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Asphalt T-140 Heating and Storing PDF
Asphalt T-140 Heating and Storing PDF
PREFACE
This technical paper is published
by Heatec, Inc. of Chattanooga,
Tennessee, a division of Astec
Industries.
It is hoped that the information
contained in the paper will benefit the hot mix asphalt paving
industry as a whole. Individual
copies may be obtained free of
charge by contacting the company.
This paper reflects the considerable experience and knowledge
Revised 11-24-03
Contents
2
3
3
4
6
9
10
11
12
12
12
13
13
15
15
17
18
19
Abstract
Heat conservation
Considerations
Basic needs
Increasing temperature
Vs maintaining it
Heating systems
Direct-fired tanks
Hot oil heaters
Expansion tanks
Electric heaters
Heating fuels
Heavy fuel preheaters
Fuel heating values
Monitoring fuel usage
Heater thermal efficiency
Impact of efficiency
Efficiency factors
Heatec heaters
20
20
21
22
24
25
25
28
28
29
32
34
35
36
37
38
39
39
40
Determining efficiency
Case histories
Burners
Heat loss
Proper insulation
HMA plant heating costs
Heat requirements
Portability
Equipment layout
Piping
Filters and valves
Asphalt pumps
Hot oil pumps
Asphalt metering
Calibration
Heater controls
Emissions
Containment
Horizontal Vs vertical tanks
Page 2
Abstract
Page 3
Figure 1
Waste not
Want not
Conservation of energy Is A Major Concern
Figure 2
Heat conservation
Considerations
Page 4
Figure 3
Figure 4
Basic needs
Page 5
Figure 5
Page 6
HOT OIL
PUMP
UNLOADING
PUMP
DIRECT-FIRED
ASPHALT TANK
WITH SCAVENGER COILS
METERING
PUMPS
Figure 6
JACKETED
PIPING
DRUM
MIXER
HOT OIL
HEATER
HORIZONTAL TANK
WITH COILS
HOT OIL
PUMP
ADDITIVE
TANK
FUEL
PREHEATER
TRAVERSE
CONVEYOR
METERING
PUMPS
UNLOADING
PUMP
Figure 7
JACKETED
PIPING
DRAG
CONVEYOR
SILO CONE
DRUM
MIXER
Increasing temperature
Vs maintaining it
Page 7
Heat Required (Btu)
Quantity
(Gallons)
Figure 8
5 Degree F
Increase
10 Degree F
Increase
15 Degree F
Increase
25 Degree F
Increase
1,000
20,000
40,000
60,000
100,000
5,000
100,000
200,000
300,000
500,000
6,750
135,000
270,000
405,000
675,000
10,000
200,000
400,000
600,000
1,000,000
15,000
300,000
600,000
900,000
1,500,000
20,000
400,000
800,000
1,200,000
2,000,000
25,000
500,000
1,000,000
1,500,000
2,500,000
30,000
600,000
1,200,000
1,800,000
3,000,000
35,000
700,000
1,400,000
2,100,000
3,500,000
Heat required = weight x specific heat x temperature difference. Weight = 8.0 pounds
per gallon. Specific heat (degrees F) = 0.5 Btu per pound per degree F. Heat required
does not include extra heat to make up for heat lost while heating.
Figure 9
Energy
Needed
Raise
Temperature
25 Degrees F
Maintain
Temperature
@ 300 Degrees F
Btu
4,127,810
1,127,810
Gallons
No. 2 Fuel
31.3
8.5
Page 8
Energy
Needed
Tank
With No
Insulation
Tank
With 3-inch
Insulation
Tank
With 6-inch
Insulation
Btu
1,034,653,248
33,834,296
18,475,382
Gallons
No. 2 Fuel
9,798
320
175
Figure 10
Temperature
& Energy
Tank
With No
Insulation
Tank
With 3-inch
Insulation
Tank
With 6-inch
Insulation
Bulk Temperature
After 60-Hours
252 Degrees F
281 Degrees F
289 Degrees F
Btu To Restore
After Shutdown
126,418,650
2,463,091
1,367,283
1197.1
23.3
12.9
Figure 11
Page 9
Figure 12
Figure 13
Heating systems
Page 10
RETURN TUBES
FIRE TUBE
COMBUSTION CHAMBER
Figure 14
BURNER
JACKETED EXHAUST STACK
LEVELS INDICATORS
ASPHALT
BURNER
FUEL
OVERFLOW PIPE
INSULATED BULKHEAD
Direct-fired tanks
Page 11
Figure 15
HELICAL
LIFTING
0.125-INCH
COIL HEATER
LUG ALUMINUM SKIN
(OPTIONAL)
TEMPERATURE
CONTROLLER
1/4-INCH STEEL
TANK WALL
LEVEL
INDICATOR
ACCESS
MANWAY LADDER
LIQUID ASPHALT
HEATING COILS
TEMPERATURE TIE-DOWN LUG
10-INCH
CONTROL VALVE
STEEL CHANNEL
SADDLE
OVERFLOW PIPE
EXPANSION
JOINT
Page 12
Figure 16
Expansion tanks
Electric heaters
Heating fuels
Asphalt heating systems using directfired tanks and hot oil heaters work with
a variety of fuels. The asphalt heating
system often uses the same fuel as the
aggregate dryer. And because the dryer
uses significantly more fuel than the
heating system, fuel choice is usually
based on dryer usage.
Two key concerns are availability of
the fuel and cost per Btu. However, the
amount of emissions it produces when
burned can be an overriding factor. Fuels
that produce high levels of emissions
are not well-suited for asphalt heating,
even though those same fuels may be
satisfactory for a dryer. Thats because
there are some important differences
Page 13
Figure 17
A heavy fuel preheater is used to preheat heavy fuel oil so it can be burned by
a fuel oil burner. Preheaters are typically
used to heat No. 5 or No. 6 fuel oils
for aggregate dryers. The pre-heating
lowers the viscosity of the oil so it can be
atomized by the burner.
A preheater is usually connected in the
fuel supply line between the fuel tank
and dryer. (Figure 17). Or, it can be
mounted inside the fuel tank. It may
be used to pre-heat the fuel flowing
directly to the burner when a single pass
through the heater raises its temperature
adequately for atomization. The fuel
may be recirculated to the fuel tank if
Page 14
Type
of Energy
Gross
or HHV
Net
or LHV
140,000 Btu/gal
132,000 Btu/gal
150,000 Btu/gal
143,250 Btu/gal
Propane (LPG)
90,500 Btu/gal
84,345 Btu/gal
Natural
1,040 Btu/Cu Ft
905 Btu/Cu Ft
Gas
104,000 Btu/CCF
Electricity
Figure 18
90,500 Btu/CCF
3,413 Btu/Kwh
CCF stands for 100 cu ft. The actual heating values of various fuels
vary from one region to another. However, the values used here are
for fuels commonly used in the US. Electrical energy is based on a
resistive load. HHV and LHV do not apply to electricity.
Type
of Energy
No. of Therms
(100,000 Btu)
Gross or HHV
Net or LHV
Net or LHV
0.714 gal
0.758 gal
0.667 gal
0.698 gal
Propane (LPG)
1.105 gal
1.186 gal
0.962 CCF
1.105 CCF
0.010 per cu ft
0.009 per cu ft
96.154 cu ft
110.497 cu ft
Natural
Gas
Electricity
Figure 19
29.300 Kwh
CCF stands for 100 cu ft. The actual heating values of various fuels vary from one region to another.
However, the values used here are for fuels commonly used in the US. Electrical energy is based on a
resistive load. HHV and LHV do not apply to electricity.
Page 15
Type
of Energy
Heating Value
(Net or LHV)
Billing
Units
NO. 2 FUEL
OIL
Btu/gal
132,000
Per
Gallon
$0.20
$0.30
$0.40
$0.50
$0.60
$0.70
$0.80
$0.90
$1.00
$1.10
$1.20
NO. 5 FUEL
OIL
Btu/gal
143,250
Per
Gallon
$0.22
$0.33
$0.43
$0.54
$0.65
$0.76
$0.87
$0.98
$1.09
$1.19
$1.30
PROPANE
(LPG)
Btu/gal
84,345
Per
Gallon
$0.13
$0.19
$0.26
$0.32
$0.38
$0.45
$0.51
$0.58
$0.64
$0.70
$0.77
NATURAL
Btu/CCF
(see note)
90,500
Per
CCF
$0.14
$0.21
$0.27
$0.34
$0.41
$0.48
$0.55
$0.62
$0.69
$0.75
$0.82
GAS
Btu/Therm
100,000
Per
Therm
$0.15
$0.23
$0.30
$0.38
$0.45
$0.53
$0.61
$0.68
$0.76
$0.83
$0.91
Btu/Kwh
3,413
Per
Kwh
$0.01
$0.01
$0.01
$0.01
$0.02
$0.02
$0.02
$0.02
$0.03
$0.03
$0.03
ELECTRICITY
Each column of cost comparisons relates the costs of various types of energy to each other based on heating values. For example, the
cost of No. 2 fuel oil at $1.00 per gallon is equivalent to a cost of $1.09 for No. 5 fuel oil for the same Btu. Thus, if No. 2 fuel oil is
$1.00 per gallon it doesnt pay to choose No. 5 fuel oil unless it is less than $1.09. Likewise, it wouldnt pay to use electricity unless it
is less than $0.03 per Kwh when No. 2 fuel oil is $1.00 per gallon. The actual heating values of various fuels vary somewhat from one
region to another. However, the values used here are for fuels commonly used in the US. CCF stands for 100 cubic feet. The net heating
value of one cubic foot of natural gas is 905 Btu. However, natural gas is normally billed at its gross heating value, which is approximately 1,000 Btu per cubic foot.
Figure 20
Page 16
MOISTURE
STACK
LOSS
HOT OIL
HEATER
Figure 21
WALL LOSS
GROSS
HEAT
INPUT
(HHV)
NET
(LHV)
AVAILABLE
HEAT
OUTPUT
TO HELICAL
COIL
HEATER
EFFICIENCY
50 PERCENT
$15.15
60 PERCENT
$12.63
70 PERCENT
$10.82
80 PERCENT
$9.47
85 PERCENT
$8.91
Figure 22
Heating load = 1,000,000 Btu per hour. No. 2 fuel oil LHV (low heating
value) = 132,000 Btu per gallon. No. 2 fuel oil cost = $1.00 per gallon.
Page 17
Figure 23
Heater
Efficiency (%)
50
60
70
80
85
88
Gallons
per hour
Total Gallons
15.15
2,036,364
$2,036,364
12.63
1,696,970
$1,696,970
10.82
1,454,546
$1,454,546
9.47
1,272,727
$1,272,727
8.91
1,197,861
$1,197,861
8.61
1,157,025
$1,157,025
Total cost
Heat demand = 1 million Btu. Fuel = No. 2 diesel oil (132,000 Btu per gallon).
Fuel cost = $1.00 per gallon.
Operation = 24 hours per day, 7 days a week, 40 weeks a year, 20 years
(heater life).
Long Term Fuel Costs For Various Efficiencies
Impact of efficiency
Page 18
Figure 24
Figure 25
Efficiency factors
Page 19
Figure 26
Heatec heaters
Page 20
BLOWER
HELICAL COIL
Figure 27
CONVECTIVE TRANSFER
RADIANT
TRANSFER
BURNER
Determining efficiency
Case histories
Figure 28
Page 21
1130
1100
1070
1039
1003
972
945
910
875
840
805
770
746
708
665
625
595
558
525
495
465
435
390
348
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
Stack Temperature
vs.
Heater Efficiency
65
70
75
80
85
90
95
Figure 29
High-Low Burner
Burners
Page 22
Figure 30
Figure 31
Heat loss
Page 23
Figure 32
Figure 33
Figure 34
Insulated
Jacket
Insulated
3 inches
4 inches
1598
86
1890
120
4 inches
6 inches
2349
122
2600
134
5 inches
8 inches
3057
148
3240
178
Uninsulated
Insulated
Uninsulated
1-1/2 inches
676
47
1205
97
2 inches
846
54
1660
115
2-1/2 inches
1024
55
2155
125
3 inches
1243
72
2485
130
Insulated
Revised 11-24-03
Page 24
Insulation Thickness For Various Operating Temperatures
Pipe
Diameter
150
Degrees F
200
Degrees F
300
Degrees F
400
Degrees F
500
Degrees F
600
Degrees F
1 inch
1 inch
1 inch
1 inch
1-1/2 inches
1-1/2 inches
2 inches
1-1/4 inches
1 inch
1 inch
1 inch
1-1/2 inches
1-1/2 inches
2 inches
1-1/2 inches
1 inch
1 inch
1 inch
1-1/2 inches
2 inches
2 inches
2 inches
1 inch
1 inch
1 inch
1-1/2 inches
2 inches
2-1/2 inches
2-1/2 inches
1 inch
1 inch
1 inch
1-1/2 inches
2 inches
2-1/2 inches
3 inches
1 inch
1 inch
1 inch
1-1/2 inches
2 inches
2-1/2 inches
3-1/2 inches
1 inch
1 inch
1 inch
1-1/2 inches
2 inches
2-1/2 inches
4 inches
1 inch
1 inch
1 inch
1-1/2 inches
2 inches
2-1/2 inches
5 inches
1 inch
1 inch
1 inch
1-1/2 inches
2-1/2 inches
2-1/2 inches
6 inches
1-1/2 inches
1-1/2 inches
1-1/2 inches
2 inches
2-1/2 inches
3 inches
8 inches
1-1/2 inches
1-1/2 inches
1-1/2 inches
2 inches
2-1/2 inches
3 inches
Figure 35
Horizontal Tank
No Insulation
Horizontal Tank
3-inch Insulation*
Horizontal Tank
6-inch Insulation*
10,000
633,850
21,217
11,760
15,000
791,621
26,179
14,347
20,000
1,006,753
33,117
18,118
25,000
1,221,886
40,054
21,889
30,000
1,437,018
46,992
25,660
35,000
1,562,050
50,933
27,755
40,000
1,786,536
58,411
31,813
Figure 36
*Btu values are for new Heatec tanks and do not include heat for valves
or connections. Old tanks may require double the heat or more.
Asphalt temperature = 300 degrees F.
Asphalt TanksMaintaining Temperature
Proper insulation
Page 25
Figure 37
Capacity
(Gallons)
No Insulation
3-inch Insulation*
10,000
170,952
5,941
15,000
213,504
7,330
20,000
271,526
9,273
25,000
329,548
11,215
30,000
387,570
13,158
*Btu values are for new Heatec tanks and do not include heat for valves or connections. Old tanks may require double the heat or more.
Type of fuel = No. 6 fuel oil. Fuel temperature = 150 degrees F
Fuel TanksMaintaining Temperature
Figure 38 shows the daily costs for heating asphalt, fuel and plant components at
a typical stationary HMA plant. Figure
39 shows the daily costs for heating
asphalt and plant components at a typical
relocatable HMA plant.
Figure 40 shows the daily costs for heating asphalt and plant components at a
typical portable HMA plant.
Note that daily usage shown in figures
38, 39 and 40 is not equal to 24 times
the hourly usage. This is because the
heat load on the hot oil system drops
while the plant is operating. We assumed
that the plant was operating for 8 hours
during the 24 hour period.
Heat requirements
Page 26
Hourly Usage
Btu
Gallons
No. 2 Fuel
CCF
Natural Gas
Btu
Gallons
No. 2 Fuel
CCF
Natural Gas
93,984
0.8
1.2
2,255,620
20
29.3
40,054
0.4
0.5
961,305
12.5
336,709
3.0
4.4
8,081,020
72
105.1
43,520
0.4
0.6
1,088,000
10
14.1
68,250
0.6
0.9
1,706,250
15
22.2
99,649
0.9
1.3
2,391,570
21
31.1
19,500
0.2
0.3
487,500
6.3
9,940
0.1
0.1
238,560
3.1
14,920
0.1
0.2
358,080
4.7
726,526
6.5
9.5
17,567,905
157
228.4
6.48
6.52
156.58
157.58
Figure 38
Asphalt temperature = 300 degrees F. Thermal oil temperature = 350 degrees F. Fuel temperature = 150 degrees F.
Heater efficiency = 85%. Tank insulation = 3 inches. Pipe insulation = 1-1/2 inches. No. 2 fuel cost = $1.00 per gallon.
Natural gas cost = $0.69 per CCF. Heavy fuel oil is used only for drum mixer. Usage includes heating for unloading pump and
metering. Highlighted cells Include additional heat load for first hour cold start.
Hourly Usage
Btu
Gallons
No. 2 Fuel
CCF
Natural Gas
Btu
Gallons
No. 2 Fuel
CCF
Natural Gas
2,255,620
20.1
29.3
93,984
0.8
1.2
38,640
0.3
0.5
966,000
8.6
12.6
55,575
0.5
0.7
1,389,375
12.4
18.1
0.7
1,234,533
11.0
16.1
51,439
0.5
9,750
0.1
0.1
243,750
2.2
3.2
9,940
0.1
0.1
238,560
2.1
3.1
14,920
0.1
0.2
358,080
3.2
4.7
2.5
3.6
6,685,918
2.45
2.46
274,248
Cost
59.6
86.9
59.58
59.97
Figure 39
Asphalt temperature = 300 degrees F. Thermal oil temperature = 350 degrees F. Fuel temperature = 150 degrees F.
Heater efficiency = 85%. Tank insulation = 3 inches. Pipe insulation = 1-1/2 inches. No. 2 fuel cost = $1.00 per gallon.
Natural gas cost = $0.69 per CCF. Heavy fuel oil is used only for drum mixer. Usage includes heating for unloading pump and
metering. Highlighted cells Include additional heat load for first hour cold start.
Hourly Usage
Btu
Gallons
No. 2 Fuel
CCF
Natural Gas
Btu
Gallons
No. 2 Fuel
CCF
Natural Gas
42,260
0.4
0.6
1,014,240
9.0
13.2
35,200
0.3
0.5
880,000
7.8
11.4
19,500
0.2
0.3
487,500
4.3
6.3
7,360
0.1
0.1
176,640
1.6
2.3
10,600
0.1
0.1
254,400
2.3
3.3
114,920
1.0
1.5
2,812,780
25.1
36.6
1.0
1.0
25.06
25.23
Asphalt temperature = 300 degrees F. Thermal oil temperature = 350 degrees F. Fuel temperature = 150 degrees F.
Heater efficiency = 85%. Tank insulation = 3 inches. Pipe insulation = 1-1/2 inches. No. 2 fuel cost = $1.00 per gallon.
Natural gas cost = $0.69 per CCF. Heavy fuel oil is used only for drum mixer. Usage includes heating for unloading pump and
metering. Highlighted cells Include additional heat load for first hour cold start.
Figure 40
Page 27
Figure 41
Pre-Startup
Run
213,091
35,200
215,929
38,640
349,270
43,520
38,725
19,363
50,171
25,085
117,000
90,962
135,000
93,184
168,000
101,884
214,000
111,230
275,000
120,752
351,000
131,156
442,000
142,618
Figure 42
Equipment
Pre-Startup
100,000
17,735
150,000
21,635
200,000
25,719
250,000
30,590
300,000
33,216
24,911
5,720
Run
34,465
9,750
3,736
390
4,377
585
4,698
683
3,593
336,709
Silos have heated cones and gates, 6-inch sidewall insulation, 8-inch cone insulation.
Page 28
Figure 43
Portability
Equipment layout
Page 29
Figure 44
Piping
Page 30
Figure 45
Figure 46
Page 31
HOT OIL
HEATER
VERTICAL TANK
WITH COILS
HORIZONTAL TANK
WITH COILS
CIRCULATING
PUMP
FUEL
PREHEATER
MANIFOLD
Figure 47
METERING
PUMPS
SIDE
PUMPS
(TWO)
TRAVERSE
CONVEYOR
ADDITIVE TANK
UNLOADING
PUMP
DRAG
CONVEYOR
JACKETED
PIPING
DRUM
MIXER
SILO
CONE
Page 32
Figure 48
Figure 49
Page 33
Figure 50
Figure 51
Page 34
Figure 52
Asphalt pumps
Page 35
Figure 53
Page 36
Figure 54
Asphalt metering
Page 37
Figure 55
Figure 56
Calibration
Page 38
Figure 57
Heater controls
Page 39
Figure 58
Emissions
Containment
Page 40
Figure 59
Figure 60
Horizontal Vs vertical
tanks
Page 41
Figure 61
Figure 62
(Figure 61).
Page 42
SPRAY BAR
Figure 63
PUMP
INLET
STAGNANT ZONE
MIXERS
IN IDEAL LOCATIONS
MANWAY
Figure 64
SMALLER
STAGNANT
ZONE
Page 43
NOTES
Page 44
NOTES
HEATEC
an Astec company