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1 Dr. Andreas Biedermann Mistura Asfáltica Sustentável - Sustainable Asphalt 7/17/2013 Ammann Technology
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1

Dr. Andreas Biedermann

Mistura Asfáltica Sustentável - Sustainable Asphalt

7/17/2013Ammann Technology

Sustainable Asphalt Production

7/17/2013Ammann Technology 2

http://www.sinicesp.org.br/

37/17/2013Ammann Technology

47/17/2013Ammann Technology

67/17/2013Ammann Technology

87/17/2013Ammann 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

107/17/2013Ammann Technology

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

7/17/2013 17

Mixing Asphalt

Ammann Technology

Reclaimed asphalt Fresh

bitumen

Aggregates

FillerAdditives

Twin-shaftpaddle mixer

separated fromheating drum

7/17/2013 18

Batch Mixing Plants – Mobile and Stationary

7/17/2013Ammann Technology 19

Fuel

High flexibility

Intensive mixingEasybatch

Global

Continuous Mixing Plants – Mobile and Stationary

7/17/2013Ammann Technology 20

75t 75t

DV

20t

65t 65t

Prime

ContiMix

TroughputConstant

Core Components Twin-Shaft Paddle Mixers

7/17/2013Ammann Technology 22

Twin-shaftpaddle mixer

Drummixer

Continuous BatchAsphalt Production

Mixed Asphalt Impossible

Drum mixing plants

ContiMixPrime

GlobalEasybatch

Ammann Technology

Mobile Continuous Asphalt Mixing

7/17/2013Ammann Technology 23

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

7/17/2013Ammann Technology 24

Prime – Highly Mobile Continuous Asphalt Mixing

7/17/2013Ammann Technology 25

7/17/2013Ammann Technology 26

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

7/17/2013Ammann Technology 27

25% 50% 75% 100%

Minimizewear

Prevent Ageing

Mix fragile Components

Prices Since 2005: Bitumen +200%

7/17/2013Ammann Technology 28

0%

100%

200%

300%

400%

1998 2000 2003 2006 2008 2011

Asphalt Cement (New Jersey)Bitumen Price (Germany)

2012

Volleyball - Keeping the Ball in the Play

Ammann Technology 7/17/2013 29

Typical Asphalt Recipe

7/17/2013Ammann Technology 30

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

7/17/2013 31

Ammann Technology

True Recycling = Future of Asphalt

Down-Cycling

TrueRecycling

7/17/2013 32

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

7/17/2013 34

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

7/17/2013 35

Ammann Technology 36

0/8

8/16

16/32

Processing and Handling of RA Material

7/17/2013 36

Ammann Technology 37

0/8 8/16 16/32Scalping screen

Processing and Handling of RA Material

7/17/2013 37

Using RAP = Blending of Bitumen

7/17/2013Ammann Technology 38

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

7/17/2013 39

Action Force Mixer For Homogeneity of the Mastic

Ammann Technology

Batch asphalt production

Continuous asphalt production

7/17/2013 40

Different Techniques

Ammann Technology 7/17/2013 41

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

Ammann Technology

RA Cold Addition – Vapour Evacation

Mixer

Vapour Evacation System

7/17/2013 44

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

Ammann Technology

RA Warm- and Cold-Addition Combined

7/17/2013 49

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

Low Temperature Asphalt Promotion

7/17/2013Ammann Technology 57

7/17/2013Ammann Technology 58

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

7/17/2013Ammann Technology 62

Low Temperature Asphalt – On Site

7/17/2013Ammann Technology 63

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 71

Same Principle – Plant and Laboratory

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 75

Ammann Warm Foam - Switzerland 2009

7/17/2013Ammann Technology 76

Ammann Warm Foam – Sweden 2009

Harbor area 2009

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 78

Foam Asphalt - Construction Site

7/17/2013Ammann Technology 79

Troxler probe measurements

7/17/2013Ammann Technology 80

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)

7/17/2013Ammann Technology 87

Long term• Norwegian Road Authority / Kolo Veidekke:

Schweizer Forschungsprojekt VSS

7/17/2013Ammann Technology 88

Thuner Tagblatt, 2012

Warm Mix Asphalt – Norway

7/17/2013Ammann Technology 89

Roar Telle, 2012

Sucessful Warm Mix in Australia

7/17/2013Ammann Technology 90

Low Temperature Asphalt Promotion

7/17/2013Ammann Technology 91

Global Technologies for Road Construction

• Sustainable Asphalt Production

• Economy and Ecology

• Twin-shaft paddle mixer –Continuous or batch process

• Recycling – Solutions for Addition

• Foaming – Low Temperature Asphalt

Ammann Technology 7/17/2013 92


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