BITUMEN EMULSION PLANTS



FRIGMAIRES OFFERS COMPLETE PLANTS ON A TURN KEY BASIS FOR THE PRODUCTION OF MODIFIED BITUMENS SUCH AS EMULSIONS.CUT BACKS.BLOWN BITUMEN.MEMBRANES AND COATINGS. THE SERVICES OFFERED BY US INCLUDES PLANT DESIGN.DETAILED ENGINEERING SERVICES,TANK FARM DESIGN,EQUIPMENT MANUFACTURE AND SUPPLY,ERRECTION AND COMMISIONING.LAB SET UP.TRAINING .FORMULATIONS.RAW MATERIAL SOURCING AND SUPPLY.PLANTS ARE TAILOR MADE TO MEET THE PROJECT COST AND LOCAL MARKET CONDITIONS.
PRODUCT RANGE FOR WHICH WE OFFER PLANT AND TECHNOLOGY :


EMULSIONS: RAPID SET.MEDIUM SET AND SLOW SET (IS 8887-2004)

CUT BACKS:RAPID SET.MEDIUM SET AND SLOW CURING

PMB:PMB120.PMB70.PMB40(ELASTOMERIC AND PLASTOMERIC (IS 15462) CRMB:CRMB50,55,60 (IS 15462) OXIDISED BITUMEN VG10,20,&30 (1S 702)

MEMBRANES: TORCH ON AND SELF ADHESIVE MEMBRANES

COATINGS: FLEXIBLE ROOF COATINGS.BITUMEN PAINTS. PROTECTIVE COATINGS AND PRIMERS

ADVANTAGES OF EMULSION PLANTS.

  • Single Source responsibility for complete plant design right from Civil-Mechanical-Electrical to Chemical process.
  • Client’s scope of work limited to bare minimum.
  • Know how and training based on years of manufacturing experience.
  • Modern Laboratory set up to meet basic international specifications (Optional).
  • Plant design complies with local standards and safety features.
  • Reduced manpower requirement.
  • Specially designed Asphalt pumps fitted with Frequency inverter for precise speed control.
  • Savings in power, user and environment friendly plant.
  • Corrosive resistant pumps with all Stainless Steel contact parts resistant to acids.
  • Use of flow meters for accurate readings.
  • Carefully designed for maintenance free and continuous operations.
  • GREASE PLANTS

  • Uses

    Rapid Setting (RS):
    Used in surface dressing and patch repair work.

    Medium Setting (MS):
    Used in pre mix with less quantity of fine aggregates and pothole repair works.

    Slow Setting (SS):
    Used in premix with appreciable quantity of fine aggregates such as slurry seal and fog seal.


    BRIEF PROCESS DESCRIPTION: 80/100 Bitumen at a flow able temp of 100-120C is pumped into the Soap Tank. Water, Emulsifiers, Chemicals and additives are fed into the Soap preparation tank at approx 40C.The flow is controlled using flow meters, instruments and gauges. Both the Bitumen and prepared Soap are pumped together into the Colloid mill at a controlled rate which breaks the bitumen into fine particles and a bitumen emulsion is prepared. The Bitumen Emulsion is finally discharged into a storage tank or into barrels.



    1.POLYMER MODIFIED BITUMEN (PMB)The properties of paving bitumen and bituminous mixes can be improved by addition of certain polymers and additives.The polymers change the elasto viscous behavior of the bitumen produced and make the binder more suitable to handle high stress. The mix produced using these polymers is called PMB.

    TYPES OF PMB AS PER IS15462

    PMB120: For cold climatic areas (<-10 Deg. C).

    PMB70: For moderate climatic areas (10 to –10 Deg. C).

    PMB 40 For hot climatic areas (>10 deg. C).

    USES: Bituminous mix prepared with modified bitumen are quite suitable for renewal course and overlay material on surfaces which are badly cracked and subjected to heavy traffic. They perform better than ordinary bitumen in high rainfall areas and in situationswhere aggregates are pronetostripping. Due to better creep resistance they can be used at busy intersections, bridge decks and roundabouts etc for increased life of the surfacing.

    EXAMPLE:For use on roads subject to high stress and traffic density(highways,airportsetc).For open pored asphalt layers,For water proof coatings

    PROCESS DESCRIPTION FOR MODIFIED BITUMEN: The raw bitumen at 180 degrees centigrade is pumped at a controlled feed rate and pressure into a specially designed heavy duty high shear milling machine. High quality polymers are simultaneously dosed into the mill using a polymer dosing system. The formulation is controlled by a PLC to manufacture the required grade of PMB.On exiting the mill chamber the processed product is transferred to the finished product storage tank provided with a recirculation pumping arrangement.

    2.Crumb Rubber Modified Bitumen CRMB is a homogenous and stable dispersion of crumb rubber articles in bitumen. Crumb Rubber is basically a 40-50 mesh size powder of scrap vulcanized tyres which is added at high temperatures to the bitumen with devulcanising and cross linking agent which aids in swelling of crumb rubber particles and also creates bond between bitumen and rubber. The bitumen rubber binder thus obtained has much enhanced engineering properties than of virgin bitumen. Due to rubbery nature of this binder it has the following benefits over conventional binder:

    »Low glass transition temperature which gives excellent performance properties of pavement at low temperatures.

    »Stiffer blend which reduces rutting and stability at high temperatures.

    »Enhanced dimensional stability and strength of pavement.

    »Improved abrasion resistance of pavement.

    »Improved fatigue resistance.

    »Improved oxidation and aging resistance.

    »Reduced structural thickness of pavement.

    »Improved UV resistance due to presence of carbon black.

    »Reduced life cycle cost of pavement.

    CRMB is available in the following grades:

    i-CRMB 50

    ii-CRMB 55

    iii-CRMB 60

    BRIEF PROCESS :As a first step the rubber powder is mixed with oil to facilitate devulcanisation and easy dispersion. This also prevents settlement.The dosage of crumb rubber to bitumen is 10%. This gives an elastic recovery of about 60%.The rise in softening rise is around 5-6 deg C due to rubber addition.The crumb rubber powder is added through the ports situated at the top of the tanks.The temperature of mixing is maintained at 190/195 deg C. The stirring and re-circulation is done for 2 hours.The sample is tested for softening point, penetration and elastic recovery. All the other tests on the sample are carried out as per IS 15462.The lot is transferred to the storage tank for further process.

    3.BITUMENEMULSIONS: Emulsified asphalt has been used for road development and waterproofing for many years. As a road material it finds application as a slurry seal for the surface layer, pot whole repair and as a bonding coat for subsequent layers. FE 5 MT Asphalt Emulsion Plant is used for producing various types of emulsified asphalts as well as SBR modified asphalt. The plant is designed for continuous operation. All operations can be performed fully-automatically, semi-automatically or manually. Our plant has been designed to keep operator requirements to the minimum and only needs two operators to conduct all the operations. The main job of the operator is to feed emulsifier to the plant and of periodic valve control. The complete plant is mounted on a sturdy mobile skid and can be moved to the required site with ease.

  • BATCH PROCESS
  • CONTINIOUS LINE
  • BITUMEN MEMBRANE MFG LINE

    Technical parameters

    1. Production capacity: annual production of modified bitumen membranes of 1-3 million Sqm. (16 hours/day, 300days/year with two shifts)

    2. Reinforcement: Polyester, Glass fiber

    3. Modified materials : SBS, APP

    4. Materials for surface: sand, scraps of stone, PE membrane, aluminum foil, etc.

    5. Specification of products: Width: 1m, thickness: 2-5mm, length: 7.5 or 10m

    6. Production speed: 0-30 m/min。

    7. Main workshop: 48× (12-15) ×(6-9)m

  • EQUIPMENT

    THE PLANT COMPRISES OF

    1. Raw Asphalt Tank made from Carbon Steel construction. Asphalt tank is provided with a Geared drive Agitator. Tank is duly insulated and cladded with aluminum sheets.

    2. Soap Preparation Tanks in SS 304 construction fitted with a Geared Drive agitator.

    3. Colloid Mill complete with heating jacket, recirculation line and gauges.

    4. Complete set of jacketed Pipelines, Instruments and Valves all within battery limits.

    5. Pumps (Asphalt Soap and Dope) with VFD’s, flow meters and gauges. Pumps are fitted with motors and mounted on base frames.

    6. Complete plant mounted on steel skid.

    7. Electric control panel with PLC for above plant is provided.

    8. Storage tanks with heating coils and Asphalt Pump 1 no

    9. Water Storage Tank with Pump and heater 1no

    10. Lab Equipment (Heating Unit for Bitumen.

  • ABOUT EMULSIONS

    Emulsified asphalt has been used for road development and waterproofing for many years. As a road material it finds application as a slurry seal for the surface layer, pot hole repair and as a bonding coat for subsequent layers. FE Asphalt Emulsion Plant is used for producing various types of emulsified asphalts as well as SBR modified asphalt.

    The plant is designed for continuous operation. All operations can be performed fully-automatically, semi-automatically or manually. Our plant has been designed to keep operator requirements to the minimum and only needs two operators to conduct all the operations. The main job of the operator is to feed emulsifier to the plant and of periodic valve control. The complete plant is mounted on a sturdy mobile skid and can be moved to the required site with ease.

    WHAT IS BITUMEN EMULSION: An Emulsion is a mixture of two immiscible liquids, one of which is dispersed in the other in the form of very fine particles. The process of emulsification is accomplished by use of an emulsifier and a stabilizer. A colloid mill is generally used for the preparation of an emulsion.

    TYPES OF BITUMEN EMULSION: Anionic: In which bitumen particles are negatively charged & Cationic: in which the bitumen particles are positively charged.

  • BRIEF PROCESS DESCRIPTION:

    80/100 Bitumen at a flow able temp of 100-120C is pumped into the Soap Tank. Water, Emulsifiers, Chemicals and additives are fed into the Soap preparation tank at approx 40C.The flow is controlled using flowmeters, instruments and gauges. Both the Bitumen and prepared Soap are pumped together into the Colloid mill at a controlled rate which breaks the bitumen into fine particles and a bitumen emulsion is prepared. The Bitumen Emulsion is finally discharged into a storage tank or into barrels.

    CUTBACK BITUMEN: The bitumen, which is used for road construction, is semisolid or solid at atmospheric temperature, is brought to certain viscosity value as required for road construction operation by fluxing it with certain petroleum distillates to obtain cutback bitumen. Upon exposure to atmospheric conditions the distillates evaporate. Leaving the bitumen to perform its function.

    TYPES OF CUTBACK BITUMEN: Rapid Curing (RC), Medium Curing (MC) & Slow Curing (SC).

    USES: RC: for surface dressing in cold weather and patch repair work. MC: are used in premix with less quantity of fines and SC: are used in premix with more quantity of fines.

    PROCESS DESCRIPTION FOR CUTBACK BITUMEN: The raw bitumen from the raw material storage tank, which is at 180DegC, is taken into the Blowing Column, where the bitumen of desired softening point and penetration is obtained (IF REQUIRED). It is then pumped into the Cutback Mixing Tank where, first the temperature of bitumen is brought down to around 100Deg. C. by water circulation in the coils provided and then it is fluxed with petroleum distillate for about thirty minutes to obtain the desired grade of Cutback bitumen. The final product is then pumped to the finish material storage tank.