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EME demonstra�on project Q – March 2014 Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
02 Ge�ng the mix design to work – Dis�n 1
Supported by
Delivering the job -‐ Produc�on
Chris Lange Boral Asphalt
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 2
Overview • Plant • Materials management • Process control • Mixing • QA
Aggregate Stockpile Management
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 3
Plant
116600ttpphh BBaattcchh PPllaanntt 66 CCoolldd FFeeeedd BBiinnss
22..44mm ddiiaa ccoouunntteerr ffllooww ddrruumm
22..2255tt mmiixxeerr
33 ffiilllleerr ssiillooss
33 xx 110000tt ffiinniisshheedd pprroodduucctt ssiillooss
44 bbiittuummeenn ttaannkkss – eelleeccttrriicc hheeaatteedd
CCoommppuutteerriisseedd mmiixxiinngg ssyysstteemm
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 4
Schema�c of Plant
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 5
Materials Management Aggregate • Careful a�en�on to
aggregate quality – mee�ngs with
Quarries – stock pile gradings
checked • High percentage
crusher dust (90% higher than DG20HM)
• No natural sand • High percentage
passing the 75 micron
Aggregate Stockpile Management
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 6
Materials Management Bitumen – EME Binder • Ensure tank able to heat and maintain temperature of 1850C
• Electrically heated (thyristor control to ensure slow rise)
• Tank flushed prior to taking load of EME binder
EME Binder Temp: 1850C
Page 2
EME demonstra�on project Q – March 2014 Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 7
Process Control Aggregate • Calibra�on of cold feed
bins • High % crusher dust – ran
two feeders to ensure accuracy
• Baghouse fines quan��es required -‐ checked
• Blend sheets reviewed and checked
• Plant trials to check gradings / binder contents
• Plant scales calibrated
Aggregate Stockpile Management
Cold Feed Calibration: Bin 1 - 10mm Aggregate
0102030405060
1 2 3
Belt Speed
tph
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 8
Process Control • Bitumen
– Tank selec�on – Circula�on – Temperature during
mixing – Inline samples taken
during produc�on – Samples taken at
supplier depot and on delivery from tanker
Aggregate Stockpile Management
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 9
Mixing and Batching • Operators briefed on ITP • Mixing temperature monitored closely: target 1850C and then 1800C
• 75 micron target 8.4% • Batching cycle �mes 50sec • Bitumen temperature maintained at 1850C
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 10
Grading Achieved
0
10
20
30
40
50
60
70
80
90
100
0.075 0.15 0.3 0.6 1.18 2.36 4.75 6.7 9.5 13.2 19 26.5 37.5
Sieve size (mm) (not to log scale)
% P
assi
ng
Strategic Allia
nce Worksho
p EM
E De
mon
stra�o
n project in Q
Produc�on – Chris Lange 11
Compliance tes�ng Sieve size Max tolerance spec Actual 13.2mm +-‐ 6 % 4
9.5mm +-‐ 6 % -‐1
6.7mm +-‐ 6 % -‐2
4.75mm +-‐ 6 % -‐2
2.36mm +-‐ 3 % 2
1.18mm +-‐ 3 % -‐1
0.6mm +-‐ 3 % -‐1
0.3mm +-‐ 3 % -‐1
0.15mm +-‐ 3 % 0
0.075mm +-‐ 1 % +1.1
Binder content +-‐ 0.5 % -‐0.1
