www.modified.globecore.com

BITUMEN EMULSION PLANT

GLOBECORE UVB 8

1. APPLICATION OF THE PLANT 2. COMPONENTS DESCRIPTION 3. PROCESS DESCRIPTION 4. SPECIFICATIONS 5. OPTIONAL EQUIPMENT 6. PICTURES 7. WARRANTY

GlobeCore UVB 8 front view

Globecore GmbH

Edewechter Landstraße 173,

Oldenburg-Eversten,

Deutschland, 26131

Tel: +49 4484 202 35 91

Email: chyk@globecore.de

1. APPLICATION OF THE PLANT

GlobeCore Bitumen Emulsion Plant UVB 8 is especially designed to fulfil the requirements of a specialized road contractor or road and waterproof materials producer for manufacturing volumes of cationic and anionic bitumen emulsion. UVB 8 is available with latex injection unit. Latex makes road and waterproof materials more flexible at low temperatures and resistant to softening in warm conditions.

2. COMPONENTS DESCRIPTION Main components of Bitumen Emulsion Plant are three static mixers and colloid mill designed and optimised for bitumen emulsion production. They produce a fine and narrow particle size distribution, which builds viscosity and improves storage stability. The mill is equipped with frequency control for speed variability. This enables to use different recipes for emulsion preparation and improves the quality of emulsion produced with various types of bitumen. The complete mill is made in stainless steel with the shaft, the rotor and the stator in a high quality alloy. Only high quality components and materials are used to ensure best operational reliability and long technical life. The water-phase pipe system is made in stainless steel to guarantee corrosion resistance. The plant is laid-out for easy access to all components and electrical wiring. Comprehensive Manuals come with the plant and include process and electrical schematic diagrams, maintenance and service instructions and technical data.

Main component of GlobeCore UVB 8 are shown on the diagram below.

Identification key:

1 – Emulsion block 2 – Water phase

block 3 – Control panel 4 – Bracket 5 – Protective cover 6 – Water phase

dosing system 7 – Additives

dosing system

Emulsion Block Emulsion block comprises the following elements, shown on the diagram below. Identification key:

1 – Bitumen pump 2 – Colloid mill 3 – Hydrodynamic

mixer 4 – Additives mixer 5 – Bitumen pump drive 6 – Gear box 7 – Mill drive 8 – Temperature and

pressure measuring sensors

9 – Pneumatic valve 10 – Bitumen T-valve 11 – Bitumen return pipe 12 – Frame

GlobeCore KLM-18 mill with heating jacket Material: stainless steel Flow rate: max. 10 m³/h Operational pressure: 0.2 MPa Nominal speed: 2910 rpm Electric motor power: 18,5 kW

Bitumen pump DC-185 Powered with three-phase asynchronous motor 5А 160 М4 (power 18,5 kW; 1500 rpm) through reducer 1MC-160-10 Operational pressure: 0,59 MPa Max. bitumen temperature:180°C Max revolutions rate: 480 rpm

Water Phase Block is mounted on the same common frame with the emulsion block and comprises the following elements shown on the diagram below. All the pipelines are made from stainless steel. Identification key:

1 – Flowmeters 2 – Additives pump 3 – Water phase pump 4 – Water pump 5 – Water phase mixer 6 – Acid, emulsifier and additives dosing tanks 7 – Water dosing system 8 – Water return pipe 9 – Water phase tank

Water pump: Vertical multi-stage pump WILO MVI 807 Water phase pump: Vertical multi-stage pump WILO MVI 207 Additives pump: Gear pump (22 l/min) powered with asynchronous electric motor type AIR 71 B4 U2 (0,75 kW, 1350 rpm)

Flowmeters: Influx Flotrack, stainless steel, measuring range 0.5 to 10 m3/h

Emulsifier Tank Heater: The heater is equipped with a bypass line and a three-way

valve.

Control Panel Control panel is a dust proof enclosure to IP54 featuring the following elements.

Buttons and switches installed on the control panel are used for manual override of the production process. Safety button is provided to safely shut down the plant in case of emergency.

Schneider Electric Zelio Programmable Logic Controller

Eight Measuring Regulators OVEN TPM 1 are connected to Zelio PLC and monitor and control the following parameters: - bitumen pressure before and after bitumen pump - bitumen temperature before and after bitumen pump - emulsion pressure before and after colloid mill - blend temperature - water temperature

3. PROCESS DESCRIPTION

Hot bitumen is pimped through tree way valve to mixer C1 and partially through valve K2 back to bitumen tank. Additive is pumped to mixer C1 by pump M5 from tank 5 through flowmeter R1 and valve EK3. Mixture of bitumen and additive under high pressure is pumped by pump M1 through valve EK1 to injection mixer C2, where it is blended with water phase. Mixture of water and bitumen enters the third hydrodynamic mixer C3, where bitumen droplets are split into smaller particles. Emulsion than stabilized in the colloid mill C4 and cools down in the water/emulsion heat exchanger on its way to emulsion tank. Water phase block is a double circuit mixer. First circuit consist of water tank, pump M4 and injection mixer C5. The second circuit – mixer C6, where water is mixed with additives, fed into injection mixer by pumps M4 and M3. Water phase is prepared in the tank 1, which is filled with warm water from water reservoir. Water circulates through water tank 1 and mixer C5 where low pressure is created by pump M4. Acid, emulsifier and additives introduced into water tank through valves K7, K10 and K12 from dosing tanks 6,7 and 8. Water phase pH level is checked by pH-meter and corrected if required.

Flow Diagram

During plant operation water phase is prepared simultaneously with emulsion preparation in the mixer C6. pH level of water phase is maintained in the range between 2 and 2.5. Water is dosed by M3 pump and water phase – by pump M4. Water and water phase flows are controlled by flowmeters R2 and R3. Water is heated to desired temperature in the water tank and in the heat exchanger 10. Emulsifier is heated in the heater and pumped with the pump M2 to dosing tank 6. Acid neutralizer 9 is used to neutralize acid vapors. Water and polymer mixture is pumped with the pump M6 through flowmeter R4, valve K16 and three way valve K15 to emulsion preparation block. Pumps, flowmeters and pipes are flushed with clean water at the end of the process. 4. SPECIFICATIONS

№

Parameter

Value

1

Capacity, m³/h

8

2 Water consumption, m³/h 3.2-6

3 Additives consumption, l/h

50-350

4

Bitumen consumption, m³/h

4-8

5

Acid consumption, l/h

20-50

6

Emulsifier consumption, l/h

50

7

Bitumen input pressure, MPa

0,2

8

Bitumen mixer pressure, MPa

1,4

9

Liquid mixer pressure, MPa

0,2

10

Bitumen input temperature, ºC

140-160

11

Water input temperature, ºC

40-60

12

Emulsion maximum head, m

10

13 Power consumption, kW

46

14

Voltage, ~50 Hz

400

15

Dimensions (with container), mm: length: width: height:

4500 2150 2200

16

Weight (with container), kg

3500

5. OPTIONAL EQUIPMENT

Latex Injection Unit is designed for injection of rubber (latex) into emulsion. It consists of the following elements shown in the diagram below.

Identification key:

1 – Membrane pump 2 – Supporting plate 3 – Pneumatic valve 4 – Pneumatic valve 5 – Latex tank 6 – Dosing valve

Bitumen Filter FBS-1 is designed for filtration of bitumen on entry to the emulsion plant. Identification key:

1 – Control panel 2 – Control panel

support 3 – Filters block 4 – Temperature sensor 5 – Heat carrier inlet

valve 6 – Bitumen inlet 7 – Bitumen outlet 8 – Permeator 9 – Pressure relay

10 – Hear carrier outlet valve

Capacity: 15 m3/h Filtration rate: 1 micron Bitumen pressure on inlet: 0. 2 MPa Heat carrier operational pressure: 0.4 MPa Bitumen temperature on inlet: 140-160 °C

Container Bitumen emulsion plant can be mounted inside a container with sliding doors. Identification key:

1 – Emulsion block 2 – Water phase block 3 – Control panel 4 – Protective cover 5 – Container

6. PICTURES

GlobeCore UVB 8 Bitumen Emulsion Plant

GlobeCore UVB 8 Bitumen Emulsion Plant in a container

GlobeCore UVB 8 Bitumen Emulsion Plant in a container

7. WARRANTY

GlobeCore warrants the machinery supplied under this specification against defects in ma-terial and workmanship under normal use and service for a period of 12 months from the date of commissioning.

Typical equipment placement plan for bitumen emulsion production site