AquaFoam Technology

Warm Mix “Technical Working Group”
Meeker Equipment’s
AquaFoam Technology For
Warm-Mix Asphalt
May 14, 2009
Respectively Submitted
Meeker Equipment, Inc.
Bill Garrett
Partner
5602 SR 655
Belleville, PA 17004
Office: 717 667 6000 ext 6
Fax: 717 667 6730
[email protected]
Production Best Practices
Aggregate Moisture Critical
• Keeping moisture out is a great way to start
• Keep track of temperature drop of material
• > 20°F from drum discharge to load out can indicate
retained moisture
Production Best Practices:
Keep Materials Dry so Bag House
temperatures can be acceptably maintained
•Temperature across baghouse must
remain above dew point (170°F)
•Insulating the baghouse is a good way
to reduce heat loss
Best Practices: Burner Optimization
at Lower Temperatures
• Warm Mix Should produce Lower Emissions
– Nox 4% decrease from HMA
– VOC 92% increased from HMA
– CO2 1% decrease from HMA
Drum Operations
 Due to lower
temperatures and
addition of RAP, buildup
on the flights and in the
drum can occur more
rapidly
 Frequent starts and stops can
be more of a problem with warm
mix in cooler temperatures
 Excessive buildup will affect
mix quality
Notice the visual difference at lower
operating temperatures
HMA - 315 F
AquaFoam - 265 F
Best Practices:
Proper Heat Balance is Critical
Best Practices:
Methods of determining heat
balance NAPA IS-52
Best Practices:
Burner Adjustments are critical
•Properly tuned burner
•Properly sized burner
•Properly sized combustion zone
•Proper fuel viscosity-(R.O.C.K.=recycled oil control kit)
Maintaining Bag House Inlet
Temperatures are critical &
Indexing slingers can help
RAP is our Friend
Maintaining Bag House Inlet
Temperatures are critical &
Exhaust gas heaters can help
Maintaining Bag House Inlet
Temperatures are critical &
Drum/Dryer VFD can help
Handling the Liquid Asphalt at
Lower Temperatures may also be
an energy saving option
•Proper Insulation of tanks, pumps, & calibration system are all critical
•Properly calibrated & controlled metering systems
Best Practices: Non-insulated
piping & poorly insulated storage,
compound issues when producing
WMA
Best Practices: Benefits of Dryer/Drum Insulation
Allows for more even temperature in the bag collector
Before
After
Voids are Created
in the Liquid
Asphalt with
Steam Micro
Bubbles,
Temporarily
changing the
Viscosity of the
Binder &Creating
AquaFoaming
Meeker’s AquaFoam Drum
AquaFoam Water Metering Skid
Meeker’s AquaFoam Drum
MEEKER’s AQUAFOAM BATCH
Without an Asphalt Injection Pump
MEEKER’s AQUAFOAM BATCH
Without an Asphalt Injection pump
BATCH: Flow Diagram &
Scale Calibration
Heat can be applied to the water system for
operation in freezing temperatures
MEEKER’s AQUAFOAM BATCH
Batch with an existing Asphalt Injection Pump System
PROD. RATE TPH
AC TEMP. °F
AC PIPE DIA. IN.
WARM MIX TEMP. °F
AC SPEED FT./MIN.
Water
% of AC
0.50
1.00
1.25
1.50
1.75
2.00
2.50
2.75
3.00
400
310
3
250
229.97
ASPHALT %
DRY AGG. TEMP. °F
AGG. VOL. CU. FT./MIN.
AC VOL. CU. FT./MIN.
AGG. MOISTURE %
5
313
63.06
11.28
5.3
RAP %
RAP TEMP. °F
RAP VOL. CU. FT./MIN.
RAP MOISTURE %
Water Water Water Vol of AC Expansion Expected Expected
TPH Lbs/Min.Gal/Min. Gal/Min
Ratio
AC Temp.F MixTemp.F
0.10
3.33
0.40
84.39
9.86
289
275
0.20
6.67
0.80
84.39
18.73
269
265
0.25
8.33
1.00
84.39
23.16
259
257
0.30 10.00 1.20
84.39
27.59
248
249
0.35 11.67 1.40
84.39
32.03
238
240
0.40 13.33 1.60
84.39
36.46
228
231
0.50 16.67 2.00
84.39
45.32
207
212
0.55 18.33 2.20
84.39
49.75
197
202
0.60 20.00 2.40
84.39
54.19
187
193
25
60
22.22
4.8
Optimizing HMA Facility for
AQUAFOAM WMA
• Proper insulation: piping, liquid storage, calibration,
baghouse, ductwork, dryer/drum
• Proper flight adjustments for heat balance & utilization.
• Proper baghouse temperatures (above dew point)
• Proper moisture removal & control in aggregates
• Properly tuned burner
• Proper testing of materials for maximum results
• Proper injection equipment as specified by the
manufacturer
Hot mix
and
Warm mix
?? Questions ??
Thank –You
Warm Mix “Technical Working Group”
Respectively Submitted
Meeker Equipment
Bill Garrett
Partner
5602 SR 655
Belleville, PA 17004
Office: 717 667 6000 ext 6
Fax: 717 667 6730
[email protected]