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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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 5
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 6
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 8
Today’s clean asphalt manufacturing
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 9
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 10
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 15
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 21
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 25
Well sorted recycling materials
0/8
8/16
16/32
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 26
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 34
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
RA 100 - The new dimension in use of RAP | © Ammann Group June, 18th 2012 37
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