LINNHOFF TECHNOLOGIES

Presented by: LEE YEN MENG Gen. Sales Manager

Better roads with Linnhoff…

Better roads with Linnhoff…

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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)

Better roads with Linnhoff…

Better roads with Linnhoff…

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4 14. Asphalt.5 9 to 13. 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 14.6 12.US Department of Transportation Federal Highway Administration. Base Base. Base Base.S.6 4.1 ? 41 ? Recycled in Highway Applications (Million metric tons) 12. Asphalt Stabilizer Asphalt. 2005 Better roads with Linnhoff… Better roads with Linnhoff… 3 .5 53.3 Small Amounts ? 7. Concrete Asphalt.5 33 ? Applications Concrete Asphalt. Structural Fill Flowable Fill.9 8 8.Use of Recycled Materials in U. Base Cement Production. Concrete Use of Recycled Materials in ENGLAND Public Roads .6 ? 8. Asphalt Base.

2009 . March 19.Thursday Better roads with Linnhoff… Better roads with Linnhoff… 4 .Use of Recycled Materials in Singapore The Straight Times.

materials is environmental friendly and absolutely saves money. Better roads with Linnhoff… Better roads with Linnhoff… 5 .is a mixture of aggregates. filler.. bitumen and occasionally additives. 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. In an increasing number of countries old asphalt or demolition waste is recycled to replace virgin aggregate and part of the binder.

/RECLAIMED ASPHALT PAVEMENT -are produced through milling. 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) + Better roads with Linnhoff… NEW AGGREGATE / NEW BITUMEN NEW PAVEMENT Better roads with Linnhoff… 6 . ripping. breaking.

1) RECLAIMED ASPHALT PAVEMENT (RAP) FROM ROAD MILLING 2) RECLAIMED ASPHALT PAVEMENT (RAP) FROM EXCAVATED ROAD PAVEMENT Better roads with Linnhoff… Better roads with Linnhoff… 7 .

Stockpile of Processed RAP 3. Loading of RAP into a Granulator for crushing RAP BINDER COURSE RAP FROM ROAD C 4. Stockpile of RAP READY FOR AMP Processing of Reclaimed Asphalt Pavement (RAP) 2.BINDER COURSE RAP FROM ROAD A WEARING COURSE RAP FROM ROAD B CRUSHED. Crushing and Screening of RAP Better roads with Linnhoff… Better roads with Linnhoff… 8 . SCREENED & STOCKPILE TESTED 1.

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. + HOT RECYCLING PLANT Better roads with Linnhoff… Better roads with Linnhoff… 9 . 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.

ASTM D4402-87 (re-approved 2000) Crushing with Granulator Processing of RAP materials with Asphalt Granulator. Trichlroethelyene (TCE) and the Centrifuge Lab equipment. Better roads with Linnhoff… Better roads with Linnhoff… 10 . Determine Penetration of Bitumen with RAP .ASTM D5-95 Determine Softening Point of Bitumen + RAP . Bitumen Content . Recover Bitumen from chemical using distillation method by Rotavapor equipment.ASTM D6-95 Determine Viscosity of Bitumen + RAP .TESTING DETAILS OF RAP SAMPLE Collect RAP sample and extract the bitumen from the mix using the chemical.Test Method ASTM D2172.

INSIDE HOPPER OF GRANULATOR SCREENING PROCESS MILLING DRUM OF GRANULATOR Better roads with Linnhoff… Better roads with Linnhoff… 11 .

Stockpile of RAP material crushed to required gradation SCREENING MATERIAL INTO DIFFERENT STOCKPILES Better roads with Linnhoff… Better roads with Linnhoff… 12 .

Perform Sieve Analysis of each hot bin . Better roads with Linnhoff… Better roads with Linnhoff… 13 .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.

2 13 19 25 . 3 0.Min Max Combined grading C) MIX FORMULATION OF HOT MIX + RAP RAP Grading Analysis until result fits the required mix specification.5 37 Better roads with Linnhoff… Better roads with Linnhoff… % Passing 14 . Sieve Size in mm . 3 6. 5 07 0. 100 90 80 70 Mix Hot Bins Grading Analysis 60 50 40 30 20 10 0 Prepare plant recipe for the hot mix + RAP. 18 1. 35 3.

0 100.HOTMIX + RAP MIX FORMULATION REPORT I.0 44.0 100.9 6.0 2.0 0.0 100.0 34.0 1.0 0.0 0.0 100 100 100 19 0.0 6.0 100.0 6.0 92.0 5.0 60.5 100. No Direct Contact of Flame/Fire with RAP material.0 100.3 100.0 100.0 100.0 34.0 0.0 25 100.0 0.9 14.0 5.0 25.0 11 17 14 0.3 0.0 29.0 6.2 0.8 58.0 100.9 8.7 3.0 0.0 25.0 19 100.2 23.0 34.0 100.0 0.0 100.0 100.0 30.0 0.075 100.0 100.0 6.5 40 50 45 1.0 5.0 34.4 4.075 0.18 0.0 100.0 27.0 75.0 5.0 100.2 6.0 0.0 37.0 34.5 58 68 63 3.0 100 100 100 13.0 100.0 100.0 60.2 100.0 0.5 5.0 3.0 100.0 100.0 0.0 30.0 0.0 100 100 100 25 0.0 100.0 30.0 100.0 100.0 34.0 0.18 100.5 33.0 5.0 0.0 70.0 35. RAP should be heated thru Recycling Drum & conservation of heat from returned hot air with temperature of 180° -200°C.1 11.0 100.0 4.0 100.0 97.0 0.0 100.0 0.7 5.0 3.8 100.0 100.0 50 100.0 100.0 25.0 100.0 0.35 100.0 46.0 2.5 0.0 25.0 100.0 0.0 100.0 1.0 30.0 100.3 0.7 100.0 100.0 0.0 100.8 14.0 100. Heated RAP material stored in Buffer Silo at temperature of 120° 140°C II.0 0.0 100.0 2.0 100.0 50.0 18.0 94.0 6.0 100.0 0.0 30.0 0.0 15.8 5.9 4 8 6 Combined Grading Specification Min Mx TARGET Better roads with Linnhoff… Better roads with Linnhoff… 15 .0 100.0 100 100 100 50 0.0 6.0 100.5 0.0 5.0 6.0 100.0 0.0 25.0 85 95 90 6.0 75 0.0 6.0 10.3 100. HOT BIN AND RAP SIEVE ANALYSIS (% PASSING) HOT BIN BIN 1 BIN 2 BIN 3 BIN 4 BIN 5 RAP FILLER (mm) 75 100.0 100.0 100.0 100 100 100 37.0 100.Part I Hot Gas Generator generating heat between 230° .0 28.1 21 31 26 0.0 1.250°C.3 0.0 30. HOT BIN AND RAP BLENDING HOT BIN BIN 1 BIN 2 BIN 3 BIN 4 BIN 5 RAP FILLER RECIPE (%) 0.2 100.0 25.0 18.1 6.0 0.0 100.0 13.35 0.0 3.0 1.0 0.0 D) MIX PROCEDURE OF HOT MIX + RAPRAP.0 100.0 5.7 1.0 34.6 99.

 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 Better roads with Linnhoff… Better roads with Linnhoff… 16 .  most of the re-circulated harmful substances are arrested at the hot air generator’s flame zone resulting in cleaner exhaust air.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.

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 Better roads with Linnhoff… Better roads with Linnhoff… 17 .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.

RAP MATERIAL MOVEMENT RAP MATERIAL MOVEMENT 2 X RAP HOPPERS Feeding RAP material into hoppers Better roads with Linnhoff… Better roads with Linnhoff… 18 .

Heating of RAP material inside the Recycling Drum RAP MATERIALMOVEMENT RAP MATERIAL MOVEMENT Hot Gas Generator Better roads with Linnhoff… Better roads with Linnhoff… 19 . Hot Recycling.Hot Gas Generator used to heat RAP material.

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 Better roads with Linnhoff… Better roads with Linnhoff… 20 .

MIXER 30% Recycling means each batch mix of say 2.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.4 ton (70%) Hot Mix and 0. Hot Mix temperature of 150°-160°C. 1. assume 100%. Mix the Hot Mix + RAP according to the mixing time setting in the computer. Discharge of Hot Mix Better roads with Linnhoff… Better roads with Linnhoff… 21 .0 tons.6 ton (30%) of RAP.

Dynamic Creep Test. Indirect Tensile Stiffness Modulus Test. ASTM D4867 / D4867M – 96. Wheel Tracking Test.ASTM D5-95 Determine Softening Point of Bitumen + RAP . D) PERFORMANCE TEST OF HOT MIX + RAP 1. 2.ASTM D6-95 Determine Viscosity of Bitumen + RAP . BS EN 12697-26 : 2004 3. DD 226 : 96 Determine Penetration of Bitumen with RAP .Test Method ASTM D2172. BS EN 12697-22 : 2003(E) Better roads with Linnhoff… Better roads with Linnhoff… 22 . Recover Bitumen from chemical using distillation method by Rotavapor equipment.ASTM D4402-87 (re-approved 2000) 4.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. Effect of Moisture on Asphalt Concrete Paving Mixtures. Bitumen Content .

KOREA. SINGAPORE Better roads with Linnhoff… Better roads with Linnhoff… 23 .HOT RECYCLING PLANT IS UTILIZED . CHINA.QUALITY OF RECYCLED ASPHALT HOT MIX AS GOOD AS HOT MIX FROM NEW MATERIAL IF . IN GERMANY > 30 YEARS • UNITED STATES • JAPAN.RAP MATERIAL IS PROPERLY PROCESSED -LABORATORY QUALITY CONTROL IS FOLLOWED WHERE IS HOT RECYCLING UTILIZED? • WIDELY IN EUROPE.

Better roads with Linnhoff… Better roads with Linnhoff… 24 .

Better roads with Linnhoff… Better roads with Linnhoff… 25 .

Better roads with Linnhoff… Better roads with Linnhoff… 26 .

com (65) 9634-7651 (65) 6863 1111 (65) 6863 3811 Linnhoff Technologies Pte Ltd 71 Tech Park Crescent Tuas Tech Park Singapore 638072 Better roads with Linnhoff… Better roads with Linnhoff… 27 .END Contact E-mail Mobile Tel Fax : : : : : Lee Yen Meng ymlee@linnhoff.