Sustainability and Innovation in Asphalt Production

1

14/06/2018David Hunt

Control �Warm Asphalt �Recycling �

Control System as1

Ammann Automation – a core competence

5 decades of control system engineering experience

as1 control systems for asphalt, concrete and mineral processing plants

95 countries30 user languages

More than 4000 systems deliveredof which 1600 as1

Ammann Automation – a core competence

Comprehensive software development knowledge Microsoft Certified Partner

as1 based on latest technologiesWindows 10 / SQL 2016 / Profinet

Core competence in control system retrofit for Ammann plants and third-party brands

Scalable as1 system conceptfor small and large plants

How the as1 control system ensures maximum quality and reliability and helps to reduce costs in asphalt production?

Ammann as1 Control System

Easy handling and fully automatic production�Data for quality and process improvements è KPI’s�Maintenance, operator training and support�

• Type examination certificate for automatic catchweighinginstrument

• Accuracy classes Y(a) and Y(b)

• Conformity with the international requirements for weighing instruments OIML R51-1

AS1 Type examination certificate

Weighing accuracy

… weighing accuracy is the base for maximum hot mix quality.

Automatic inflight correction for more accurate dosing

Inflight correction(batch related)

Correction due to deviation of theflow speed

Flow speed

- +

[kg/s]

Inflight

Correction due to deviation ofmultiple weighings

Inflight calculation(continuous)

Scale end weight[kg]

Tolerance bandSoll

������

Correction of inflightparameter

Inflight

High information level – Operator always kept in the loop

Actual capacityAveragedaily capacity

Steam flap

Doorheating

Drop door

Mixer loadNominal mix timeActual mix time

Bag addition

# units

Mixed material

temperature

Shut off flap fibre

Actual batchsize

closed

Opening/closing

open

Wait for unlock

Error

offStart uponAfter run activeError

• Quality report for a recipe within a definable period

• Immediate evaluation after production

• Detection of quality deviations

• Evaluation according freely definable quality requirements

AS1 QualiView – Visualized quality

Benefit

… helps localizing causes of defect and to improve asphalt mix quality

• Management of any sample plans for freely configurable recipe groups

• Reminder for the operator when a sample is due to be taken

• Evaluation of the OCL (Operating Compliance Level) according EN13108-21

• Seamless process documentation

AS1 Sample Planning – certified quality

Benefit

Asphalt plant

Asphalt laboratoryResults Sample

AS1 indicates

sample due

AS1 evaluates operating compliance level

… supports the asphalt sample takingprocess according EN13108-21

• Automatic online transfer of the related production data to the lab

• Analysis of production data by the lab without delay

• Fast detection of possible quality problems

• Sample plan transfer between lab and mixing plant

• Integrated inspection scheduling in accordance with EN 13108

• Less administration work on the plant

AS1 LDE – online connected to the laboratory

Benefit

… online quality data workflow for timely lab analysis and less administration work …

Laboratory

LASTRADA

AS1 Client

Orders, sites, clients

Products, recipes

Product ID and Spec.

Delivery Ticket

Interface between Client, AS1 and LASTRADA

=> Sales=> Operations

=> Technical

Goals:No double data entry for Product Code, Recipe, Order, Delivery Ticket

• Simple display for the operator about his energy consumption development

• Visualization of the most important indices

• Shows long term energy consumption trends

• Generates transparency and comparability between various plants

• Shows larger deviations and irregularities

AS1 EcoView – Energy efficiency made visible

Benefit

… only those who know how much and where energy is consumed, can influence

Electrical energy Bitumen tank heating E-BIT

Electrical energy Entire plant

Fuel(s)White burner

Fuel(s)Black burner

Total energy consumption

AS1 EcoView – Report of energy per tonnes

Statistics – for every stakeholder

• Batch protocol (drying / mixing)• Batch summary protocol (mixing)• Production statistics• Component statistics• Component per recipe statistics• Recycling statistics• Capacity reports• Management report• Daily reports• Quality reports• Event counter report (operation hours etc.)• Parameter reports• Recipe listings• Fieldbus occupation• Error listings

AS1 Excel addIn – create your own dash board

as1 Plant Information Point (cloud service)

• Online document archive access• Business intelligence based on actual

plant data• Asphalt order APP• Plant order management

Low Temperature Asphalt – Foam Asphalt

19

Paving of hot mix asphalt

165 �C

Paving of foam asphalt

100�C

Foam Asphalt on the Job Site

Low Temperature Asphalt – Foam Asphalt

20

Hot Mix Asphalt Low Temperature Asphalt

10°C temperature decrease = 50% decrease of fumes

180 �C 115�C

Foam asphalt on the asphalt plant

CO2-Emissions of Asphalt Production

21

Asphalt-Mixing-PlantDirect Emissions

LogisticsCO2

RAP Dryer CO2

Bitumen StorageCO2

Aggregate Dryer

CO2

Indirect EmissionsProduction of raw materials and energy

Productionof BitumenAggregatesElectricity

CO2

CO2-Emissions of Asphalt Production

22

Production of raw materials and energy

Specific model calculation, Transport not included (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

Asph

alt

Bit. Storage Logistics Dryer

During asphalt production

20 kg CO2

Direct Emissions

Total50 kg CO2

Low Temp. Asphalt

Low Temperature Asphalt – Foam AsphaltBasic Principle of Foam Asphalt Production

23

Hot Bitumen

160°C

+Cold

Water2 - 4%

=Bitumen

Foam

+Fine

Distribution

1 litre 0.03 litre 15 litres

5% of asphalt

0.15% of asphalt

water: 0.05% of asphalt

Low Temperature Asphalt

24

0�C 50�C 100�C 150�C 200�C

Drying and heating

Heating

Fuel

con

sum

ptio

n

Cold Mix Asphalt Warm Mix Asphalt Hot Mix Asphalt

Global trend towards reduction of asphalt mix temperature

115�C 180�C

1.5 kgfuel/t

CMA

FoamBitumen

AdditivesHMA

Low Temperature Asphalt – Foam AsphaltBasic Principle of Foam Asphalt Production

25

Static Mixer

Hot Bitumen

Foaming water2-4% of bitumen(0.1-0.2% of asphalt)

Spraying nozzles

High pressure (water & bitumen)

Foamed bitumen

Mixer

Asphalt Recycling

26

Down-Cycling

Recycling

Re-Usage of Old Roads

Asphalt Recycling

27

Addition intoaggregate dryervia middle ring

max. 50% RAP

Cold Recycling Systems

Cold addition via hot elevator

max. 15% RAP

Cold additiondirect into mixer

25% - 40% RAP

Warm Recycling Systems

Separate dryer todry and preheatRAP and thenaddition into mixer

max. 60% RAP

Separate counterflow dryer to dry and preheat RAP and then additioninto mixer

max. 100% RAP

Asphalt Recycling

28

RAP Cold Addition into the Mixer

Addition rates of25% to 40% achievable.

Superheatedaggregate

Steam evacuation

Cold RAP feed

270°C

170°C

20°C

Asphalt Recycling

29

RAP Warm Addition via Separate RAP Dryer

Combination of cold- and warm-addition for maximum flexibility!

220-240°C

120-140°C

160-180°C

Addition ratesof up to 60% achievable.

Asphalt Recycling

30

Warm RAP System

Cold RAP System

Combinablewith 100%

Hot Recycling System

Ammann Universal HRT

CO2-Emissions of Asphalt Production

31

Model calculation, Transport not considered (5-15 kg CO2 per t of Asphalt)

Production of raw materials and energy

Indirect Emissions

30 kg CO2

0

5

10

15

20

Aggregates Bitumen Electricity

kg C

O2

per

t of

Asp

halt

Bit. Storage Logistics Dryer

During asphalt production

-4 to -5kg CO2

Direct Emissions

Low Temp. Asphalt

Asphalt-Recycling

CO2-Emissions of Asphalt Production

32

Model calculation, Transport not considered (5-15 kg CO2 per t of Asphalt)

Indirect Emissions

0

5

10

15

20

Aggregates Bitumen Electricity

kg C

O2

per

t of

Asp

halt

Bit. Storage Logistics Dryer

Reduction of30% CO2

Low Temp. Asphalt

Asphalt-Recycling

Direct Emissions

33

Low temperature and recycling: Global trends

U.S.A.: 25% of asphalt produced is low temperature asphalt, ofwhich 90% is produced with foam bitumen.

NL:Over 70% of reclaimed asphalt is being reused for roadconstruction. 60% of paved asphalt contains RAP material.

China?- Construction of new roads shifts to road maintenance.- Strong thightening of environmental protection laws.

Three Crucial Steps towardsSustainable Asphalt Production

Thanks for listening!