 rpm)
  10. 6 – Gear box
  11. Reducer 1MC-160-10
  12. 7- Mill drive
  13. Three-phase asynchronous motor, power 18 kW, 3000 rpm
  14. 8 – Temperature and pressure sensors
  15. Temperature transducer type TCP-1-5-Pt-100, temperature range – 0…+250 °C,
  16. Pressure transmitter type A-10, pressure ranges – -1 …24 bar, signal outputs – 4…20 ma
  17. 9 – Pneumatic valve
  18. Pilot pressure – 6 – 8 bar
  19. 10 – Bitumen T-valve
  20. Three-way bitumen valve with heating jacket, type – K-80-S-00-01, Ø80
  21. 12- Frame
  22. Mounting frame consists of steel profiles and serves for safe mounting and piping of all machines and devices.
  23. Material: construction steel St 37-2

Water phase block consists:

  1. Flow metersFlow meters FloTrak Metal VA, accuracy – ± 2% FSD, repeatability – 0.5% of flow, materials – 316 SS standardMeasurement range, m³/h – 1st Flow meter: to 10 m³/h2nd Flow meter: to 4 m³/h3rd Flow meter: to 0,5 m³/h
  2. Solvent (kerosene) pumpGear pump NS-14 (three-phase asynchronous motor ,0,75 kW, 1350 rpm),capacity – 22 L/min
  3. Water phase pumpWILO MVI 207 -Vertical High Pressure Centrifugal Pump with three-phase (1.1 kW)
  4. Water pumpWILO MVI 807 – Vertical High Pressure Centrifugal Pump with three-phase (3.0 kW)
  5. Water phase mixerstainless steel AISI 316Ti
  6. Emulsifier and additives dosing tanks
  7. Water dosing system
  8. water conducting pipeline – stainless steel AISI 316Ti
  9. Water phase tank

Bitumen emulsion plant Control panel

The Control panel of Asphalt bitumen emulsion plant

In steel enclosure, panel, waterproof. Containing all electrical apparatuses, contactors, thermo-relays, fuses, press buttons and main switch.

 Technological parameters of the bitumen emulsion production process are programmed and controlled by controller LOGIC ZELIO Schneider Electric.

 Control and measuring device 2ТРМ1 – Pressure of bitumen after pump

Control and measuring deviceТРМ1 – Bitumen temperature after pump

Control and measuring deviceТРМ1 – Bitumen temperature before pump

Control and measuring deviceТРМ1 – Bitumen pressure before pump

Control and measuring deviceТРМ1 – Water blend temperature

Control and measuring deviceТРМ1 – Water temperature

Control and measuring deviceТРМ1 – Temperature of emulsion before mill

Control and measuring deviceТРМ1- Pressure of emulsion before mill

4. Asphalt bitumen emulsion plant principle of operation

Hot bitumen is pimped through tree way valve to mixer C1 (see the flow diagram below) and partially through valve K2 back to bitumen tank. Additive is pumped to mixer C1 by pump M5 from tank 5 through flowmeter R1 and valve EK3. Mixture of bitumen and additive under high pressure is pumped by pump M1 through valve EK1 to injection mixer C2, where it is blended with water phase. Mixture of water and bitumen enters the third hydrodynamic mixer C3, where bitumen droplets are split into smaller particles. Emulsion than stabilized in the colloid mill C4 and cools down in the water/emulsion heat exchanger on it’s way to emulsion tank.

PRINCIPLE OF OPERATION of asphalt bitumen emulsion plant

Water phase block is a double circuit mixer. First circuit consist of water tank, pump M4 and injection mixer C5. The second circuit – mixer C6, where water is mixed with additives, fed into injection mixer by pumps M4 and M3. Water phase is prepared in the tank 1, which is filled with warm water from water reservoir. Water circulates through water tank 1 and mixer C5 where low pressure is created by pump M4. Acid, emulsifier and additives introduced into water tank through valves K7, K10and K12 from dosing tanks 6,7 and 8. Water phase pH level is checked by pH-meter and corrected if required. During plant operation water phase is prepared simultaneously with emulsion preparation in the mixer C6. pH level of water phase is maintained in the range between 2 and 2.5. Water is dosed byM3 pump and water phase – by pump M4. Water and water phase flows are controlled by flow metersR2 and R3.

Water is heated to desired temperature in the water tank and in the heat exchanger 10. Emulsifier is heated in the heater and pumped with the pump M2 to dosing tank 6. Acid neutralizer 9 is used to neutralize acid vapors. Water and polymer (Butanol) mixture is pumped with the pump M6 through flow meter R4, valve K16 and three way valve K15 to emulsion preparation block. Pumps, flow meters and pipes are flushed with clean water at the end of the process.

Bitumen Emulsion System UVB-14

Applicatuion:

Bitumen-emulsion system UVB-14 (water phase) is designed to produce anion and cation bitumen emulsions that in road construction are used:

  • to prepare old road base for asphalt-concrete;
  •  to prepare cold asphalt-concrete mixtures;
  • for surface treatment of the roads;
  • for making thin protective coatings;
  • for patch road repairs;
  • to ensure water-tightness of buildings and other constructions;
  • for construction and repairing of soft roofs.

The unit is used at enterprises that produce road concrete mixtures.

It is designed to be operated indoors as well as outdoors under a shelter.

The construction of the machine provides its up state when operating complies under the temperature from +5 0C to +40 0C

Primary specifications:

 Parameter

Value

1. Capacity, m3/h – batch operation

– continuous operation

8

16

2. Bitumen consumption, m3/h

10,5

3. Water consumption, m3/h

5-7*

4. Solvent consumption, dm3/h

50-350*

5. Acid consumption, dm3/h

50-150*

6. Emulsifier consumption, dm3/h

до 50*

7. Bitumen input pressure, MPa

0,2

8. Bitumen mixer pressure, MPa

1,4

9. Liquid mixer pressure, MPa

0,2

10. Bitumen input pressure, C

140-160

11. Water input temperature, 0C

40-60

12. Emulsion maximum raise height, m

10

13. Set power consumption, kW

38

14. Dimensions, mm:

14.1. Bitumen mixing unit

– length

– width

– height

2300

1000

1100

14.2. Liquid mixing unit

– length

– width

– height

1600

1300

1500

15. Power circuit voltage, V

380220

16. Mass, kg

1990

*According recipe

As per customer request, these units can be equipped with a wide range of electronic devices to simplify the process of emulsion production.

Control of all operations is displayed on a screen, fitted on the electric control panel.