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RA 100 – The new dimension in use of RAP Rolf Jenny Senior Vice President Ammann Group Chairman Ammann Australia Pty. Lt

AAPA Technology Tour 18 th June 2012. RA 100 – The new dimension in use of RAP Rolf Jenny Senior Vice President Ammann Group Chairman Ammann Australia Pty. Ltd. Road construction in Europe and Australia. Many similarities. Europe. Important differences. Australia.

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RA 100 – The new dimension in use of RAP Rolf Jenny Senior Vice President Ammann Group Chairman Ammann Australia Pty. Lt

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  1. AAPA Technology Tour 18th June 2012 RA 100 – The new dimension in use of RAPRolf JennySenior Vice President Ammann GroupChairman Ammann Australia Pty. Ltd.

  2. Road construction in Europe and Australia Many similarities Europe Important differences Australia • 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 • European Road Construction requires maximum flexibility • Asphalt mix are adjusted to all kind of needs (>100 recipes) • European environmental standards are different • CO, NOX, C, dust (applicable atall location ). • Wet washers/wet scrubbers are impossible to use in Europe

  3. Sustainable road construction means: Intact living space High Mobility +

  4. It means also well maintained road network Wellmaintainedroads

  5. Improvements of construction equipment Speed of Change • Environmental Requirements • Shift from “New Roads” to “Maintenance” • Improved Quality Requirement • Economical Crisis • Competitive Market 2000 2012

  6. These methods have gone a long time ago… In the Mountains of Nepal in 2002

  7. The good old days

  8. Today’s clean asphalt manufacturing

  9. Road Maintenance Construction of New Road Shift from new roads to maintenance Tonnes per year Total global Asphalt Production • 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.a 2015 1980 2012

  10. The 3 segments of global road construction markets Total Asphalt Production Maintenance Rural to Paved Road New Road India, South America, Africa • Characteristics • low investment • mobility • projects

  11. The 3 segments of global road construction markets Total Asphalt Production Total Asphalt Production Maintenance Maintenance Rural to Paved Road Rural to Paved Road New Road New Road China, Russia, Eastern Europe, Asia Pacific India, South America, Africa • Characteristics • low investment • mobility • projects • Characteristics • open for new technologies • environment coming • improved quality

  12. The 3 segments of global road construction markets Total Asphalt Production Total Asphalt Production Total Asphalt Production Maintenance Maintenance Maintenance Rural to Paved Road Rural to Paved Road New Road New Road New Road China, Russia, Eastern Europe, Asia Pacific India, South America, Africa USA, Western Europe, Australia • Characteristics • low investment • mobility • projects • Characteristics • open for new technologies • environment coming • improved quality • Characteristics • environment • flexibility • quality

  13. Ammann’s answer to the 3 segments Total Asphalt Production Total Asphalt Production Total Asphalt Production Maintenance Maintenance Maintenance Rural to Paved Road Rural to Paved Road New Road New Road New Road EasyBatch Speedy Batch Blackmove 75-100% Recycling 25-60% Recycling

  14. The future is already here Wearing coarse with 92% RECYCLING in Hamburg Germany AC 0/11 Recycling (0/11) 92 % Mineral (8/11) 8 %

  15. Strategy: Recycling and Economy of scale Very well sorted Reclaimed Asphalt • Consolidation: 100  50 plants • High volume production • High recycling ratios • High flexibility Production:1000‘000 t.p/a Recycling: 600‘000 t.p/a

  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 16

  17. Strategy: 100% Recycling • Highly Competitive thanks to RAP • High RAP storage volume • High flexibility • Quality Assured RAP

  18. RAH 100% Reclaimed Asphalt Hot 100% Ammann developed a new asphalt recycling concept for 0% - 100% reclaimed asphalt

  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 19

  20. 100% Recycling Device Process Air Heater RA Dryer Process Air Circulation 20

  21. 100% recycling device (protected) Process Air Circulation Raw Gas to Filter (95°) Drying Drum(turning) Process Air Heater(combustion chamber) Heated Reclaimed Asphalt (165°C) Gas Mixing • 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

  22. RAH 100% drying drum

  23. Process air heater

  24. Treatment of reclaimed asphalt Binder 4,0 %Filler 10,6 %Sand 45,8 %> 2 mm 43,6 % RA 0/22 Screening 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 0/8 RA 8/22

  25. Well sorted recycling materials 16/32 8/16 0/8

  26. Blending of reclaimed asphalt 16/32 8/16 0/8 Scalping screen

  27. Bitumen characteristics after heating sample A (cold)taken at RA feeder sample B (hot)taken at drum outlet through-put timeapprox. 10 min. • 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

  28. Bitumen characterstics after heating (guide values) Softening point ring & ball: Average: Increase of the temperature of softening point R&B of 3°C.

  29. Bitumen characterstics after heating (guide values) Penetration values: Average: Decrease of penetration value of 0,5 mm; respectively 21%

  30. Intelligent, fully integrated road construction • Closing the Loop: from Road to Road • High quality, reduced costs and construction time • Ecology, Economy, Safety

  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.

  32. Leadership in sustainable road construction AAPA Resolution 2011 National and state road authorities Supporting new technologies Road construction companies Investing in new technologies Equipment Manufacturing R&D new technologies

  33. Asphalt back to asphalt Tier IV„TA Luft“ Sustainable Road Construction • Financial: • Lack of Funding • Market competitiveness Shift of Focus: - From new roads to Maintenance Drivers for sustainbalbe road construction • Government: • Emissions • Recycling

  34. Asphalt Recycling • Low Temperature Mix • Lower Moisture Cont. -25% CO 2 • Alternative Energies • Ecology SW tools, • Integrated Constr. New Technologies tocome Technology Objective: The neutral asphalt plant 50 kg CO2 per t of Asphalt 0 Traditional Production Direct and indirect emissions considered, without transport

  35. Solar heated bitumen farm

  36. Global solar radiation Many countries in best solar area

  37. Wood dust fired burner • CO2 neutral fuel • Cost savings

  38. Wood availability

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