LINNHOFF TECHNOLOGIES

Presented by: LEE YEN MENG Gen. Sales Manager

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Better roads with Linnhoff

ASPHALT FOUND TO BE MOST RECYCLED OF VARIOUS 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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Better roads with Linnhoff

Use of Recycled Materials in U.S. Highway

By-Product Materials Produced Blast Furnace Slag Coal Bottom Ash Coal Fly Ash Foundry Sands Cement Kiln Dust Bottom Ash Nonferrous Slags Steel Slags Recycled Asphalt Pavement (RAP) Reclaimed Concrete Production (Million metric tons) 14 14.5 53.5 9 to 13.6 12.9 8 8.1 ? 41 ? Recycled in Highway Applications (Million metric tons) 12.6 4.4 14.6 ? 8.3 Small Amounts ? 7.5 33 ? Applications Concrete Asphalt, Base Cement Production, Structural Fill Flowable Fill, Asphalt Stabilizer Asphalt, Base Base, Asphalt Base, Asphalt, Concrete Asphalt, Base Base, Concrete

Use of Recycled Materials in ENGLAND

Public Roads - US Department of Transportation Federal Highway Administration. 2005

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Better roads with Linnhoff

Use of Recycled Materials in Singapore

The Straight Times, March 19, 2009 - Thursday

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Better roads with Linnhoff

- is a mixture of aggregates, filler, bitumen and occasionally additives. In an increasing number of countries old asphalt or demolition waste is recycled to replace virgin aggregate and part of the binder.

materials is environmental friendly and absolutely saves money. Recycling old asphalt pavement is not only proven to be cost effective but an environmental process helping to save the natural resources and revitalize an existing pavement.

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Better roads with Linnhoff

/RECLAIMED 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 mix asphalt mixture

RECYCLING WITH ASPHALT MIXING PLANT

OLD / EXISTING PAVEMENT (RECLAIMED ASPHALT PAVEMENT) (RAP)

+
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NEW AGGREGATE / NEW BITUMEN

NEW PAVEMENT
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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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Better roads with Linnhoff

BINDER COURSE RAP FROM ROAD A WEARING COURSE RAP FROM ROAD B

CRUSHED, SCREENED & STOCKPILE TESTED

1. Stockpile of RAP
READY FOR AMP

Processing of Reclaimed Asphalt Pavement (RAP)

2.

Loading of RAP into a Granulator for crushing

RAP

BINDER COURSE RAP FROM ROAD C

4.Stockpile of Processed RAP

3. Crushing and Screening of RAP

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Better roads with Linnhoff

WHAT IS REQUIRED IN A HOT RECYCLING PLANT SYSTEM?

ASPHALT MIXING PLANT
A) 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 and 11-19mm sieve screens. Stockpile Processed RAP on location to prevent contamination with other materials & covered. Take sample and perform Extraction Test to determine Bitumen Content and Grading Analysis of the RAP.

+
HOT RECYCLING PLANT

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Better roads with Linnhoff

TESTING DETAILS OF RAP SAMPLE

Collect RAP sample and extract the bitumen from the mix using the chemical, Trichlroethelyene (TCE) 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)

Crushing with Granulator

Processing of RAP materials with Asphalt Granulator.

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INSIDE HOPPER OF GRANULATOR

SCREENING PROCESS

MILLING DRUM OF GRANULATOR Better roads with Linnhoff Better roads with Linnhoff

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Stockpile of RAP material crushed to required gradation

SCREENING MATERIAL INTO DIFFERENT STOCKPILES

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Better roads with Linnhoff

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Stockpile of RAP material crushed to required gradation

B) 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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Min

Max

Combined grading

C) MIX FORMULATION OF HOT MIX + RAP

RAP Grading Analysis until result fits the required mix specification.

100 90 80 70

Mix Hot Bins Grading Analysis

60 50 40 30 20 10 0

Prepare plant recipe for the hot mix + RAP.

5 07 0.

3 0.

18 1.

35 3.

3 6.
Sieve Size in mm

.2 13

19

25

.5 37

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Better roads with Linnhoff

% Passing

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HOTMIX + RAP MIX FORMULATION REPORT

I. HOT BIN AND RAP SIEVE ANALYSIS (% PASSING)
HOT BIN BIN 1 BIN 2 BIN 3 BIN 4 BIN 5 RAP FILLER (mm) 75 100.0 100.0 100.0 100.0 100.0 100.0 100.0 50 100.0 100.0 100.0 100.0 100.0 100.0 100.0 37.5 100.0 100.0 100.0 100.0 100.0 100.0 100.0 25 100.0 100.0 100.0 100.0 100.0 100.0 100.0 19 100.0 100.0 100.0 100.0 100.0 100.0 100.0 13.2 100.0 100.0 75.0 100.0 100.0 94.0 100.0 6.3 100.0 100.0 4.0 50.0 97.0 60.2 100.0 3.35 100.0 100.0 2.0 3.0 70.0 46.7 100.0 1.18 100.0 100.0 1.0 1.0 35.0 29.8 100.0 0.3 100.0 100.0 0.0 0.0 10.0 15.6 99.0 0.075 100.0 100.0 0.0 0.0 2.0 5.8 58.0

D) MIX PROCEDURE OF HOT MIX + RAPRAP- Part I

Hot Gas Generator generating heat between 230 - 250C. RAP should be heated thru Recycling Drum & conservation of heat from returned hot air with temperature of 180 -200C. No Direct Contact of Flame/Fire with RAP material. Heated RAP material stored in Buffer Silo at temperature of 120 140C

II. HOT BIN AND RAP BLENDING HOT BIN BIN 1 BIN 2 BIN 3 BIN 4 BIN 5 RAP FILLER RECIPE (%) 0.0 0.0 25.0 5.0 34.0 30.0 6.0 75 0.0 0.0 25.0 5.0 34.0 30.0 6.0 100.0 100 100 100 50 0.0 0.0 25.0 5.0 34.0 30.0 6.0 100.0 100 100 100 37.5 0.0 0.0 25.0 5.0 34.0 30.0 6.0 100.0 100 100 100 25 0.0 0.0 25.0 5.0 34.0 30.0 6.0 100.0 100 100 100 19 0.0 0.0 25.0 5.0 34.0 30.0 6.0 100.0 100 100 100 13.2 0.0 0.0 18.8 5.0 34.0 28.2 6.0 92.0 85 95 90 6.3 0.0 0.0 1.0 2.5 33.0 18.1 6.0 60.5 58 68 63 3.35 0.0 0.0 0.5 0.2 23.8 14.0 6.0 44.5 40 50 45 1.18 0.0 0.0 0.3 0.1 11.9 8.9 6.0 27.1 21 31 26 0.3 0.0 0.0 0.0 0.0 3.4 4.7 5.9 14.0 11 17 14 0.075 0.0 0.0 0.0 0.0 0.7 1.7 3.5 5.9 4 8 6

Combined Grading

Specification

Min
Mx

TARGET

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Schematic View of Asphalt Recycling Plant

Environmental Friendly
Proper temperature control and re-circulation of hot gases
minimizes the production of harmful fumes from heating of asphalt. most of the re-circulated harmful substances are arrested at the hot air generators flame zone resulting in cleaner exhaust air. asphalt fumes not circulated are captured by fines injected at the Flume Arrester before going into the baghouse. Re-circulated hot gases reducing energy consumption due to increasing efficiency rate

RECYCLED ASPHALT

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Better roads with Linnhoff

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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 and maximum 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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Better roads with Linnhoff

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RAP MATERIAL MOVEMENT

RAP MATERIAL MOVEMENT

2 X RAP HOPPERS

Feeding RAP material into hoppers

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Better roads with Linnhoff

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Hot Gas Generator used to heat RAP material.

Hot Recycling. Heating of RAP material inside the Recycling Drum

RAP MATERIALMOVEMENT

RAP MATERIAL MOVEMENT Hot Gas Generator

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Better roads with Linnhoff

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Buffer Silo/RAP Weigher

Buffer Silo for storage of heated RAP material

Opening into Mixer of Asphalt Plant

RAP weigher Conveyor belt discharging RAP into Mixer

RAP MATERIAL MOVE MENT RAP Direction To Twin Shaft Mixer of AMP

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Better roads with Linnhoff

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

D) MIX PROCEDURE OF HOT MIX + RAP Part II

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

MIXER

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 in the computer. Hot Mix temperature of 150-160C.

Discharge of Hot Mix

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D) TEST OF HOT MIX WITH RAP

Collect Hot Mix sample from AMP and extract the bitumen from the mix using chemical (tri-chlroethelyene) and the Centrifuge Lab equipment. Bitumen Content - Test Method ASTM D2172. Recover Bitumen from chemical using distillation method by Rotavapor equipment.

D) PERFORMANCE 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

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)

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

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Better roads with Linnhoff

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QUALITY OF RECYCLED ASPHALT HOT MIX

AS GOOD AS HOT MIX FROM NEW MATERIAL IF - HOT RECYCLING PLANT IS UTILIZED - RAP MATERIAL IS PROPERLY PROCESSED -LABORATORY QUALITY CONTROL IS FOLLOWED

WHERE IS HOT RECYCLING UTILIZED? WIDELY IN EUROPE, IN GERMANY > 30 YEARS UNITED STATES JAPAN, CHINA, KOREA, SINGAPORE

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Better roads with Linnhoff

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Better roads with Linnhoff

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Better roads with Linnhoff

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Better roads with Linnhoff

Better roads with Linnhoff

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END

Contact E-mail Mobile Tel Fax

: : : : :

Lee Yen Meng ymlee@linnhoff.com (65) 9634-7651 (65) 6863 1111 (65) 6863 3811

Linnhoff Technologies Pte Ltd 71 Tech Park Crescent Tuas Tech Park Singapore 638072

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Better roads with Linnhoff

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