linnhoff presentation cold & hot recycling_2009

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Better roads with Linnhoff…

Presented by:

LEE YEN MENG

Gen. Sales Manager

LINNHOFF TECHNOLOGIES


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Better roads with Linnhoff… Better roads with Linnhoff…

ASPHALT FOUND TO BE MOST RECYCLED OFASPHALT FOUND TO BE MOST RECYCLED OFVARIOUS MATERIALSVARIOUS MATERIALS

- 80% of the asphalt pavement removed each year is reused.- 60% Aluminium Cans- 56% Newspaper- 37% Plastic Drinking Bottles- 31% Glass Bottles

((Recyclingtoday.com News - 5/1/00)

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By-ProductMaterials Produced

Production (Millionmetric tons)

Recycled in HighwayApplications

(Million metric tons)Applications

Blast Furnace Slag 14 12.6 ConcreteCoal Bottom Ash 14.5 4.4 Asphalt, Base

Coal Fly Ash 53.5 14.6Cement

Production,Structural FillFlowable Fill,

AsphaltCement Kiln Dust 12.9 8.3 StabilizerBottom Ash 8 Small Amounts Asphalt, BaseNonferrous Slags 8.1 ? Base, Asphalt

Steel Slags ? 7.5 Base, Asphalt,Concrete

Recycled AsphaltPavement (RAP) 41 33 Asphalt, Base

ReclaimedConcrete ? ? Base, Concrete

Foundry Sands 9 to 13.6 ?

Use of Recycled Materials in U.S. Highway

Public Roads - US Department of TransportationFederal Highway Administration. 2005


Use of Recycled Materials in ENGLAND

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Use of Recycled Materials in Singapore

The Straight Times, March 19, 2009 - Thursday


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- is a mixture of aggregates, filler, bitumen andoccasionally additives.

In an increasing number of countries old asphalt ordemolition waste is recycled to replace virgin aggregateand part of the binder.


materials is environmental friendlyand absolutely saves money. Recycling old asphaltpavement is not only proven to be cost effective but anenvironmental process helping to save the naturalresources and revitalize an existing pavement.

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//RECLAIMED ASPHALT PAVEMENTRECLAIMED ASPHALT PAVEMENT

-are produced through milling, ripping,breaking, crushing or pulverizing

-are the materials used for recycling

-are combined with virgin aggregate and

mixed homogenously for the new hot mixasphalt mixture


+OLD / EXISTING PAVEMENT

(RECLAIMED ASPHALTPAVEMENT)

(RAP)

NEW AGGREGATE /NEW BITUMEN

NEW PAVEMENT

RECYCLING WITH ASPHALT MIXING PLANTRECYCLING WITH ASPHALT MIXING PLANT

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1) RECLAIMED ASPHALT PAVEMENT (RAP) FROM ROAD MILLING

2) RECLAIMED ASPHALT PAVEMENT (RAP) FROM EXCAVATED ROAD PAVEMENT

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RAPREADY FOR

AMP

WEARING COURSERAP FROM

ROAD B

BINDER COURSERAP FROM

ROAD C

CRUSHED,SCREENED

&

STOCKPILETESTED

BINDER COURSERAP FROM

ROAD A


3.3.Stockpile of Processed RAP

11..

4.4.

Stockpile of RAP

Crushing and Screening of RAP

2.2. Loading of RAP into aGranulator for crushing

Processing of Reclaimed Asphalt Pavement (RAP)

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WHAT IS REQUIRED IN A HOT RECYCLING PLANT SYSTEM?

ASPHALT MIXINGPLANT

HOTRECYCLING

PLANT

+


A)A) PREPARATION OF RAP BEFORE MIXING WITH HOT MIX:PREPARATION OF RAP BEFORE MIXING WITH HOT MIX:

Crushed the RAP by using Asphalt Granulator

Screen it passing into say 2 stockpiles of 0-10mm and11-19mm sieve screens.

Stockpile Processed RAP on location to prevent contaminationwith other materials & covered.

Take sample and perform Extraction Test to determine BitumenContent and Grading Analysis of the RAP.

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TESTING DETAILS OF RAP SAMPLETESTING DETAILS OF RAP SAMPLE

Collect RAP sample and extract the bitumen from the mix using the chemical, Tri-chlroethelyene (TCE) and the Centrifuge Lab equipment. Bitumen Content - TestMethod ASTM D2172.

Recover Bitumen from chemical using distillation method by Rotavapor equipment.

Determine Penetration of Bitumen with RAP - ASTM D5-95

Determine Softening Point of Bitumen + RAP - ASTM D6-95

Determine Viscosity of Bitumen + RAP - ASTM D4402-87 (re-approved 2000)


Crushing with Granulator

Processing of RAP materials withAsphalt Granulator.

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INSIDE HOPPER OF GRANULATOR

MILLING DRUM OF GRANULATOR


SCREENING PROCESS

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SCREENING MATERIAL INTO DIFFERENT STOCKPILES


Stockpile of RAP material crushed to required gradation

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Stockpile of RAP material crushed to required gradation


B)B) PREPARATION OF HOT MIX BEFORE MIXING WITH RAP:PREPARATION OF HOT MIX BEFORE MIXING WITH RAP:

Take samples from the 4/5 Hot Bins of the AMP.

Perform Sieve Analysis of each hot bin .

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C)C) MIX FORMULATION OF HOT MIX + RAPMIX FORMULATION OF HOT MIX + RAP

Prepare plant recipe for the hot mix + RAP.

RAP GradingAnalysis

until result fitsthe required

mix specification.

Mix Hot BinsGrading Analysis


0

10

20

30

40

50

60

70

80

90

100

37.5251913.26.3

3.351.180.3

0.075

Sieve Size in mm

% P

assi

ng

Min Max Combined grading

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I. HOT BIN AND RAP SIEVE ANALYSIS (% PASSING)HOT BIN (mm) 75 50 37.5 25 19 13.2 6.3 3.35 1.18 0.3 0.075

BIN 1 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0

BIN 2 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0

BIN 3 100.0 100.0 100.0 100.0 100.0 75.0 4.0 2.0 1.0 0.0 0.0

BIN 4 100.0 100.0 100.0 100.0 100.0 100.0 50.0 3.0 1.0 0.0 0.0

BIN 5 100.0 100.0 100.0 100.0 100.0 100.0 97.0 70.0 35.0 10.0 2.0

RAP 100.0 100.0 100.0 100.0 100.0 94.0 60.2 46.7 29.8 15.6 5.8

FILLER 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 99.0 58.0

II. HOT BIN AND RAP BLENDING

HOT BINRECIPE

(%) 75 50 37.5 25 19 13.2 6.3 3.35 1.18 0.3 0.075

BIN 1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

BIN 2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

BIN 3 25.0 25.0 25.0 25.0 25.0 25.0 18.8 1.0 0.5 0.3 0.0 0.0

BIN 4 5.0 5.0 5.0 5.0 5.0 5.0 5.0 2.5 0.2 0.1 0.0 0.0

BIN 5 34.0 34.0 34.0 34.0 34.0 34.0 34.0 33.0 23.8 11.9 3.4 0.7

RAP 30.0 30.0 30.0 30.0 30.0 30.0 28.2 18.1 14.0 8.9 4.7 1.7

FILLER 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 5.9 3.5

Specification Min 100 100 100 100 100 85 58 40 21 11 4

Mx 100 100 100 100 100 95 68 50 31 17 8

TARGET 100 100 100 100 100 90 63 45 26 14 6

Combined Grading 100.0 100.0 100.0 100.0 100.0 92.0 60.5 44.5 27.1 14.0 5.9

HOTMIX + RAP MIX FORMULATION REPORTHOTMIX + RAP MIX FORMULATION REPORT


D)D) MIX PROCEDURE OF HOT MIX + RAPMIX PROCEDURE OF HOT MIX + RAP-- Part IPart I

Hot Gas Generator generating heat between 230° - 250°C.

RAP should be heated thru Recycling Drum & conservation of heatfrom returned hot air with temperature of 180° -200°C.

No Direct Contact of Flame/Fire with RAP material.

Heated RAP material stored in Buffer Silo at temperature of 120° -140°C

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RECYCLEDASPHALT

Schematic View of Asphalt Recycling PlantSchematic View of Asphalt Recycling Plant


Environmental Friendly

Proper temperature control and re-circulation of hot gases

most of the re-circulated harmful substances are arrested at the hot airgenerator’s flame zone resulting in cleaner exhaust air.

asphalt fumes not circulated are captured by fines injected at the Flume Arresterbefore going into the baghouse.

Re-circulated hot gases reducing energy consumption due to increasing efficiencyrate

minimizes the production of harmful fumes from heating ofasphalt.

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Conservation of Energy

High pressure oil atomizing burner

Radial/axial flow fan couple with regulator

ensure exact air-fuel ratio to minimize fuel wastage andmaximum combusted flame at burner head.

Re-circulate Hot Air

Hot Air Generator flame entering is mixed with return air to give final optimum heat

transfer temperature of to the RAP

Special System Design Ensures optimum temperature of 120-140 Deg C for the RAP before

discharging to buffer silo


HOT RECYCLING PLANT

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RAP MATERIAL MOVEMENT


2 X RAP HOPPERS

Feeding RAP material into hoppers

RAP MATERIAL

MOVEMENT

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Hot Gas Generator

Hot Gas Generator used to heat RAP material.

RAP MATERIALMOVEMENT


Hot Recycling. Heating of RAP material inside the Recycling Drum

RAP MATERIAL MOVEMENT

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Buffer Silo/RAP Weigher

Buffer Silo for storage of heated

RAP material

RAP weigher

RAPRAPMATERIALMATERIAL

MOVEMOVEMENTMENT


Conveyor beltdischarging RAPinto Mixer

Opening intoMixer of AsphaltPlant

RAP Direction To Twin Shaft Mixer of AMP

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Mixing of heated RAP material and virgin aggregates insidetwin shaft mixer of asphalt plant

Discharge of Hot Mix

MIXER


D)D) MIX PROCEDURE OF HOT MIX + RAPMIX PROCEDURE OF HOT MIX + RAP –– Part IIPart II

Hot Mix goes thru normal process of AMP and RAP incorporated into themixer.

30% Recycling means each batch mix of say 2.0 tons, assume 100%, 1.4 ton(70%) Hot Mix and 0.6 ton (30%) of RAP.

Mix the Hot Mix + RAP according to the mixing time setting inthe computer. Hot Mix temperature of 150°-160°C.

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D)D) TEST OF HOT MIX WITH RAPTEST OF HOT MIX WITH RAP

Collect Hot Mix sample from AMP and extract the bitumen from the mix usingchemical (tri-chlroethelyene) and the Centrifuge Lab equipment.Bitumen Content - Test Method ASTM D2172.

Recover Bitumen from chemical using distillation method by Rotavapor equipment.

Determine Penetration of Bitumen with RAP - ASTM D5-95

Determine Softening Point of Bitumen + RAP - ASTM D6-95

Determine Viscosity of Bitumen + RAP - ASTM D4402-87 (re-approved 2000)


D)D) PERFORMANCE TEST OF HOT MIX + RAPPERFORMANCE TEST OF HOT MIX + RAP

1. Effect of Moisture on Asphalt Concrete Paving Mixtures.ASTM D4867 / D4867M – 96.

2. Indirect Tensile Stiffness Modulus Test. BS EN 12697-26 : 2004

3. Dynamic Creep Test. DD 226 : 96

4. Wheel Tracking Test. BS EN 12697-22 : 2003(E)

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QUALITY OF RECYCLED ASPHALT HOT MIX

AS GOOD AS HOT MIX FROM NEW MATERIALIF

- HOT RECYCLING PLANT IS UTILIZED

- RAP MATERIAL IS PROPERLYPROCESSED

-LABORATORY QUALITY CONTROL IS FOLLOWED


• WIDELY IN EUROPE, IN GERMANY > 30 YEARS

• UNITED STATES

• JAPAN, CHINA, KOREA, SINGAPORE

WHERE IS HOT RECYCLING UTILIZED?

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END


Contact : Lee Yen MengE-mail : [email protected] : (65) 9634-7651Tel : (65) 6863 1111Fax : (65) 6863 3811

Linnhoff Technologies Pte Ltd71 Tech Park CrescentTuas Tech ParkSingapore 638072

linnhoff presentation cold & hot recycling_2009

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