Tag Archives: bitumen

GlobeCore’s UBV-1 Bitumen-Emulsion Equipment is the Best Solution to Today’s Road Construction Problems

Road construction industry, , ,

It is has always been difficult to provide a competely effective road surface pavement because of the wide range of factors such as:

(1) short road construction seasons;

(2) unpredictable and unfavourable weather conditions;

(3) shortage of financial resources;

The situation had remained unchanged for a long period of time, but recent developments with bitumen emulsion products has made it possible to extend the service life of road surface pavements.  This construction material has been used all over the word for the last few decades.  Our experience has shown that bitumen emulsions are much more effective than bitumen for performing road construction projects.  The performance characteristics of bitumen emulsion allow the builders to apply the so-called ‘cold methods’ of roadway construction.

GlоbeCоre has designed universal bitumen-emulsion equipment designated as the UBV-1 line that produces cationic bitomen emuslsion as well as anionic bitumen emulsion with specified performance characteristics.  The final product is characterized by low viscosity and high adhesion that allow the builders to use it at low temperatures.  Additionally, it can be stored for a long period of time.

The process of bitumen emulsion production includes several stages. At the first stage, the water solution is prepared. The blending tank is supplied with hot water, acid, and an emulsifier.  The ready-made solution gets into the colloid mill which blends it with liquid bitumen.  When the process is completed, the final product is placed into the storage tank.

GlоbeCоre equipment fully complies with all international standards and regulations and is designed to meet all customers’ needs involved in the road-building enterprises or at bitumen-concrete production plants.

Horizontal Bitumen Tank

Solutions,

Storage and preparation of bitumen on your own company property has a number of advantages for the company.  The availability of bitumen boilers allows companies to create and replenish their own stocks of the material without fear of market fluctuations and irregular supply.  There are various special containers for storage and heating of bitumen.

GlobeCore offers equipment that is optimally adapted to the technical features of your enterprise.

The basic unit of bitumen complex is bitumohranilische. Its main advantage is that it can be used both as a storage container of asphalt emulsion and as a tank for storing the bitumen-heater.

Bitumohranilische is a “reservoir tank”, i.e. made from 6 mm thick sheet metal.

A horizontal bitumen tank can be used by enterprises that are engaged in the production of asphalt pavements, foundation waterproofing, and concrete structures.

The GlobeCore design department has developed specific solutions for a variety of construction enterprises. Thus, depending on the type of enterprise and the technologies and materials, you can choose the most efficient type of equipment with the minimal expenditure of resources and money.

For example, when installing the burner flame tube as a heating agent, it can use a gas furnace or diesel fuel.  As an alternative coolant it can use thermal oil.  In this case it is carried out in a special heating boiler.  Also for this purpose it can use a MTG-generator with a capacity of 400 thousand. Kcal.  This type of equipment is made by our factory and can be delivered to the customer together with the horizontal bitumen tank.  Its main advantage over similar equipment is the increased capacity.

The long-term experience of our engineers in the field of mechanical engineering allows us to create and implement technical solutions for enterprises of any complexity.  On request, a horizontal bituminous container can be made in two constructive designs depending on which substance is used for heating.

Bitumohranilischa volume depends on the presence or absence of a flame tube and can vary from 28 to 30 m. Cu.

In recent years, there have been industrial trends towards the use of plants for thermal oil. This is due to their efficiency, environmental friendliness and preservation of all necessary requirements for the subsequent operation of the properties of the bitumen.  The  heating tube uses a temperature not exceeding the boiling temperature of the bitumen, thereby avoiding overheating.  In addition, the heat generated by the oil generator can be used to heat all bitumohranilischa consisting of at least 3-4 horizontal tanks.

In the second case, the bitumen may overheat and fall as sludge to the bottom and, consequently, lose its properties.  To avoid this, you need to constantly monitor the processes occurring inside the tank.  After use, it is necessary to drain the bitumen and to clean the tank itself.  It is also worth noting that the bitumen cannot be drained completely (it should at least cover the flame tubes).

Despite the current shortcomings, this type of unit is has also found its application in many companies that use gas or other fuels.

The design department and engineers at GlobeCore constantly improve the technology eliminating all sorts of shortcomings while introducing modern technologies and devices.

Since asphalt is a sufficiently viscous substance, in the container structure  there is a special horizontal mixer consisting of three pieces that accelerates the mixing of hot and cold layers of material.

A distinctive feature of our manufactured containers for storage and heating of bitumen is their container structure, ie, mounting dimensions are similar to the dimensions of the “Ocean Going” sea container. This allows us to deliver a horizontal bitumen container via sea transport anywhere in the world.

When transporting the container with a gas burner and the flame tube there is the possibility of removing the last premises in special registers.

In order to put the equipment into working condition, you need to install the flame tube in the original position according to the scheme that is contained in the technical documentation that comes with the equipment.

The range of the horizontal bitumen vessel may include a special pump for feeding the bitumen. This part is also produced by our factory.

Thus, the customer can order a bituminous complex that has been appropriately tested and certified.

Comparative Characteristics of the Technical Data of Various Performance Settings

Characteristic

Bitumohranilische burner

Bitumohranilishte of Thermal
The total volume of the boiler, m. Cube

32

32
The working volume of the boiler, m. A cube

28

28
Type of Heating

fire

Termomaslo
Installed capacity, kW

23
The parameters of the burner
– Rated Power, kW

430
– Maximum power, kW

540
– Fuel

Natural gas G20
– Gas pressure

20 bar
– Maximum flow rate, m. Cc / hr

38
The parameters of the electric current

380V / 50Hz

380V / 50Hz
Dimensions, mm, max.
-length

11750

11750
– width

2100

2100
– height

2500

2500
Weight, no more

12700

12700

Questions that you may have:

1. Should the tank and system be constantly filled?

For each type of container, there are differences in the response to this question.

The advantage of using a thermal oil for heating is that the bitumen can be filled and drained from the tank half or even completely. In this case, it will be in working order.

When using the flame tube it is not recommended to drain below their standard substance, as in this case it is possible to have burning bitumen. This may result in a fire the entire system.  For reheating it is necessary to fill the tank with new bitumen.

2. How to control the filling?

Installation of the system has certain special devices that includes:

  • level sensors (located on the perimeter of the installation);
  • Temperature sensors for the upper and lower layer of bitumen;
  • overflow sensors (at the top of the unit- are needed to improve the accuracy of measurements).
  • backup level sensor;
  • overflow pipe.

When triggered, the high level sensor shuts off the pump feeding the material into the bitumen tank.  For emergencies, there are special openings for quick drainage of bitumen.

3. In what form is the unit received by the buyer?

The unit is supplied to the customer with the need to separately deliver the gears.   In the second part, the burner.  Our engineers can visit the area and make the installation and make the unit run and operate properly.

4. The terms of the warranty?

Warranty period – 12 months from date of shipment from the supplier’s warehouse. The manufacturer guarantees the stable operation of the unit if the consumer observes the correct installation, operation, maintenance, transportation and storage.

5. How many operators are necessary for the management of the equipment?

The minimum number of operators during bitumen production is two people.

GlobeCore Model VBU-6P

Road construction industry, , ,

One of the essential pieces of equipment that is being used more and more in modern industrial and developing nations is the “Bitumen Emulsion” production plant.

The use of bitumen emulsion has several advantages over simple bitumen or tar products in most or all applications.  Most important is that bitumen emulsion does not require constant heating thereby increasing the efficiency of industrial operations and lowering operating costs.

Bitumen emulsion has a more complex structure than tar and simple bitumen, and due to its lower costs, it has become more and more popular in the road construction industry.  Bitumen emulsion production equipment is now indispensable to the road construction and related industries.

The bitumen emulsion equipment by produced GlobeCore is the most up to date and efficient bitumen emulsion equipment in the industry today.  GlobeCore engineers remain leaders in their field and are always seeking to improve and upgrade the quality and efficiency of the GlobeCore equipment line.  That is why new GlobeCore equipment will never be outdated versions of yesterday’s models.

The GlobeCore universal bitumen model makes both anionic and cationic bitumen emulsions. Often, this kind of equipment is used by companies that produce asphalt mixes.  Bitumen emulsion of this type is most often used for the priming of old pavement before applying a new layer of asphalt.  It is also used in the preparation of cold asphalt mixes, for the surface treatment of existing road surfaces, for making thin protective coatings, and for patching roads.

One of the latest bituminous equipment developments by GlobeCore is the VBU-6P model designed for the production of bitumen emulsions.  The name of the new model reveals the main differences from the previous models with a production rate of 6.5m3/hr and the ability to work continuously without interruption.

The Globecore VBU6-P consists of two main parts, the  bitumen part and the base part.  The Bitumen part stands vertical and has a pump made ​​in Italy.  The base portion is where the emulsifier, acid and bio chlorine additive are mixed and then fed into the polypropylene container. Each component of the mixture pass through dosing pumps.  The pumps automatically measure the required amount of each component of the mixture.

The  VBU-6P system works by feeding bitumen from a reservoir into the bitumen part through a feed pipe and passes the bitumen through to a set of heating rings.   Water is supplied to the mixing cylinders and the dosing pumps then pump the emulsifier acid according to the product recipe.

The container, in which the mixing occurs, is equipped with volume level sensors.  When the amount of mixed fluid reaches the high-level indicators, the sensor signals the completion of the preparatory phase.  Next, the water valve opens and the unit starts to run the aqueous phase of the process.  The VBU-6P will continue to run unless the water supply is cut off, or until the operator turns it off

The VBU-6P is  fully automated.  The only manual control is for  the adjustment of the ratio of bitumen to water (a mix of 70% bitumen and 30% water will be made at the rate of 6m3 while a mix of 50% to 50% will be made at a rate of 9m3).

It is also possible to manually adjust the amount of emulsifier that needs to be fed into the process. For fast decaying emulsions, emulsifiers of 0.25% are used.  For slow decaying emulsions – 2% are used.  Acid is added automatically through the acid probe found on the dosing pump.  It is responsible for regulating the engine speed and the feed rate and volume of the acid.

The GlobeCore VBU-6P bitumen emulsion processing unit is a high quality product that leads the industry.  It is both durable and highly resistant to delamination and corrosion.  The VBU-6P’s automated process of mixing the various components combined with a versatile design make the GlobeCore VBU-6P unit the most advanced bitumen emulsion processing unit in the industry today.

Dry road bitumen emulsion

Road construction industry, , ,

Powder emulsions has been known for a long time. I am sure most of us remember powdered milk. What if it is possible to apply this technology to make bitumen emulsion used in road construction then it will revolutionize the bitumen emulsion industry. It will be add convenience bitumen transportation to remote areas and it will add convenience in use.

To make dry road bitumen emulsion you a special polymer must be present. The polymer allows encapsulation and water elimination. Some companies are working to solve this problem since 1995 and have achieved considerable success in areas of agricultural chemistry and pharmacology. The developed technologies and processes may apply to the production of dry road bitumen emulsion.

It is possible to achieve this using a typical bitumen emulsion. A required extra step introduces an aqueous polymer into the mix and then dries the substance until capsule-like particle is formed. The polymer resembles each capsule contains a liquid droplet.

Long-term study of the physicochemical emulsion properties suggests synthesis of a hydrophilic polymer polyacrylate that has a low viscosity. It consists of hydrophobic substances, which do not inhibit the water solubility. Polyacrylate was the material that helped in making dry road bitumen emulsion production.

During the drying process, it is important to maintain minimal ratio of 10 between the granule size and emulsion droplet size.

It should be noted that the drying process has little or no effect on the bitumen emulsion properties in fact in some cases they actually improve. For example, the stability of the dry emulsion increases because the encapsulation process prevents its decay.

Another advantage of these materials is the possibility of mixing two or three emulsions that under normal conditions are not compatible with each other.

The general principle behind obtaining the dry road bitumen emulsion can be described as follows: first, the polymer is added directly to typical emulsion, then it is dried by one of available methods (e.g., dry spay), and the resulting powder is collected and stored. It at any time the powder may be dispersed in water, and restored to the original emulsion condition for later use.

Composition of bitumen emulsion

Road construction industry, , ,

Composition of bitumen and tar emulsion depends on the type of emulsifier used and the surface on globules will form. Direct emulsions are characterized by adsorption of emulsifier particles on the outer surface of the globules, and the reverse – on the inside.

Small emulsifier concentration leads to a disperse phase, but at the same time it also promotes destabilization of the emulsion over time. Increase in emulsifier concentration can achieve lower surface tension, which leads to the formation of an adsorption layer on the globules.

In addition, reduction in the emulsifier concentration leads to a reduction in the price of bitumen emulsion.

In order to achieve a strong bond between bitumen film and mineral material, its concentration in the emulsion should range from 55-70%. When working with stone materials the surface is pre-treated with hydrated lime, which promotes better adhesion of extracted bitumen from the emulsion.

Tar-bitumen emulsion is composed of bitumen and tar at 80:20 ratio and 2% kerosene. The ratio of binder to alkali solution is 70:30.

Bitumen composition also depends on the manufacturer. For example, bituminous emulsions manufactured by Kharkov plant consists of 48-52% of bitumen type BN-II and 52-48% aqueous emulsifier. Latter consisted from lie treated wood pine resin. This recipe provides a fast-disintegrating emulsion.

Groznenskiy oil plant proposed this emulsion composition 49% petroleum tar, 49% sodium hydroxide solution and 2% emulsifier. As the latter consisted of fat that formed soap.

Typical emulsion ingredients are bitumen or bitumen mixture with a solvent like diesel fuel.

New type of bitumen emulsion was developed to simplify the treatment of stone surfaces like reverse type: 60 % tar brand D-2, 40 % of bitumen brand BN-II, 2% kerosene. Tar-bitumen emulsion contains 70-75% of binder mix and 30-25% of aqueous sodium hydroxide.

Emulsion formation is significantly influenced by the brand and method of bitumen production. The ingredients used in the preparation process can affect the dispersion property of the emulsion from high to low. Some bitumen brands tend not to emulsify.