DR. JÜRGEN HUTSCHENREUTHER

The advances of the recycling of asphalt are very highlevelled.Is the 100% Recycling of asphalt only a dream or is itreality?

www.hutschenreuther.de

10.08.2014 2

Asphalt recycling

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

4

Recycling = Reduction of Costs and CO2

HomogenisedReclaimed-Asphalt

Production: 600‘000 tons of Asphalt per yearRecycling: 300‘000 tons of Asphalt per year

= 50% Recycling

Sorted Reclaimed-Asphalt

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High Oil Price forces Energy Reduction

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100

150

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US Energy Information Administration, 2011

2011

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True Recycling = Future of Asphalt

Asphalt Layers(AC, MA, PA,PMA, PFA….)max.34cm

Gravel Layers

Basement(incl. Installations)

~30 cm

Down-Cycling

TrueRecycling

Waste of Asphalt Next Due To Start-Up andShut-Down

Undefined and inhomogeneousmixture of aggregates and bitumen.

Cannot be used for high quality asphalt

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Roofing for Deposits and Cold Feeders

Storage for reclaimed asphalt

Taking min 5 samples of the deposite(reclaimed asphalt)

Deposite of reclaimed asphalt

Samples of reclaimed asphalt

Testing of the deposite (reclaimed asphalt)according QMS / standards

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 theaverage sample of the deposite (reclaimed asphalt) , addingthe new modified Bitumen with CCBit113AD® andaggregates

Using for the new asphalt the maximum possible amount ofthe deposite asphalt (reclaimed asphalt)

Alowed Content of ReclaimedAsphalt

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Country Wearing Course Binder Course Base Course

Belgium 25% 50%

Denmark 30% 100%

France 40%

Germany 50% 100%

Hungary 10% 20%

Ireland 10% 50%

Poland 20% 30%

Portugal 10% 50%

Spain - 10-50%

Sweden 20% 30%

Switzerland 30%* 30% 60%

*: Depending on traffic load

Using RAP = Blending of Bitumen

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40

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60

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70

0

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0% 25% 50% 75% 100%

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0% RAP100% B 70/100

100% RAP0% B 70/100

Acceptable Rangefor Ring and Ball

Acceptable Rangefor Penetration

Possible RA addition rangewithout rejuvenators

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Allowed RA Ratio Depending on Homogeneityaccording lab test results (QMS)

Ring & Ball Binder < 63um 63um-2mm >2mm

Variety of RA characteristics

Germany, Base course, combined course, fundation, DAVRA Addition [%]

Typical Asphalt mix design (base course)

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Sand 0/416%

Aggregates 4/85%

Aggregates 8/1626%

Filler2%

Fresh Bitumen70/100

2%

ReclaimedAsphalt 0/16

49%

Base course

Reclaimed Asphalt + Fresh Bitumen

+ =+

Twin-shaftmixer

Reclaimedasphalt

Fresh bitumen

+ =

Double-coated grains

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RECYCLING – ACCORDING EUSTANDARDS -ZERO LOSS METHOD

• Cold milling machines are now bearing asphalt layerswith thicknesses up to 30 cm in one operation from.By the choice of milling heads and their arrangementon the milling, the milling pattern can be controlled.Fine milling is possible to produce a base, on thethinner asphalt layers can be applied. With coldmilling machines but also the individual asphaltlayers can be selectively expanded so that materialswith well-defined properties for reuse are (in hotmixing plants) are available. When the milling is topay attention to the ingredients in layers to be milled(eg asbestos) and appropriate health and safetymeasures 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

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RA-Addition Systems for wantedRequirements

RA Warm Additions

ConventionalCoflow,

directly heatedmax. 70% RA

NewCounter flow,

indirectly heated100% RA

RA Cold Additions

Continuous

Cold addition viamiddle ring

max. 50% RA

Cold additiondirect into mixer

> 25% RA

Cold additionvia pug mill

max. 25% RA

Batch

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Fuel Saving with Less Moisture

Drying37%

HeatingAggregates

54%

Exhaust Gas Losses< 7%

Insulation Losses< 2%

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

2% less moisture- 1.4 kg oilper tonne

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Mineral

Füller

Bitumen

Mischen

Entleeren

0 10 20 30 40 50 60 70

10.08.2014www.ammann-group.com

Typical Batch Process

Discontinuous Production

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Start up solution

Steam evacuation

Superheatedaggregate

Advantages

RA and aggregates dosedseparately into pug mill

use of screen not affected

Inexpensive, straightforwardsolution

good to combine with lowtemperature mixes

Limits:

Steam evacuation

Superheating of aggregates

RA Cold Addition via Pug Mill for 25% RA at 3% Moisture

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Combined Hot and Cold Recycling: Up to 60%

Proven technologyParallel Drums for 60%Cold Addition for 30%

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RAH – Hot RA

60% RA@ 3% H2O

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100% recycling device

Process air heaterRA dryer

Process air circulation

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Blending of recycling material

0/8 8/16 16/32

Sculping screen

Summary

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• Many european countries have a recycling quote of almost100%

• The european countries adapt their individual standards andstrategies according to geological and meteorologicalconditions

• Europe has not installed one common standard

• Standards for asphalt recycling are also handled individuallyby each country

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 bemet by the mixing plant.

37DAV, 2011

38DAV, 2011

≤100%

Effects

• The 100% recycling technology is totalyenvironmantal friendly

• It is a demand of EU standardisation

• 100% = no loss in material

• As by using 50% reclaimed material you haveto add 50% virgin aggregates andCCBit113AD® mod. Bitumen, according thenew developed mix design.

• Saving up to 50% of costs!!!

WTT – Wheel Tracking Test

Hamburg Device: Steel Wheels in Water Bath at 50°C

New Device: Rubber Wheels in Air Bath at 60°C (In Compliance with the European Standard)

INDEPENDENT LAB: making mix designand Check Testing of quality in lab and on site

Inspection on site

and Check Testing of quality

Different Techniques To Keep the Asphalt in the Road

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0% 25% 50% 75% 100%

in elevator

in pug mill

in drying drum

parallel drum

dedicated counter flow drum

Possible Ratio of Reclaimed Asphalt

Dr. Hutschenreuther 43

For more information

www.ccbit113ad.com

www.hutschenreuther.de