Emulsified Bitumen Equipment

Emulsified bitumen equipment is a professional equipment, mainly used for the production of sprayable emulsified asphalt, widely used in pavement permeable layer, sticky layer, sealing layer and other engineering scenarios. Its core working principle is to melt the asphalt and disperse it into water in the form of fine particles to form an emulsion, thus realizing convenient storage, transportation and construction of asphalt.

From the core composition, emulsified bitumen equipment mainly includes control systems, core emulsifier components, metering systems, process piping, emulsifier dilution tanks and pumps and other key parts, the components work together to ensure the stable production of emulsified asphalt. Compared with traditional asphalt production equipment, emulsified bitumen equipment with its environmental protection, high efficiency features, adapt to the green construction needs of modern road projects, pavement construction and maintenance of the core support equipment.

Emulsified bitumen equipment has a wide range of applications, mainly focused on highway construction and maintenance projects, by virtue of its strong versatility, to meet the construction needs of different scenarios, specific applications are as follows:

In the new highway construction, emulsified bitumen equipment production of emulsified bitumen is mainly used for permeable layer, adhesive layer and sealing construction, for the new pavement to provide stable adhesion and protective effect, to protect the integrity of the pavement structure and durability, to lay a solid foundation for the subsequent pavement.

In the road maintenance project, emulsified bitumen application scene is more abundant, can be used for fog sealing layer, thin slurry sealing layer, micro-surface treatment, gravel sealing layer, ultra-thin wear layer construction, as well as pavement pothole repair and other types of maintenance operations. Through these maintenance methods, it can effectively repair road damage, extend the service life of the road surface, reduce maintenance costs, and realize the long-term operation and maintenance of roads.

In the field of highway pavement regeneration, Emulsified bitumen equipment also plays an important role in the production of emulsified bitumen can be used for asphalt pavement cold regeneration project, the realization of the old asphalt mixture after milling recycling, not only reduces the waste of resources, but also in line with the concept of green sustainable development, is an important embodiment of the circular economy of the field of highway construction.

Emulsified bitumen equipment depends on the stable operation of the core components of the synergistic cooperation, different components bear different functions, the specific composition and role of the following:

1. Clear water system

Water system consists of water tanks, pumps, pipelines, etc., the main function is to provide clean water for the emulsion production, to ensure the smooth progress of the emulsification process, is the emulsified bitumen production of basic protection components.

2. Emulsion system

Emulsion system consists of AB emulsion tanks, flow meters, emulsion pumps, regulating valves, etc., is responsible for emulsion storage, delivery and flow regulation, to ensure a stable supply of emulsion according to the production demand, to ensure production continuity.

3. Bitumen Supply System

Bitumen supply system consists of asphalt tank, asphalt pump, asphalt pipeline, etc., the core role is to achieve the storage and delivery of asphalt, the melted asphalt will be accurately transported to the emulsification link to provide raw material support for the emulsion reaction.

4. Emulsified Bitumen System

Emulsified bitumen system contains emulsifier, sampling valve, heat exchanger and other components, is the core of the emulsification reaction, is responsible for the asphalt and emulsion mixing, the formation of emulsified bitumen in line with the quality requirements.

5. Heat Exchange System

Heat exchanger system consists of heat exchanger, emulsified bitumen discharge pipeline, submersible pump (or sewage pump), cooling water import and export pipelines, mainly used to control the temperature of the materials in the production process, to ensure that the emulsification reaction in the appropriate temperature conditions, to ensure that the quality of emulsified bitumen stability.

6. Heat Conducting Oil System

Thermal oil system is a set of automatic temperature control closed-loop system, under the action of the thermal oil pump, thermal oil to the equipment needs to be heated parts for heating, heating is completed after the thermal oil back to the thermal oil pump, to achieve the recycling of heat, to ensure that the equipment of the temperature of the heated parts of the stability.

7. Electrical Control System

The electrical control system includes two modes of manual control and automatic control, which can realize the precise control of the overall operation of the equipment, and switch the control mode flexibly according to the production demand, reduce the operation difficulty and improve the production efficiency.

8. Additive System (Optional)

Additive system is optional, according to the production needs of emulsified bitumen, add the appropriate additives to optimize the performance of emulsified bitumen, suitable for different engineering scenarios.

9. Pneumatic Control System (Optional)

Pneumatic control system is also optional, with an air compressor as a power source, through five solenoid valves to control the switch of five normally closed pneumatic valves to facilitate the realization of the injection and drainage pipeline convenient switch to enhance the convenience of equipment operation.

Emulsified bitumen equipment production process is clear and orderly, mainly divided into the preparation stage, production stage and completion of the three links, each link has a clear operating standards to ensure that the production of emulsified bitumen in line with quality requirements.

Preparation Stage

Preparation stage is the basis of production, the first need to heat the water and asphalt to the specified process temperature. Among them, the ordinary emulsified bitumen process temperature of 55-60 ℃; if you use 90 # asphalt, the temperature can be controlled at 130-135 ℃; if you use 70 # asphalt, the temperature needs to be controlled at 135-140 ℃, the specific temperature can be adjusted with reference to the laboratory formula. When the water temperature reaches the requirements, it will be pumped into the mixing tank, in accordance with the formula ratio, the first to add a specified amount of water, and then add emulsifier to the soap tank, and then add acid, thickeners, stabilizers and other additives, and finally replenish the water to the specified volume, to complete the preparation of soap. At the same time, the asphalt also needs to be heated to the corresponding process temperature. In addition, it is also necessary to open the preheating pipeline and the pump switch, the asphalt and soap liquid pipeline cycle check to confirm that there is no abnormality before entering the production stage.

Production Stage

Production stage is the core of emulsified bitumen preparation, the start-up sequence should strictly follow the “first start the soap pump, and then start the colloid mill, and finally start the asphalt pump” principle. To be three normal operation of the motor, check the material situation, including brown material for the best state. Subsequently, adjust the soap pump and asphalt pump speed, until the target solid content, the adjustment process needs to be adjusted first soap flow, and then adjust the asphalt flow, pay attention to adjust the asphalt flow, the emulsion flow will change. In the production process, you need to pay attention to the state of the soap at all times, to avoid only asphalt into the colloid mill and lead to clogging problems.

Completion Stage

Completion stage is mainly the finishing work after the end of production, first stop the asphalt pump, to stop the asphalt pump completely stop running, and then stop the colloid mill and soap pump. After all equipment stop running, with hot water or water to rinse the soap tank, and then start the soap pump, with water to rinse the soap pipeline and the colloid mill, to ensure that there is no residual material inside the equipment. Special attention needs to be paid to the end of winter production, the need to take measures against the cold, to prevent equipment damage due to low temperature.

In the emulsified bitumen production process, by the process, equipment, operation and other factors, it is easy to appear all kinds of problems, affecting the quality of emulsified bitumen and production efficiency, the main common challenges are as follows:

Separation Issues

Separation problem is one of the most common problems in the production of emulsified bitumen, mainly manifested in the separation of asphalt and water, resulting in the production of emulsified bitumen uniformity is poor, which in turn affects the stability of the subsequent construction effect, can not meet the quality requirements of pavement construction.

Viscosity Control

Viscosity control is difficult, viscosity stability is the core indicator of emulsified bitumen performance, temperature fluctuations, emulsifier ratio is not appropriate and other factors, will lead to fluctuations in the viscosity of emulsified bitumen, affecting its spraying and construction performance, can not be adapted to the different scenes of the construction needs.

Temperature Sensitivity

Temperature sensitivity, emulsification process, asphalt and water phase need to maintain a specific temperature, even a slight temperature deviation will lead to emulsion instability, delamination, emulsion breaking and other problems, affecting the quality of emulsified bitumen.

In addition to the above, other potential problems may occur, such as poor material flow due to clogged filters, clogged metering pipes, and production interruptions due to sensor malfunctions, automation system software errors, and so on. These problems can be strengthened by careful monitoring of the production process, precise control of process parameters, carry out systematic equipment maintenance and real-time data monitoring, etc., to minimize its impact on production.

Selection of Emulsified bitumen equipment, need to combine their own project needs, a comprehensive consideration of various factors to ensure the applicability of equipment, stability and economy, specific key considerations are as follows:

Core compatibility

Core compatibility is the first consideration, the equipment needs to be compatible with the expected production of emulsified bitumen type, including cationic, anionic, fast cracking or slow cracking emulsified bitumen, only to ensure compatibility, in order to produce emulsified bitumen products to meet the requirements.

Production Capacity and Flexibility

Production capacity and flexibility, according to the actual production needs of the project, select the appropriate production capacity of the equipment, while ensuring that the equipment has a certain degree of flexibility, can be adapted to different formulas, different specifications of emulsified bitumen production needs, to meet the construction of multiple scenarios to use.

Automation Level

Automation level, give priority to the use of PLC control system equipment, such equipment can effectively reduce the operator's human error, material metering, temperature control and other aspects of the precise control, improve production efficiency and product quality and stability.

Energy System

Energy system, according to their own use of scenarios and preferences, choose thermal oil heating or electric heating type of equipment, the two heating methods have their own advantages, need to be combined with the actual use of demand and energy supply to choose.

Material Quality

Material quality, equipment and emulsion contact parts, give priority to stainless steel, especially in the production of acid-containing phase scenarios, stainless steel has a stronger corrosion resistance, can extend the service life of the equipment, reduce maintenance costs.

Structural Design

Structural design, give priority to compact structure, easy to move the equipment, this type of equipment is more suitable for multi-project site use, and easy to transport and relocation, can effectively reduce the cost of transportation and site deployment difficulties.

Auxiliary materials is an integral part of the production of emulsified bitumen, the rationality of its selection directly affects the quality and performance of emulsified bitumen, mainly including fillers and additives, the specific selection method is as follows:

Fillers

 are mainly divided into chemically active filler and non-chemically active filler two kinds, in the production of emulsified bitumen, filler can effectively enhance the stability of the slurry mixture, regulate the emulsified bitumen emulsion breaking speed, and at the same time to enhance the strength of the sealing layer, to protect the construction quality. Elected chemical active filler, need to fully consider the filler and mineral materials, modified emulsified bitumen between the reactivity and compatibility, to avoid poor compatibility resulting in emulsified bitumen performance degradation.

Additives

Additives are mainly divided into two categories of coagulant and retarder, the specific choice of which type of additives, need to be determined through laboratory tests, or follow the relevant specifications of the emulsifier manufacturer. Production of modified emulsified bitumen, you need to prepare slow cracking fast-setting type (BA-3) emulsifier and SBR modifier two core materials, of which the dosage of BA-3 emulsifier for the weight of asphalt 1%-1.2%, the amount of SBR modifier for the weight of asphalt 3%-6%, and the two materials need to be prepared on-site 1-2 days before the use of the site. In addition, the choice of emulsified bitumen need to be combined with the nature of the stone and the construction environment, acidic stone or low-temperature construction scenarios, cationic emulsified bitumen should be used; alkaline stone or with cement, lime with the use of anionic emulsified bitumen should be used.

Need to be especially reminded that the filler and the appropriate additives is the key to the production of emulsified bitumen, the choice needs to be extra careful to avoid improper selection of auxiliary materials to avoid the impact of emulsified bitumen quality.

Emulsified bitumen equipment can be widely used in the field of road engineering, the core is that it has a number of outstanding features, taking into account the practicality, economy and convenience, the specific core features are as follows:

Modular Design

Modular design, the equipment adopts an integrated modular structure, easy to install, move, transport and relocation, its structural design in line with the container transportation standards, can be loaded into a 40HQ container, suitable for sea or land transport, significantly reducing the cost of transport and transport risk, especially for export.

Core Component

Core components of excellent quality, the core of the equipment emulsifier using the world's advanced high-speed shear grinding technology, equipped with a unique stator-rotor gap adjustment structure, can maintain a minimum stable gap; components made of special stainless steel, with corrosion-resistant, wear-resistant advantages, emulsification fineness can reach a higher standard, to ensure that the uniformity and stability of emulsified bitumen.

More Accurate and Flexible

Precision and flexibility, the use of computer precision control, can ensure that the formula tolerance minimization, to protect the consistency of emulsified bitumen quality; equipped with automatic control system and automatic monitoring function, according to the production needs of flexible adjustment of additives ratios, mixing ratios can be freely set within the range of 10% -70% to adapt to different production needs.

Automatic Control System

Humanized control system, equipped with automatic control system, can realize the setting of all parameters such as oil-water ratio, production capacity, etc., and at the same time, it has the functions of alarm and sensor calibration, etc.; it adopts the touch screen human-machine interface, which is simple and easy to understand, so it is easy for the operators to grasp it quickly, and reduce the difficulty of operation.

Good Material Properties

Excellent material performance, all materials in contact with the emulsion are made of stainless steel, corrosion resistance, can be adapted to different types of emulsified bitumen production needs, to extend the service life of the equipment, reduce maintenance costs.

Emulsified bitumen equipment not only has the advantages of environmental protection, high efficiency, but also has outstanding economic performance, can reduce production and construction costs for the user to enhance the return on investment, specifically reflected in the following aspects:

Energy Saving

Energy-saving effect is remarkable, diluted asphalt in kerosene or gasoline content of up to 50%, while the emulsified bitumen in the content of such fuel is only 0-2%, in the production and use of the process can save a lot of white fuel, reduce energy consumption costs, in line with the development trend of energy saving.

Versatility

Strong versatility, emulsified bitumen application methods, the same batch of emulsified bitumen, can be used for large-scale pavement sealing construction, can also be used for small pavement pothole repair and other operations; at the same time, emulsified bitumen can be stored in tanks for long periods of time, to facilitate the use of construction in remote areas, to enhance the convenience of construction.

Easy to Use

Convenient operation, emulsified bitumen professional spraying needs to be equipped with professional spraying equipment, while the small area of construction, you can directly manually dumping, paving, such as small pothole repair, crack filling and other operations; small batch cold mix production can be completed only the basic equipment, without the need for complex auxiliary facilities, reducing the construction threshold and cost.

Emulsified bitumen equipment as a representative of green construction equipment, its pollution emissions are far lower than traditional asphalt production equipment, the core reason lies in its unique production process and design concepts, specifically reflected in the following aspects:

Green Production Process

Green production process, emulsified bitumen is dispersed into the water phase of the asphalt emulsion formed at room temperature, with natural materials as the main raw material, compared with the traditional hot asphalt, you can save more than 50% of the energy to reduce asphalt consumption of 10% -20%, reducing the emission of pollutants from the source.

Low-temperature Construction

The advantages of low-temperature construction is obvious, emulsified bitumen can be sprayed and mixed at room temperature, no need to heat the asphalt and stone, not only greatly simplifies the construction process, but also to avoid the possible scalding accidents in the construction process of hot asphalt, and at the same time eliminating the smoke phenomenon of the asphalt steam in the high-temperature mixture, reducing the pollution of the air, favored by the road maintenance personnel.

Resource Recycling

Resource recycling, Emulsified bitumen equipment can be used in conjunction with asphalt cold regeneration technology, the old asphalt mixture after milling, according to a certain grading, modified emulsified bitumen as a regeneration agent, re-mixed for road construction of grass-roots level or surface layer, to achieve the recycling of old asphalt mixture, reducing the waste of resources and environmental pollution, in line with the concept of sustainable development of green.

Emulsified bitumen as the core output of emulsified bitumen equipment, which has a number of advantages, further highlighting the value of the application of Emulsified bitumen equipment, road construction and maintenance of the field of preferred materials, the specific advantages are as follows:

Convenient room temperature application, with the need for high-temperature heating to use the standard asphalt is different, emulsified bitumen can be used at room temperature, more flexible, more convenient operation, to adapt to different construction environments and construction conditions, reducing construction difficulties and energy consumption.

Road Construction and Maintenance

Suitable for road construction and maintenance, emulsified bitumen is widely used in pavement sealing, adhesive layer, thin slurry sealing and other construction links, its bonding with the aggregate is strong, able to form durable, high quality pavement surface layer, even in the changing weather conditions, but also to ensure the quality of the construction; at the same time, its construction speed, without the need for prolonged heating and cooling, is very suitable for rapid repair of the road operation, which can significantly shorten the construction period. The construction period can be greatly shortened.

Recycling and Cold Mix Applications

Contribute to sustainable development, emulsified bitumen is the core material of cold mix technology, can realize the recycling of existing road materials, reduce the demand for new raw materials, reduce the waste of resources, in line with the development concept of sustainable construction, is an important support for green road construction.

Versatility in Application

Wide range of application scenarios, emulsified bitumen formulations can be customized according to demand, suitable for a variety of application scenarios, such as unpaved roads, dust treatment, waterproofing of building foundations, etc., can be adjusted through the formula to enhance its adhesion, durability and weathering resistance, suitable for different types of projects such as rural and urban.

Shear technology is the core technology of emulsified bitumen production, directly affecting the fineness and uniformity of emulsified bitumen, which in turn determines the quality of its products. High-quality Emulsified bitumen equipment equipped with high-precision colloid mill technology, its core advantage lies in the gap can be adjusted to a very small range, to ensure that the cationic and anionic emulsified bitumen particle size uniformity, to protect the stability of the emulsified bitumen and the use of performance, for the subsequent construction of the quality of providing a solid guarantee.

Emulsified bitumen equipment is vital to the safe operation of the hardware facilities and operational procedures need to be taken from the four aspects of the perfect safety measures to prevent safety accidents, the specific safety requirements are as follows:

Personal Protection

Personal protection, operators must wear appropriate personal protective equipment (PPE), especially heat-resistant overalls, protective gloves and goggles, to avoid personal injury caused by contact with high temperature materials or chemical reagents.

Equipment Safety

Equipment safety, all major equipment should be set up on the easy to reach emergency stop button to facilitate rapid shutdown in case of emergencies; equipment tanks, pipelines and chemical drums need to be clearly labeled, and the dangerous areas need to be set up cofferdam pallets, to prevent material leakage caused by potential safety hazards.

Fire Safety

Fire safety, the fire extinguishing system needs to maintain normal operation status, and regular testing to ensure that the fire can be disposed of in time to prevent the spread of fire.

Electrical Safety

Electrical safety, the electrical system of the equipment needs to comply with ATEX or similar explosion-proof standards, to avoid sparks due to electrical failure, triggering safety accidents, to protect the electrical safety of equipment operation.

Scientific maintenance is to ensure long-term stable operation of Emulsified bitumen equipment, to avoid the key to failure and shutdown, need to follow the “regular maintenance and continuous monitoring combined” principle, the specific maintenance requirements are as follows:

Daily Maintenance

Daily maintenance, every day you need to check the equipment temperature readings, pressure levels and whether there is fluid leakage, etc., timely detection and treatment of minor anomalies, to avoid the expansion of small problems.

Weekly Maintenance

Weekly maintenance, every week you need to clean the filter, check the calibration of the sensor, verify the accuracy of the metering pump, to ensure that the components of the equipment is in normal working condition, to protect the production accuracy and continuity.

Monthly Maintenance

Monthly maintenance, monthly need to check the wear and tear of the colloid mill, the state of the mechanical seals and the operation of the heating system; at the same time, need to update the software, check the automation system log, timely detection and resolution of potential equipment failure.

Core recommendations, the use of preventive maintenance concept, in advance to detect potential equipment hazards, before the failure to deal with timely, to minimize downtime, to protect the continuity and stability of production, to extend the service life of the equipment.

Yes, the emulsified bitumen equipment adopts skid-mounted modular design, the entire production line can be loaded into a standard 40-foot HQ container, significantly reducing the cost of international transportation and on-site assembly time, easy to transport and install overseas, and can quickly complete the site deployment and put into production use.

Yes, of course. The manufacturer can provide customized solutions according to your specific project requirements, including:

① Customized production capacity (1 ton/hour to 10 tons/hour); ② Add modifier mixing system for the production of modified emulsified bitumen; ③ According to the conditions of the construction site, the design of mobile or stationary equipment; ④ Equipped with advanced control systems, remote monitoring, automatic fault diagnosis and other functions; ⑤ Adjust the emulsifier mixing system to produce special emulsified bitumen to meet the needs of specific projects.

Emulsified bitumen equipment transportation, installation convenience and customization capabilities, directly affecting its application flexibility and adaptability, specific instructions are as follows:

Transportation and installation, the equipment adopts skid-mounted modular design, the entire production line can be loaded into a standard 40-foot HQ container, which significantly reduces the cost of international transportation and on-site assembly time, facilitates overseas transportation and installation, and enables the rapid completion of site deployment and production use.

Customized service, the manufacturer can provide personalized customized solutions according to the user's specific project needs, including: customized production capacity (1 ton/hour to 10 tons/hour); add modifier mixing system for the production of modified emulsified bitumen; according to the construction site conditions, the design of mobile or stationary equipment; equipped with advanced control systems to achieve remote monitoring, automatic troubleshooting and other functions; Adjust the emulsifier mixing system, the production of emulsified bitumen adapted to the needs of specific projects.

Qualified Emulsified bitumen equipment are in line with relevant international industry standards, to ensure that the production of emulsified bitumen to meet the quality requirements of road construction, specific compliance is described below:

Core Compliance

Core compliance, high-quality Emulsified bitumen equipment in line with a number of international standards, including the U.S. ASTM D977 standard, the European Union EN 13808 standard, as well as China's GB/T 50052 standard, to ensure that the equipment's production process and product quality to meet the international level.

Product Quality Compliance

Product quality compliance, the emulsified bitumen produced by the equipment meets the relevant standards for road construction, and meets the specifications in terms of needle penetration, ductility, storage stability and other key indicators, which can meet the construction quality requirements of different road projects.

Certification Support

Certification support, most manufacturers can provide CE, ISO and other related certificates to ensure that the equipment meets the requirements of global environmental protection and quality regulations, for the export and use of equipment to provide quality assurance.