Bitumen Emulsion

emulsion1-1

A bitumen emulsion is a dispersion of bitumen in water. However, in the same way as water and oil do not mix easily, water and bitumen together do not get on.
 
At RAD International, Bitumen emulsions are made using ATOMIX ® colloid mill, In the colloid mill energy is applied to the system by passing the mixture of hot bitumen and water phase between a rotating disc, cone or flywheel and a stator. The rotor as well as stator may be grooved or have teeth in order to create a turbulent flow.

Emulsion storage tank

 

A) Emulsion Plant

The heart of a bitumen emulsion production system is the mill. The ATOMIX ® colloid mill consists of 3 parts:

  • fixed body or stator with two intakes ports and delivery connections. The stator includes a reheating chamber which operates either by vapour or thermal oil (Atomix ® type A and type D).
  • moving body or rotor mounted on a central shaft and built on bearings. This rotor has curved blades, the tips of which are concentric to the stator's body. The curved blades and the body of the stator form the throttling surface.
  • sleeve is mounted in the stator in order to control the gap between the rotor and the stator.

Emulsion Plant

The soap solution is injected directly in the centre of the rotor with two pipes: one on each side. The bitumen is injected around these pipes in order to reheat the soap solution. These two products are mixed in the centre of the ATOMIX ® mill and then sent on the sleeve. The high speed of the rotor (around 44 m/s for ATOMIX ® A) helps to shear the bitumen. The emulsion exits are on each side of the ATOMIX ® and a special outlet loop is used to get the emulsion from only one pipe.

The ATOMIX® is a very robust, easy to-use in the system, and very easy to maintain. The gap increases with the production tonnage of the product. The unit can re build like as new mill again by simply replacing the sleeve and the rotor.

The rotor is designed so that the ATOMIX ® can deliver the emulsion directly to the storage tank up to several meters in height.

The ATOMIX ® can produce all types of bitumen emulsion as tack coats, seal coats, prime coats, grave emulsions, slurry seals, cold mixes, recycling and retreatment emulsions, emulsion with latex, emulsion from SBS bitumen, anionic emulsions, etc….

The production unit system is created to produce 15 tons/hour with ordinary bitumen (around 200Cps at 140°C). The production unit is mounted on a skid.

This unit is designed for a production of 15 tons/hour with normal bitumen (around 200Cps at 140°C).

The unit is assembled on a skid on which are installed the following elements:

  • ONE COLLOIDAL MILL ATOMIX® A2

  • ONE DOSING UNIT FOR BITUMEN.

  • ONE DOSING UNIT FOR SOAP SOLUTION.

  • ONE DOSING UNIT FOR FLUXANT
  • ONE CONTROL DESK GATHERING THE COMMANDS OF THE UNIT
  • ONE SET OF PIPES AND VALVES CONNECTING THE ELEMENTS

 
This unit runs in manual mode. Dosing of bitumen and soap solution are realised through the control of the speed of each pump as these ones are volumetric.
 
The speed of the pump is displayed on the control desk and a curve indicating the outflow allows knowing the quantity of bitumen and soap solution used.
 
On the soap solution line, the operator can check the dosing by looking on a needle flow meter.
 
Electric connections: three phases 400V 50H-60z (neutral + ground).
Electric consumption of the unit: around 37KW.
 
Dimensions of the skid:

Length: 2.8m
Width: 2.2m
Height: 1.7m
 
Emulsion plant 

  

Detailed list of the elements installed on the production skid

1) A group of production with:

ONE COLLOIDAL MILL ATOMIX A2

  • Pressure head: 1, 5/2 bar

  • Rotation speed: 3.200 rpm


With:

  • reheating room by thermal oil

  • injection device

  • outlet pipe with ball check valve

  • one glass thermometer 0-120°C at the emulsion outlet

  • screw + packing device
  • driven by one electrical motor.
  • power: 30 Kw for a speed of 3.000 rpm
  • Coupling by pulley 

One Colloidal Mill Atomix 

 

2) A group to dose the Bitumen with:

ONE MOTOPUMP UNIT:

  • One volumetric pump with variable flow : 1 to 12 m3 / h

  • Pressure head: 3 bars


With:

  • safety reheated valve
  • reheating room by thermal oil

  • filter on the inlet.

  • one manual reheated three ways valve to recycle the bitumen
  • Driven by one variable speed reducer
  • Power: 3 KW.

  • Frequency inverter

  • Speed indicator and its detector

 

ONE GLASS THERMOMETER (0-200°C)

Motopump Moto pump

 
 

3) A group to dose the soap solution with: 

ONE MOTOPUMP UNIT

  • One volumetric pump with variable flow : 1 to 7.5 m3 / h

  • Technology: flexible impeller
  • 
Pressure head: 0,4 bar


With:

  • check valve in stainless steel

  • manovacuometer with electrical contact checking the water level

  • filter in stainless steel on the inlet
  • driven by one variable speed reducer
  • power: 1,1 KW frequency inverter
  • speed indicator and its detector


ONE FLOW METER FOR SOAP SOLUTION:

  • Type: needle

  • Indicating the soap solution flow in l/minute

Flow Meter 

- ONE THERMOMETER (0-120°C)


4) One Control Desk:
 
The various elements of the unit are controlled from this desk, which is placed on the skid.
With : on the upper level, one mimic diagram and the set of control buttons. on the lower level, the electric devices for the production unit.
 

FLUXANT

Fluxant (kerosene, gas oil, etc…) is used to make the bitumen more fluid, thus enabling a better emulsion of the bitumen. The addition of fluxant can be determined in cooperation with the chemists who work on the formulas of the emulsions. We propose this option to enlarge the range of the emulsions which can be produced with our unit.

Dosing of around 3% in the emulsion

Dosing of fluxant is realised through the control of the speed of the pump as this one is volumetric.
The speed of the pump is displayed on the control desk and a curve indicating the outflow allows knowing the quantity of fluxant used.

The operator can check the dosing by looking on a needle flow meter.

ONE VOLUMETRIC PUMP:

  • Variable flow: 100 to 900 l/h
  • 
Pressure head: 3 bars


With :

  • Safety valve

  • Check valve
  • Filter in steel at the inlet
  • Driven by one SPEED REDUCER
  • Power : 0,55 KW, Frequency inverter, speed indicator and its detector


ONE FLUXANT FLOW METER:

  • Type: needle

  • Indicating the flow in %

Type of fluxant:


  • Fluxant type oil which does not imply the ATEX standard

  • Viscosity: around 5 cPs at 20°C.

  • Density: around 0,85

  • Temperature: ambiant

 


B) SOAP SOLUTION PLANT TO PROVIDE THE EMULSION PLANT INCLUDING:

The soap solution unit provides the soap and transfers it to the mill ATOMIX®. This unit is assembled on its own skid.
The production process is known as semi-continuous as the two tanks are used alternatively to supply the emulsion production unit. The operator prepares a soap tank while the second soap tank is used to produce the emulsion. The production does not stop and the emulsion can be realised in a continuous way.

The two cylindrical tanks in special polymers are resistant against corrosion. The capacity of each tank is around 4000 litres.

The unit is assembled on a skid on which are installed the following elements:

  • TWO TANKS OF 4000 LITRES
  • ONE DOSING FOR HOT WATER
  • ONE DOSING UNIT FOR LIQUID CATIONIC EMULSIFIERS
  • ONE DOSING UNIT FOR HYDROCHLORIC ACID
  • ONE ELECTRIC BOX GATHERING THE COMMANDS OF THE UNIT
  • ONE SET OF PIPES AND VALVES CONNECTING THE ELEMENTS

The dosing of hot water, hydrochloric acid and liquid emulsifier is realised through a pump, fitted with a meter. The operator sets the desired quantity, starts the pump, which stops when the quantity is reached.

The selection valves for the product and the tank are manual.

  • Electric connections: three phases 400V 50H-60z (neutral + ground).
  • Electric consumption of the unit: around 7kW.

Dimensions of the skid:
Length: 5m

Width: 2.2m

Height: 2.55m

 

DETAILED LIST OF THE ELEMENTS INSTALLED ON THE SOAP SOLUTION SKID:
 
1) TWO CYLINDRICAL TANKS
Construction: polypropylene HD

Capacity: 4000 litres.

Each tank having:

  • one cover with an orifice + security

  • one level with a float
  • one high level sensor

  • one low level sensor

  • one agitator with stainless steel blades

  • one filling pipe
- one digital thermometer with probe

  • one valve for samples (PH)

  • one tilted bottom for 100% emptying

Cylindrical tankcylindrical tank 

 


2) ONE MANUAL DOSING GROUP FOR HOT WATER

Hot water supplied by the customer at 500c with a flow of 13m3/h


ONE TRANSFER PUMP

  • 
Outflow : 13 m3/h at 2 bar
  • 
Power : 2,2 Kw

water meter

ONE HOT WATER METER AND ONE WATER DOSING METER


 
3) ONE MANUAL DOSING GROUP FOR LIQUID EMULSIFIERS,
with:
Maximum viscosity: around 300 cPs at 20°C.

ONE TRANSFER PUMP with an outflow of 300 litres / h.

Pressure head : 10mce

Manual dosing group

 Manual dosing group
ONE EMULSIFIER METER AND ONE PREDOSING METER | TWO MANUAL VALVES IN STAINLESS STEEL
 
4) ONE MANUAL DOSING GROUP FOR ACID, with :
Concentration of acid HCL : 33%
ONE TRANSFER PUMP with an outflow of 1000 litres/h
Manual dosing group for acidManual dosing group

ONE ACID METER AND ONE PREDOSING METER | TWO MANUAL VALVES IN POLYPROPYLENE


5) ONE GENERAL ELECTRICAL BOX:

Placed on the skid, it allows controlling the elements of the soap solution unit.


6) ONE MANUAL PH METER:

The pH can be checked by taking a sample of soap solution in the preparation tank.

 

Contact Us

Office # 2209, Regal Tower
Business Bay, Dubai, U.A.E.
Tel: +971 4 4541491
Fax: +971 4 4541492
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