1
Dr. Andreas Biedermann
Mistura Asfáltica Sustentável - Sustainable Asphalt
7/17/2013Ammann Technology
7/17/2013Ammann Technology 9
Our Approach To Process Development
Field Tests / Experiments
Numeric Simulation
Engineering & Development
TheoryProduct
Field TechniciansProcess Engineers
Engineering at FactoriesTechnology Centre
Global Technologies for Road Construction
7/17/2013Ammann Technology 14
Map: Educational Options, Inc., 2007
Ammann Technology 15
CO2–Emissions caused by the Asphalt-Production
Production of BitumenAggregatesElectricity
CO2
Asphalt-Mixing-PlantDirect Emissions
LogisticsCO2
Parallel Drum CO2
Thermal OilCO2
New Material Drum
CO2
Indirect EmissionsProduction of raw materials and energy
7/17/2013
Ammann Technology
Production of raw materials and energy
CO2 Emission per Tonne of Asphalt
Model calculation, Transport not considered
Indirect Emissions
30 kg CO2
0
5
10
15
20
Aggregates Bitumen Electricity
kg C
O2
per t
onne
of a
spha
lt
Bitumen Storage Logistics Dryer
On the Mixing Plant20 kg CO2
Direct Emissions
Total50 kg CO2
7/17/2013 16
Quality Asphalt - Requirement on the Mixing
Ammann Technology
Distribution of components
Coating of aggregates
Homogenous mastic
Reactivation of bitumen
Low initial ageing
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Mixing Asphalt
Ammann Technology
Reclaimed asphalt Fresh
bitumen
Aggregates
FillerAdditives
Twin-shaftpaddle mixer
separated fromheating drum
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Batch Mixing Plants – Mobile and Stationary
7/17/2013Ammann Technology 19
Fuel
High flexibility
Intensive mixingEasybatch
Global
Continuous Mixing Plants – Mobile and Stationary
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75t 75t
DV
20t
65t 65t
Prime
ContiMix
TroughputConstant
Core Components Twin-Shaft Paddle Mixers
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Twin-shaftpaddle mixer
Drummixer
Continuous BatchAsphalt Production
Mixed Asphalt Impossible
Drum mixing plants
ContiMixPrime
GlobalEasybatch
Ammann Technology
Mobile Continuous Asphalt Production
• Highly mobile & compact
• Continuous asphalt production
• Clear separation of drying & mixing
• Suitable for various additives
• Adjustable mixing time according to recipe and capacity
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Continuous Asphalt Production with Twin-Shaft Mixer
Bitumen
Asphalt
Twin Shaft Paddle Mixeroperated in continuous mode
Aggregates
Counterflow DrumAddition Systems
Prime 140 - Variable Wet Mixing Times
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25% 50% 75% 100%
Minimizewear
Prevent Ageing
Mix fragile Components
Prices Since 2005: Bitumen +200%
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0%
100%
200%
300%
400%
1998 2000 2003 2006 2008 2011
Asphalt Cement (New Jersey)Bitumen Price (Germany)
2012
Typical Asphalt Recipe
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Sand 0/416%
Aggregates 4/85%
Aggregates 8/1626%
Filler2%
Fresh Bitumen 70/1002%
Reclaimed Asphalt 0/16
49%
Base course
0%
25%
50%
75%
100%
No RA 30% RA 60% RA 90% RA
Material costs per to
n of aspha
lt
Bitumen Aggregates Water AdditivesRA Fuel RA Analysis
Cost Benefits from Recycling Asphalt (RA)
Ammann Technology
-40% Material costs
Estimated costs
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Allowed Content of Reclaimed Asphalt
Ammann Technology
Country Wearing Course Binder Course Base CourseBelgium 25% 50%Denmark 30% 100%France 40%Germany 50% 100%Hungary 10% 20%Ireland 10% 50%Poland 20% 30%Portugal 10% 50%Spain - 10-50%Sweden 20% 30%Switzerland 30%* 30% 60%
*: Depending on traffic load7/17/2013 33
Ammann Technology
Homogenity Drives the Allowed RA Ratio
Ring & Ball Binder < 63um 63um-2mm >2mmVariety of RA characteristics
Germany, Base course, combined course, fundation, DAVRA Addition [%]
Highvariety
Homogeneity
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Ammann Technology
Waste of Asphalt Next Due To Start-Up and Shut-Down
Undefined and inhomogeneousmixture of aggregates and bitumen.
Cannot be used for high quality asphalt
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Ammann Technology 37
0/8 8/16 16/32Scalping screen
Processing and Handling of RA Material
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Using RAP = Blending of Bitumen
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40
45
50
55
60
65
70
0
20
40
60
80
100
0% 25% 50% 75% 100%
Resulting
Ring an
d Ba
ll [°C]
Resulting
Pen
etratio
n of BItu
men
[mm/10]
0% RAP100% B 70/100
100% RAP0% B 70/100
Acceptable Rangefor Ring and Ball
Acceptable Rangefor Penetration
Possible RA addition rangewithout rejuvenators
Reclaimed Asphalt + Fresh Bitumen
Ammann Technology
+ =+
Twin-shaftmixer
Reclaimedasphalt Fresh bitumen
+ =
Double-coated grains
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Action Force Mixer For Homogeneity of the Mastic
Ammann Technology
Batch asphalt production
Continuous asphalt production
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Different Techniques To Keep the Asphalt in the Road
Ammann Technology
0% 25% 50% 75% 100%
in elevator
in pug mill
in drying drum
parallel drum
dedicated counter flow drum
Possible Ratio of Reclaimed Asphalt7/17/2013 42
Ammann Technology
RA Cold Addition Into Pugmill – 25% RA
Steam evacuation
Superheatedaggregate
Advantages• RA and aggregates dosed
separately into pug mill• use of screen not affected• Inexpensive, straightforward
solution• good to combine with low
temperature mixes
Limiting factors• Steam evacuation• Superheating of aggregates
at 3% Moisture
900+ installationsworldwide
7/17/2013 43
Cold RA Addition in Pugmill
Ammann Technology
Minerals
Reclaimed Asphalt
Steam Evacuation
Filler
Bitumen
Wet Mixing Time
Discharge
Mix as long as possible
Thermal transfer
Time
7/17/2013 45
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
Ammann Technology
20+ RAH 50 drums
in operation / delivery
7/17/2013 46
RAH 50 – Gentle Heating of Reclaimed Asphalt
Ammann Technology
Virgin Aggregates
ReclaimedAsphalt (RA)
Hot Mixof RA and Virgin Aggregates
7/17/2013 47
Ammann Technology
RA Warm-Addition with Parallel Drum – Up to 60%
Combination of cold- and warm-addition for maximum flexibility!
100-fold well-proven system:
300+ parallel drums
7/17/2013 48
Asphalt Recycling – Future of Road Construction• Reclaimed asphalt = material of
value – Ever more!Homogenous, recipe definition, variability in use
• True recycling = use asphalt for same layer again and again and …
• Reactivation of bitumen and homogenization of additivesAction force mixer to be favored
• Proven plant technology is available; from max 15% up to 100%
Ammann Technology 7/17/2013 56
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Production of raw materials and energy
CO2 emission per ton of Asphalt in Australia
Australia, model calculation, Transport not considered (5-15 kg CO2 per t of Asphalt)
Indirect Emissions
30 kg CO2
0
5
10
15
20
Aggregates Bitumen Electricity
kg C
O2
per t
of
Asp
halt
Bitumen Storage Logistics Dryer
On the Mixing Plant20 kg CO2
Direct Emissions
Total50 kg CO2
7/17/2013Ammann Technology 59
0°C 50°C 100°C 150°C 200°C
Heating &Drying
Ener
gy C
onsu
mpt
ion
per t
on a
spha
lt
ColdAsphalt
Half WarmAsphalt
WarmAsphalt
HotAsphalt
Technology Trend = Lower Temperatures
115°C 180°C
1.5 kgOil
Lower Temperature reduces Energy Consumption
CMC
Foam
AdditivesHMA
7/17/2013Ammann Technology 60
Temperature reduction of 10°C reduces fume by approximately 50%.50 °C cooler = - 80% emissions.
Hot-MixFoam Asphalt
Emissions during loading
180 °C
~ No Emissions
115°C
Loading of Hot Mix and Ammann Warm Foam
Ammann Technology 61
Lower Emissions at the Construction Site
Emission during paving
165 °C
No emissions
100°C
7/17/2013
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160
Foaming: Same Viscosity at Lower Temperature
Viscosity of Bitumen
Temperature [°C]and / or Time
0 80
Bitumen B 50/70
Foamed Bitumen
Schematic Illustration
Bitumen with Wax
Low Temperature: On Plant and On Construction Site!
7/17/2013Ammann Technology 64
Temperature ReductionOn Plant On Site
Foam Based ++ ++Wax Based + +Zeolithes + ++
7/17/2013Ammann Technology 65
Six Approaches For Low Temperature Asphalt
Low Temperature Asphalt
Foaming
Mixing Technology
Waxes
Chemical Additives
Wet Components
Recycling
Combined Application
7/17/2013Ammann Technology 66
0°C 50°C 100°C 150°C 200°C
Heating &Drying
Ener
gy C
onsu
mpt
ion
per t
on a
spha
lt
ColdAsphalt
Half WarmAsphalt
WarmAsphalt
HotAsphalt
Technology Trend = Lower Temperatures
Lower Temperature reduces Energy ConsumptionHMA
CMC
AmmannFoam
WAMFoamFoam
Bitumen
Bitumen Foaming
7/17/2013Ammann Technology 67
Hot Bitumen
160°C
+Cold
Water2 - 4%
=Bitumen
Foam
+Fine
Distribution
1 litre 0.03 litre 20 litres
5 % of asphalt
0.15% of asphalt
water: 0.05% of asphalt
Benefits of Foamed Bitumen
7/17/2013Ammann Technology 68
Foam Aggregates Easier to mix
Easier to coat coarse aggregates
Easier to compact at lower temperatures
7/17/2013Ammann Technology 69
Ammann Foam Generator – Basic Principle
Static Mixer
Hot Bitumen
Foaming water2-4% of bitumen(0.1-0.2% of asphalt)
Spraying nozzles
High pressure (water & bitumen)
Foamed bitumen
Mixer
7/17/2013Ammann Technology 70
Ammann Warm Foam - Switzerland 2009
Bitumen
Water
Mixer
Bitumen & Water
SampleTaking
7/17/2013Ammann Technology 73
Ammann Foam – Pure Foam Bitumen - 100 – 120 °C
10 20 30 40 50 600 7010 20 30 40 50 600 70
MixingMixing
DischargeDischarge
Time [s]Recommended Values. Individual times depending on specific installation and materials.
Aggregates > 2mmAggregates > 2mm
Foamed BitumenFoamed Bitumen
Aggregates < 2mmAggregates < 2mm
FillerFiller
E.g. Cold Recycling
7/17/2013Ammann Technology 77
Switzerland – Foam Bitumen - AC T 22 N - 2011
HMA Foam
About 50% RA (cold and warm addition)
7/17/2013Ammann Technology 81
Roller passes vs. compaction
Hot Mix Asphalt Foam Asphalt
5 – 10 roller passes needed
7/17/2013Ammann Technology 82
Ammann Warm Foam – Visible Characteristics
on truck
after paver
after compaction
7/17/2013Ammann Technology 86
15 months after construction – No ruts• Principal road close to Bern
• After paving: 0 – 2 mm (some ruts up to 3 mm)• After 15 months: 1 – 2 mm (some ruts up to 4 mm)