BITUMEN EMULSION PRODUCTION PLANT

Capacity: 10 m3/h

The unit can produce alltypes of bituminous emulsions

General view of bitumen emulsions production plant installed inside of container

1- emulsion preparation section; 2- water phase section; 3- control cabinet; 4 - protective cover, 5 -
container.

Components description

1- emulsion production block

2- water phase block
3- unit control system
4- support arm
5- protecting cover plate of water phase solution
supply pipeline
6- flux supply pipeline
Water phase production block (mixing of water, acid, emulsifier and adhesion additives)

1- Flow meters

Accuracy: ± 2% FSD
Repeatability: 0.5% of Flow
Protection: IP65
Materials: 316 SS standard

2-flux pump

Type: gear pump

Capacity: 22 L/min
Drive: Asynchronous, short-circuited electric
motor, typ AIR71B4U2 (power 0,75 kV, 1350
RPM)

3- soap solution pump

Type: Vertical multistage pump, Vilo 7MVI 207

4- water supply pump

Type: Vertical multistage pump, Vilo MVI 807

5-water/soap solution mixer (hydro-dynamic)

All components are fed under pressure into the
mixer. Principle of mixing is hydrodynamic
cavitations. Due to high pressure and speed inside
of mixer highly dispersed structure of all
components is achieved. Performed in welded
design, material: stainless steel
6-tanks for consumables (acid, emulsifier, adhesion additives)
Plastic tanks, chemical-resistant, volume: 0,30 m3
each

7-water supply pump-line

In welded design. Material 316 stainless steel.

8- «water reverse»
In welded design. Material 316 stainless steel.
Installed to regulate water flow in order to heat
pipe-lines and pumps.

9- soap solution tank

Plastic tank, chemical-resistant, volume 1 m3
Emulsion preparation unit

1-bitumen pump

Typ: gear pump

Rated pumping speed: 500 l/min
Working pressure: 0,59 (6) MPa (kg/cm2)
RPM: 415
Rated capacity: 8,15 kW
Suction lift: 1 m

2-colloidal mill

In welded design. Material: 316 stainless steel. Intended

for:
Maintenance of dispercity of bitumen at 5 µm at the
beginning and at the end of the process (during
turbulator achieves operating capacity). Operating
time during dispercity maintenance: 5-8 sec.
Mixing of bitumen emulsion and latex (in case of
operating in latex injection mode)

3- hydrodynamic triple-stage mixer

Casing: in welded design. Material: steel

Mixing chamber: in welded design. Material: 316 stainless

steel. Intended for premixing of bitumen and
water phase. Bitumen pressure inside the chamber 14 bar,
water phase pressure: 2 bar.

Venturi tube: In welded design. Material: 316 stainless

steel. Intended for further mixing of bitumen and water
phase. Dispercity of bitumen particles in water achieved: 20
µm

Turbulator: In welded design. Material: 316 stainless

steel. Turbulator is a perforated pipe intended for achieving
of dispecity of bitumen particles in water: 5 µm
4- flux blender

Designed to add flux to bitumen in case of low

penetration grade

5-bitumen pump drive

Type: three-phase, asynchronous
Capacity: 18,5 kW
Rotation speed: 1500 r/min

6-reduction gear
Type: worm, single-stage
Rated rotation speed of output shaft: 180 r/min
Rated rotational moment: 550
Mass: 204 kg

7- mill drive

Type: asynchronous
Capacity: 11 kW
Rotation speed: 3000 r/min

8-temperature and pressure measuring unit

Bitumen sensors:

Temperature
Pressure

9-valves with pneumatic drive

Valves with pneumatic drive and pneumatic cylinder serve

for operating of emulsion manufacture technological
process
10-three-way bitumen valve
Controlled by a pneumatic cylinder a 3-way valve serves
for the bitumen supply in to a mixer injector, and also for
the partial supply of bitumen back into reservoir

11-“reverse bitumen”

12-frame
The frame consists of steel profiles and serves for safe
mounting and piping of all machines and devices.
Material: construction steel St 37-2
Painting: primed and lacquered with chemically resistant
lacquer, color grey/black

Control cabinet
The technological parameters of water-bituminous
emulsion preparation process are regulated by the
comptroller of Schneider zelio, on which signals come
from the measuring devices of type:

- 2ТРМ1 – bitumen pressure after pump;

- ТРМ1 – bitumen temperature after pump;
- ТРМ1 – bitumen temperature before pump;
- ТРМ1 – emulsion pressure before colloidal mill.
The measuring devices listed below are used for the
reflection of current value of measureable parameter:
- ТРМ1 – bitumen pressure before pump;
- ТРМ1 – blend temperature; Reflection of the chosen current measuring
- ТРМ1 – water temperature; on a built-in LED digital indicator.
- ТРМ1 – emulsion temperature before colloidal mill.
Emulsifier tank heater
Emulsifier tank heater is a pipe-welded construction with
a heat-transfer fluid circulating inside. The heater is
equipped with a bypass line and a three-way cock used
for heater disconnecting from the general heating system.
During unit operation emulsifier tank is wrapped with heat
insulation material. The heater is mounted into the
general plant oil heating system.
Operating principles

Flowsheet of equipment

1- vessel of blending
2-vessel with acid
3- vessel with additives
4- vessel with emulsifier
5- vessel with kerosene
6,7,8 - measuring vessels
9- neutralizator of acid steams
10- heat-transfer device of water heating
Emulsion production

A hot bitumen through the 3-way valve КІ flows into mixer С1 and partly through the ajar valve
K2 back in a boiler.

Flux is passed out from vessel 5 through rotametr R1, regulative valve and electro-controlled
valve EK 3 into blending machine С1.

A bitumen, mixed with flux, passes by the pump M1 through the controlled 3-way valve ЭК1
(pneumatic cylinder serves as a valve drive) under high pressure in the mixer-injector C2,
where it mixes with a water phase, and the mixture flows into the third hydrodynamic blending
machine C3.

In the blending machine C3 occures crushing of bituminous marbles and emulsion flows to a
rotor mill – C4, where takes place a stabilizing of emulsion.

Further emulsion partly is cooled down in heat-transfer device of water heating 10 and enters
the vessel of finished product.

Water phase

First contour of water phase block- polymeric vessel 1, pump M4, injection mixer C5.

The second contour is a mixer C6, in which blend and water are mixed, given accordingly by the
pumps M4 and M3.

A blend is prepared in a polymeric vessel 1, which is originally filled with warmed water from a
water reservoir.

After turning on the pump M4 water circulates in a blending vessel 1 through the mixer-injector
C5, in which creates discharging. By sequential opening of valves K7, K10,K12 from the
measured vessels 8; 7; 6, that are fastened on blending vessel framework, - acid, additives,
warmed emulsifier, are passed in.

The mixed mixture (blend) is checked up by a pH-meter on accordance to a pH-value, if

necessary, corrected.

A water phase is manufactured directly in the process of emulsion manufacturing, at mixing in

the blending machine C6 of warmed water with blend. PH-value of water phase goes from 2 to
2,5.

Water is passed up by the pump M3 from a water reservoir, blend - by the pump M4 from the
blending vessel 1.

Control of expense and dosage of water and blend is carried out through rotameters R2, R3.

Water for technological needs is warmed up in a reservoir for water and partly in heating water
heat-transfer device 10.

Emulsifier is heated by a heater 11, on which a vessel with emulsifier is placed.

With the help of plunger-pump M2 emulsifier through a pipeline flows into the measured vessel
6.

For neutralization of evaporation of acid, neytralizator of steams of acid is used 9.

Water-polymeric mixture (Butanol) from a vessel M6 through the flowmeter R4 regulative valve
K17 and 3-way valves K18 and K19 is passed by the pump to the mixer of emulsion
manufacturing block.

After operating is finished, a pump, a flowmeter and pipelines should be washed with clean
water.
 Flowsheet of bituminous emulsions production

- - - - - - equipment and accessories supplied by Globecore

1 - bitumen boiler
2 - bitumen pump
3 - heat carrier pumping station
4 –water tank;
5 - flux vessel
6 - emulsion storage
7- station with oil heater;
8- emulsion supply pump
9 – compressor
10 – bitumen emulsions manufacture unit
11- heat-transfer device
12 - container

EMULSION PRODUCTION SITE (PLACEMENT EXAMPLE)

To receive further information contact:

[email protected]