RA 100 – The new dimension in use of RAP Rolf Jenny Senior Vice President Ammann Group Chairman...

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012

RA 100 – The new dimension in use of RAP

Rolf JennySenior Vice President Ammann GroupChairman Ammann Australia Pty. Ltd.

1

AAPA Technology Tour 18th June 2012

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 2

Road construction in Europe and Australia

Many similarities

Europe Australia

1. European market is extremely competitive• Coal dust is used as fuel -> big reduction in energy cost• High % of recycling -> big reduction in material cost• Latest technologies -> reduction in operating cost

2. European Road Construction requires maximum flexibility• Asphalt mix are adjusted to all kind of needs (>100 recipes)

3. European environmental standards are different • CO, NOX, C, dust ( applicable at all location ). • Wet washers/wet scrubbers are impossible to use in Europe

Important differences

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 3

+

Intact living space High Mobility

Sustainable road construction means:

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 4

It means also well maintained road network

Well maintained roads

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Improvements of construction equipment

Speed ofChange

1. Environmental Requirements2. Shift from “New Roads” to “Maintenance”3. Improved Quality Requirement 4. Economical Crisis5. Competitive Market

2000 2012

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These methods have gone a long time ago…

In the Mountains of Nepal in 2002

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 7

The good old days

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Today’s clean asphalt manufacturing

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Shift from new roads to maintenance

Road Maintenance

Total global Asphalt Production Tonnes per year

1980

Construction of New Road

• Growth of 4.1% each year• 2.2 billion tonnes in 2015• 0,3 to p.a and Inhabitant• North America 650 Mio. to

p.a 5% of the world population using 1/3 of the global prduction

• China 440 Mio. tonnes p.a2012 2015

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The 3 segments of global road construction markets

India, South America, Africa

Characteristics• low investment• mobility• projects

Total Asphalt Production

Maintenance

New Road

Rural to Paved Road

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 11

The 3 segments of global road construction markets

India, South America, Africa

Characteristics• low investment• mobility• projects

Total Asphalt Production

Maintenance

New Road

Rural to Paved Road

Maintenance

Total Asphalt Production

New Road

Rural to Paved Road

China, Russia, Eastern Europe, Asia Pacific

Characteristics• open for new

technologies• environment

coming• improved quality

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 12

The 3 segments of global road construction markets

India, South America, Africa

Characteristics• low investment• mobility• projects

Total Asphalt Production

Maintenance

New Road

Rural to Paved Road

Maintenance

Total Asphalt Production

New Road

Rural to Paved Road

China, Russia, Eastern Europe, Asia Pacific

Characteristics• open for new

technologies• environment

coming• improved quality

Maintenance

Total Asphalt Production

New Road

USA, Western Europe, Australia

Characteristics• environment• flexibility• quality

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 13

Ammann’s answer to the 3 segments

Total Asphalt Production

Maintenance

New Road

Rural to Paved Road

Maintenance

Total Asphalt Production

New Road

Rural to Paved Road Maintenance

Total Asphalt Production

New Road

EasyBatch Speedy Batch Blackmove 25-60% Recycling 75-100% Recycling

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 14

The future is already here

AC 0/11Recycling (0/11) 92 %Mineral (8/11) 8 %

Wearing coarse with 92% RECYCLING in Hamburg Germany

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Strategy: Recycling and Economy of scale

Production:1000‘000 t.p/aRecycling: 600‘000 t.p/a

Very well sortedReclaimed Asphalt

• Consolidation: 100 50 plants• High volume production• High recycling ratios• High flexibility

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 16

Hot and Cold Recycling up to 75%

Proven technology (Batch & Conti) 500 Parallel Drums for 60% 1000 Cold Additives for 30%

Limitations: • Super-heating• Emissions• RA outlet temperature

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 17

Strategy: 100% Recycling

• Highly Competitive thanks to RAP• High RAP storage volume• High flexibility• Quality Assured RAP

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012

Ammann developed a new asphalt recycling concept for 0% - 100% reclaimed asphalt

RAH 100% Reclaimed Asphalt Hot 100%

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 19

World’s 1st Plant Using up to 100% Recycling Asphalt

100% Recycling

Device

Why up to 100% recycling?•Excess of reclaimed asphalt•Ecological requirement to preserve natural resources•Economical to reuse available material

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 20

100% Recycling Device

Process Air HeaterRA Dryer

Process Air Circulation

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100% recycling device (protected)

Process Air Heater(combustion chamber)

Raw Gas to Filter (95°)

Drying Drum(turning)

Process Air Circulation

Gas MixingHeated Reclaimed Asphalt (165°C)

Low ageing of bitumen• No radiation heat• Soft heat exchange

High efficiency• Counter flow dryer• Process air

circulation

Low emissions (TOC)• Indirectly heated• Low temp. heat exchange

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 22

RAH 100% drying drum

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 23

Process air heater

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Treatment of reclaimed asphalt

Binder 4,0 %Filler 10,6 %Sand 45,8 %> 2 mm 43,6 %

Binder 3,6 %Filler 6,9 %Sand 24,7 %> 2 mm 68,4 %

Binder 5,1 %Filler 12,4 %Sand 52,5 %> 2 mm 35,1 %

RA 0/22

RA 0/8 RA 8/22

Screening

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Well sorted recycling materials

0/8

8/16

16/32

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Blending of reclaimed asphalt

0/8 8/16 16/32Scalping screen

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 27

Bitumen characteristics after heating

sample A (cold)taken at RA feeder

through-put timeapprox. 10 min.

sample B (hot)taken at drum

outlet

Determination of the parameter in the laboratory:

• Bitumen content• Grading curve

• Softening point ring & ball R&B• Penetration• Fraaß breaking point

to guarantee match of sample A and B

characteristic to evaluate thermal stress of bitumen

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 28

Bitumen characterstics after heating (guide values)

Softening point ring & ball:

R&B softening point before and after thermal stress of RA

56,4

6158,4

60,460,462,4

65,664,6

54,6

73,2

57,557,2 55,8

61,46163,2

60,4

66,668

70,2

55,2

76,2

6059,2 60

64,6

50

55

60

65

70

75

80

85

1. (160°C) 2. (163°C) 3. (164°C) 4. (190°C) 5. (162°C) 6. (155°C) 7. (120°C) 8. (167°C) 9. (170°C) 10. (192°C) 11. (170°C) 12. (145°C) 13. (183°C)

Sample No. and RA outlet temperature [°C]

R&

B v

alue

[°C

]

R&B (sample cold)

R&B (Sample hot)

Limit

vAverage:

Increase of the temperature of softening point R&B of 3°C.

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 29

Bitumen characterstics after heating (guide values)

Penetration in 1/10mm before and after thermal stress of RA

30

2022

35

31

26

15

31,2

15,1 15,518,8

23 23

2825

15

2125

26

23

11

30,4

9,711,3

13,8

23

0

5

10

15

20

25

30

35

40

1. (160°C) 2. (163°C) 3. (164°C) 4. (190°C) 5. (162°C) 6. (155°C) 7. (120°C) 8. (167°C) 9. (170°C) 10. (192°C) 11. (170°C) 12. (145°C) 13. (183°C)

Sample No. and RA outlet temperature [°C]

Pen

val

ue [1

/10m

m]

Pen (sample cold)

Pen (sample hot)

Limit Pen

Penetration values:

Average:

Decrease of penetration value of 0,5 mm; respectively 21%

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 30

Intelligent, fully integrated road construction

• Closing the Loop: from Road to Road• High quality, reduced costs and construction time• Ecology, Economy, Safety

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 31

AAPA resolution 2011

Australia Leader in Sustainable Road Construction– What we take out of the road, we put back!– Green Asphalt preferred in tenders– Government adopts performance based principles– Phase out processes that are not environmentally

friendly.

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 32

Leadership in sustainable road construction

National and state road authorities

Supporting new technologies

Road construction companies

Investing in new technologies

Equipment ManufacturingR&D new technologies

AAPAResolution 2011

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 33

Thank you very much for your attention

www.ammann-group.com

Productivity Partnership for a Lifetime

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Drivers for sustainbalbe road construction

Asphalt back to asphaltSustainable

Road Construction

Shift of Focus:- From new roads to

Maintenance

Government:- Emissions- Recycling

Financial:- Lack of Funding

- Market competitiveness

Tier IV„TA Luft“

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 35

Objective: The neutral asphalt plant

Direct and indirect emissions considered, without transport

0

50

kg C

O2 pe

r t o

f Asp

halt

TraditionalProduction

2• Asphalt Recycling• Low Temperature Mix• Lower Moisture Cont.

-25% CO

NewTechnology

• Alternative Energies• Ecology SW tools, • Integrated Constr.

Technologiesto come

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 36

Solar heated bitumen farm

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Global solar radiation

Many countries in best solar area

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 38

Wood dust fired burner

• CO2 neutral fuel• Cost savings

RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 39

Wood availability