Need to construct and sustain roads better? Bitumen emulsion is a new, eco-friendly and cost effective material replacing conventional hot-mix asphalt. Learn how this multitasking solution can help the next project, save on energy and help in making our future a better place.
Efficiency and sustainability are not merely buzz words in the modern road construction and maintenance industry, and they are actually a requirement. The conventional hot-mix asphalt needs immense temperature, uses enormous levels of energy and emits harmful emissions. In this case, bituminemulsion comes in as a better option since it is safer, cleaner and less expensive.
A bitumen emulsion is a liquid, water-soluble suspension of fine particles of bitumen suspended in water, and maintained by an emulsifying agent. This new technology enables bitumen to be manipulated and to be used in much lower temperatures; there will be no need to heat it further and spend a lot of money and adversely affect the environment.
Production of a good quality bitumen emulsion is a multi-stage and precise process and is dependent on specific equipment and balance of ingredients. The core components are
1. Bitumen:
This is the main adhesive and is melted to a liquid form in order to lower its viscosity.
The endless stage where the bitumen is scattered.
Emulsifying Agent: A chemical surfactant which covers the particles of the bitumen and it provides them with an electrical charge and moreover they are not able to re-coalesce.
Acids or other chemicals that are added to modify the pH of the water phase so that the final emulsion could maintain stability and the required characteristics.
The milling process is mainly performed in a colloid mill. This is a strong engine that is the core of the process. The following is a simplified list of the steps:
Water is heated, and the emulsifying agent and other additives are well mixed in it to produce a soap solution. The kind of emulsifier on the type of emulsifier to be used will dictate whether the end product will be cationic (positively charged) or anionic (negatively charged).
The uncooked Bitumen is heated to approximately 135o C to make it pumpable.
The Emulsification Process: The aqueous solution and the heated bitumen are measured into the colloid mill. The mill is made by high speed rotor rotating over a static stator and the strong shear forces separate the bitumen into tiny droplets, generally only a few microns in width.
When the droplets of bitumen are sheared the emulsifying agent coats each minute particle and provides it with a uniform electrical charge. This is a charge that causes the droplets to repel one another and consequently, they do not reglue to form a homogenous liquid. The ensuing emulsion is cooled and stored.
This careful procedure makes sure that the bitumen is in suspension in water therefore it can be easily handled, transported and used without the need of using high temperatures in heating.
A bitumen emulsion plant refers to the entire industrial plant or modular unit, which is intended to automate and control the entire above process of manufacturing. It is an advanced system which consists of:
Bitumen and Water Tanks: To store and heat the raw materials.
Aqueous Phase Tank: In this step, the water, emulsifier and other additives are combined.
Dosing Systems: Accurate pumps and flow meters to maintain the right amounts of each of these components into the colloid mill.
Colloid Mill: This is the heart on which the emulsification is done.
Control System: It is an automated system (frequently controlled by a PLC) that regulates temperatures, flow rates and mixing ratios to maintain products of consistent quality.
The main benefits of a well-designed bitumen emulsion plant include: accuracy in formulation, efficient manufacturing and the capacity to manufacture various type of emulsions (e.g.
rapid-setting, medium-setting and slow-setting) that could be used to suit different project needs. New plants can be modular and containerized in nature, and can be transported and installed on-site, which further increases their cost-efficiency and cross-application.
The paving industry is undergoing a revolution with the Emulsion technology offering a variety of advantages that the conventional methods cannot offer:
Bitumen emulsion can be applied to ambient or low temperatures, which will reduce energy consumption and greenhouse gas emissions significantly. It also avoids the emission of harmful fumes, hence it is safer to the workers and environment.
The fuel becomes cheaper as the heating needs are lower. Cold-mix asphalt is also capable of being used and ensures that the construction season lasts longer and hence construction can still occur in colder climates.
There is no high-temperature handling required so the chances of burns and fire risks are eliminated dramatically.
Bitumen emulsions are applicable in a large range of applications including surface dressing, tack coats, fog seals, and cold-mix asphalt to repair potholes and to apply new layers of pavement.
The liquid nature of the emulsion is convenient to the aggregates penetration and adhesion resulting in a stronger and durable bond and extended pavement.
With increased pressure on the world to build greener and more resilient infrastructures, bitumen emulsion will be adopted as the new road construction material. When you adopt solutions that run on this new technology, not only are you investing in the future viability of the projects that you are undertaking, but you will also be investing in a green and clean future.
Worried to know more about how our sophisticated bitumen emulsion plants can be used to serve as a sure solution to the next project? Today, you should contact us to reveal to us your unique needs and realize what difference could be made out of good and innovation.
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