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
0
50
100
150
1987 1992 1997 2002 2007
Euro
pe
anSp
ot
Mar
ket
(Do
llars
pe
rB
arre
l)
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
45
50
55
60
65
70
0
20
40
60
80
100
0% 25% 50% 75% 100%
Re
sult
ing
Rin
gan
dB
all[
°C]
Re
sult
ing
Pe
net
rati
on
of
BIt
um
en
[mm
/10
]
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