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The advances of the recycling of asphalt are very high

levelled.
Is the 100% Recycling of asphalt only a dream or is it
reality?

DR. JRGEN HUTSCHENREUTHER

www.hutschenreuther.de

Asphalt recycling

10.08.2014

The roads in Europe with


Raw Materials
Aggregates
(TL Gestein rocks)
Bitumen
(TL Bitumen)
Emulsions
(TL BE / Bitumen Emulsions)

Asphalt as the road product


ASPHALT
- TL Asphalt
- ZTV Asphalt

Recycling = Reduction of Costs and CO2


Sorted Reclaimed-Asphalt

Homogenised
Reclaimed-Asphalt
Production:
Recycling:

600000 tons of Asphalt per year


300000 tons of Asphalt per year

= 50% Recycling

European Spot Market (Dollars per Barrel)

High Oil Price forces Energy Reduction


150

100

50

0
1987
US Energy Information Administration, 2011

1992

1997

2002

2007

2011
5

True Recycling = Future of Asphalt

True
Recycling
Asphalt Layers
(AC, MA, PA,
PMA, PFA.)
max.34cm
Gravel Layers
Basement
(incl. Installations)

~30 cm

Down-Cycling
6

Waste of Asphalt Next Due To Start-Up and


Shut-Down
Undefined and inhomogeneous
mixture of aggregates and bitumen.
Cannot be used for high quality asphalt

Roofing for Deposits and Cold Feeders

Storage for reclaimed asphalt

Testing of the deposite (reclaimed asphalt)


according QMS / standards

Samples of reclaimed asphalt

Deposite of reclaimed asphalt


Taking min 5 samples of the deposite
(reclaimed asphalt)

Take min 5 samples of the deposite (reclaimed asphalt)

Producing an average sample of the 5 deposite samples


(reclaimed asphalt)
Test the average sample of the deposite in the lab
(reclaimed asphalt)
Make a new mix designand using the Test results of the
average sample of the deposite (reclaimed asphalt) , adding
the new modified Bitumen with CCBit113AD and
aggregates
Using for the new asphalt the maximum possible amount of
the deposite asphalt (reclaimed asphalt)

Alowed Content of Reclaimed


Asphalt
Country

Wearing Course

Belgium

25%

Denmark

Binder Course

Base Course
50%

30%

France

100%
40%

Germany

50%

100%

Hungary

10%

20%

Ireland

10%

50%

Poland

20%

30%

Portugal

10%

50%

10-50%

Sweden

20%

30%

Switzerland

30%*

Spain

*: Depending on traffic load

30%

60%
12

100
80
60

70
65

Acceptable Range
for Ring and Ball
Acceptable Range
for Penetration

40
20
0

60

50%

50
45

Possible RA addition range


without rejuvenators
0%
25%
0% RAP
100% B 70/100

55

75%

Resulting Ring and Ball [C]

Resulting Penetration of BItumen [mm/10]

Using RAP = Blending of Bitumen

40
100%100%
RAP
0% B 70/100
13

Allowed RA Ratio Depending on Homogeneity


according lab test results (QMS)
Variety of RA characteristics
Ring & Ball
Binder
< 63um

Germany, Base course, combined course, fundation, DAV

10.08.2014

63um-2mm

>2mm

RA Addition [%]

14

Typical Asphalt mix design (base course)


Sand 0/4
16%
Aggregates 4/8
5%

Reclaimed
Asphalt 0/16
49%

Base course
10.08.2014

Aggregates 8/16
26%

Filler
2%
Fresh Bitumen
70/100
2%
15

Reclaimed Asphalt + Fresh Bitumen


Reclaimed
asphalt

Fresh bitumen

Double-coated grains

+
Twin-shaft
mixer

=
16

RECYCLING ACCORDING EU
STANDARDS -ZERO LOSS METHOD

Cold milling machines are now bearing asphalt layers


with thicknesses up to 30 cm in one operation from.
By the choice of milling heads and their arrangement
on the milling, the milling pattern can be controlled.
Fine milling is possible to produce a base, on the
thinner asphalt layers can be applied. With cold
milling machines but also the individual asphalt
layers can be selectively expanded so that materials
with well-defined properties for reuse are (in hot
mixing plants) are available. When the milling is to
pay attention to the ingredients in layers to be milled
(eg asbestos) and appropriate health and safety
measures to be taken.

Fine milling

standard milling

milling head

Large milling machine in operation

Reclaiming

Prepare open the storge

Granular breaking process

Transportation

2 chanal adding

RA-Addition Systems for wanted


Requirements
RA Cold Additions

Continuous

Batch

Cold addition
direct into mixer
> 25% RA

Cold addition
via pug mill
max. 25% RA

RA Warm Additions

Conventional
Coflow,
directly heated
max. 70% RA

New
Counter flow,
indirectly heated
100% RA

Cold addition via


middle ring
max. 50% RA

28

Fuel Saving with Less Moisture


Drying
37%

Heating
Aggregates
54%

2% less moisture
- 1.4 kg oil
per tonne

Insulation Losses
< 2%

Exhaust Gas Losses


< 7%
Model Calculation, White dryer with 4% Moisture of Aggregates, 180C

29

Typical Batch Process

Mineral
Fller
Bitumen
Mischen
Entleeren

10

20

30

40

50

60

70

Discontinuous Production
www.ammann-group.com

30
10.08.2014

Start up solution
RA Cold Addition via Pug Mill for 25% RA at 3% Moisture
Advantages
RA and aggregates dosed
separately into pug mill
Superheated
aggregate

use of screen not affected


Inexpensive, straightforward
solution

Steam evacuation

good to combine with low


temperature mixes
Limits:
Steam evacuation
Superheating of aggregates
31

Combined Hot and Cold Recycling: Up to 60%


Proven technology
Parallel Drums for 60%
Cold Addition for 30%

32

RAH Hot RA

60% RA
@ 3% H2O

33

100% recycling device


RA dryer

Process air heater

Process air circulation


34

Blending of recycling material

0/8

8/16

16/32
Sculping screen

35

Summary
Many european countries have a recycling quote of almost
100%
The european countries adapt their individual standards and
strategies according to geological and meteorological
conditions
Europe has not installed one common standard
Standards for asphalt recycling are also handled individually
by each country
36

Requirements for High Rates of RA Addition


The prerequisites for this are

careful sourcing,
effective receiving inspection,
separate storage,
extensive initial type tests,
excellent mix design and
machine- and process-specific requirements to be
met by the mixing plant.

DAV, 2011

37

100%

DAV, 2011

38

Effects
The 100% recycling technology is totaly
environmantal friendly
It is a demand of EU standardisation
100% = no loss in material
As by using 50% reclaimed material you have
to add 50% virgin aggregates and
CCBit113AD mod. Bitumen, according the
new developed mix design.
Saving up to 50% of costs!!!

WTT Wheel Tracking Test

INDEPENDENT LAB: making mix design


and Check Testing of quality in lab and on site
Hamburg Device: Steel Wheels in Water Bath at 50C
New Device: Rubber Wheels in Air Bath at 60C (In Compliance with the European Standard)

Inspection on site
and Check Testing of quality

Different Techniques To Keep the Asphalt in the Road


dedicated counter flow drum
parallel drum
in drying drum
in pug mill
in elevator

0%

25%

50%

75%

Possible Ratio of Reclaimed Asphalt

100%
42

Dr. Hutschenreuther

43

www.ccbit113ad.com
www.hutschenreuther.de
For more information