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Early February, members of GlobeCore had a business trip to Baku (Azerbaijan).  The purpose of the trip was commissioning and launching of the previously supplied UVB-1 plant (capacity of 2 m3/h), designed to produce bitumen emulsions.

The project was completed on time,  in full compliance with international quality standards – which allowed the workers of Azerbaijan to start  production of bitumen emulsions.

Today bitumen emulsions are generally used for:

• Surface treatment.  The main advantage of using bitumen emulsion is its ability to work with wet gravel;
• Fine sealcoating.  Selecting an emulsifier allows for quick coating.  Active traffic can be resumed in 1 or 2 hours after completion of works;
• Preparation of cold mixes for recycling directly on the site;
• Impregnation of soil consisting of gravel and sand;
• Seal coat (waterproofing, providing non-skid surface, anti-glare surface, reducing deterioration and cracks);
• Surface tack coat treatment (for best bond strength treatment of pavements);
• Macadam pavement (gravel impregnated with bitumen).

GlobeCore produces all types of bitumen emulsions to meet the challenges of road construction, as well as modified emulsions for roofing and waterproofing works.

he UVB-1 2m3/hour bitumen emulsion plant makes cationic and anionic bitumen emulsions. The emulsion can be used for the following purposes:

•      tack coating before application of asphalt-concrete
•      production of cold asphalt concrete mixes
•      surface treatment of roads
•      thin protective film
•      patch repairs of roads
•      water proofing of buildings and structures
•      construction of soft roofs
•      production of liquid rubber spray

UVB-1 (2 m3/hour) can be used by asphalt concrete mix production facilities. The plant can be installed and operated either indoors or outdoors.

The unit operates in ambient temperatures between +5°C and +40°C.

UVB-1 2m3/hour plants are made for production of cationic and anionic emulsions for road surfaces as well as liquid rubbers, part of roofing spray emulsions.

This production capacities is ideal for moderately sized facilities with daily emulsion requirement of 12-16 ton/day.

Bitumen emulsion first came into use in Europe in the 1930s. With time, the process has been improved by innovations, which improved efficiency, quality and technology. Today bitumen emulsions are a promising material used in road and civil construction, and emulsion production is growing. This is because the

The UVB-1 plant is designed for production of anionic and cationic bitumen emulsion used in repairs and construction of roads, as well as liquid rubber, which can be used for roofing. A 1 cubic meter per hour unit is ideal for small repair facilities with everyday needs of 6 – 9 tons of emulsion.

Bitumen emulsions were first used in Europe in the 1930s. Since then, the industry has seen many promising designs, which allowed to improve production efficiency and process, as well as product yield. At this time, bitumen emulsions of all types (anionic, cationic, water in oil, oil in water, fast, medium and slow setting) are without a doubt a promising material for various construction works. The number of processes where bitumen emulsions are used is growing. Application of these materials is highly profitable and reliable Количество технологических процессов,  при которых в той или иной степени используются битумные эмульсии, неуклонно растет.

Plants developed and manufacture by GlobeCore are highly efficient and feature high quality. The use of innovative technology saves user costs, at the same time ensuring the following:

•      Reliable component parts;
•      High quality of the product. The use of hydrodynamic mixer along with a colloid mill makes finely dispersed emulsions possible. Such product is in full compliance with industry standards, in many case exceeding their requirements;
•      Automatic or semi-automatic control of the plant;
•      Precise portioning of water phase and unique blending technology;
•      customization;
•      spare part depositories and worldwide customer support.

The UVB-1 bitumen emulsion units are semi-automated plants with components mounted on metal frame and connected with pipelines.

The rate of emulsion consumption depends on the type of surface treated. For asphalt surface, the consumption is 500 g/m2, in case of gravel the consumption grows to 1200 g/m2. Treatment of asphalt crumbs increases consumption up to 2000 g/m2.

Water-bitumen emulsion is a dark brown liquid. Emulsion is made by dispersing of bitumen in water with the addition of surfactants.

Bitumen emulsions are indispensible for various road construction tasks. It forms a protective layer for automobile roads (asphalt, gravel or concrete).

Specific areas of application are:

•      creation of tack coat for road construction;
•      permeation and surface treatment in road cover construction;
•      creation of thin film wear layers;
•      patch repairs (as part of mineral-emulsion mix).

Bitumen emulsions. General information. Principles.

The main component of any such system is the binding. In normal conditions, bitumen is solid, therefore to mix it with mineral material, it must be made liquid by heating.

An alternative – emulsification of bitumen

The amount of solid material (bitumen) in emulsion is up to 70%. In the form of small particles it is suspended in water. General viscosity of the emulsion coincides with the viscosity of water phase; therefore it is liquid at room temperature.

Emulsion stabilized by emulsifiers.

An emulsifier molecule is bipolar. The “tail” of the molecule solves in the bitumen particles, while the “head” pushed away other emulsifier molecules and does not allow bitumen particles to coalesce. This is why the particles remain suspended in water (emulsion stability). When emulsion contacts mineral material, the system balance is disrupted because emulsifier leaves the surface of bitumen droplets and the destabilized emulsion envelops gravel. The difference of chanrges between the grave and the emulsifier pushes out the water which then evaporates. Bitumen road emulsion is used as a binding film creating material in repairs and construction of automobile roads, bridges, streets, overpasses and other structures. The technologies based on pouring of material (surface treatment, tack coat, patch repairs and permeation) use fast setting emulsion. It can be used in all moderate to warm climates from Europe to Asia.

Quality – the ability to ensure high quality without the need to heat mineral material and binding. This alone saves up to 40% energy in comparison with regular “hot” process.

Environmental considerations. Bitumen emulsion does not cause harmful emissions in the atmosphere, there is no risk of explosion or burns during transportation or bitumen solution processing.

Transportation of bitumen emulsion

Bitumen emulsions are transported in special tanks, bitumen carrier, cubic vessels and metal barrels.

Storage of bitumen emulsion

Bitumen emulsions are stored in special tanks or other cylindrical vessels. The vessels must be clean: must not contain residual emulsions, bitumen, POL or other acidic or alkaline materials.

Emulsion of different composition must not be mixed in one vessel. Tanks must be tightly closed to prevent ingress of foreign objects and evaporation of water. The temperature of storage must be at least 5°С.  If the volume of the emulsion is more than 1m3, the tanks should be equipped with special stirring agitators.

Our company offers special vertical emulsion storage tanks SBE and SMB to store emulsion and polymer modified bitumen respectively. These tanks are equipped with heating and circulation systems and can easily integrate into the existing production process of a facility.

Visit our new office: 35 Main Road, Anderbolt Ext 31, Boksburg Gauteng, South Africa.
Tel: +27761054167
Att: Mr. Frank May

Colloid mill CLM, referred to as the mill throughout this text, is specially designed for the production of highly stable colloidal solutions, extremely fine suspensions, mixtures and emulsions. “Wet” grinding technique is used, as the rotor and stator cone gap is wider at the inlet and narrower at the outlet. Additionally, the complex micro relief of the generator (stator) surface creates increased turbulence, shearing the particles.Under the influence of centrifugal force and high velocity of the rotor relative to the stator, liquid and semi-liquid substances are finely dispersed and homogenized, any mix of materials are also emulsified, homogenized and dispersed.

The mill allows for simultaneous dispersion and homogenization. Heating jacket allows to heat or to cool the crushing zone as required.

The mill features high production rate; it allows to produce highly stable emulsions as well as colloid suspensions, and ensures high degree of homogenization with particle size down to 1 micron.

Additionally, mashing effect and cavitations effects occur in the mill i.e. explosion of micro caverns by internal pressure. The mill can be retrofitted into existing lines of production. To facilitate high quality grinding, the product must enter the mill at designated solid to liquid phase ratio and constant rate.

Particle size and pumping performance may vary depending on physical and mechanical properties of the material and carrier phase.

SPECIFICATIONS
of serially produced colloid mills

Note.
* – Dimensions are driven assembly.
** – If necessary, the product can be either heated or cooled to a desired temperature.
*** – Depending on the physical and chemical characteristics of the product capacity may vary.

Clients speak about GlobeCore mills:

Mr. Shekanabo, the United Republic of Tanzania:

“I can only say good things about GlobeCore mills. After seeing the production facility, I had no doubts that this is a serious and reliable company with professional staff, and the system works like a clock. Of course, the production itself seems complicated, but the equipment is powerful and rugged.”

Mr. Patel, the United Republic of Tanzania:

“I want to wish GlobeCore success in the future and I think we will maintain our cooperation for many more years. May you have as many successful products and new developments as possible.”

Warranty period is 12 months from the moment of commissioning.

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GlobeCore has increased the production facility floor by 8,000 square meters.