Bitumen emulsion plant UVB-1 (Production capacity 1 m3/hour)

The UVB-1- bitumen unit is designed for the production of anionic and cationic bitumen emulsions, which are used in road construction for the following purposes:

• tack-coating of the old road pavement base before laying new asphalt concrete;
• preparation of cold asphalt concrete mixes;
• surface treatment of pavements;
• thin protective coatings;
• road top patching;
• dampproofing of buildings and structures;
• soft roofs construction and repairing.

The unit can be used on factories producing asphalt concrete mixes. The unit is designed for operation both indoors and outdoors, for outdoors operation use sheltered area. The unit’s operation is in compliance with placement category 4 and climatic design UHL as per State Standard 15150-69, but at ambient temperature +5⁰С to +40⁰С.

Basic technical specifications of the unit are given in table

Parameter	Value
1 Maximum capacity (taking into account preparation time), m3/h	1
2 Minimum bitumen consumption (at penetration rate 90…130), m3/h	0,97
3 Water consumption, m3/h	0,6…0,7*
4 Flux consumption (at bitumen penetration rate less than), dm3/h	0…50*
5 Acid consumption, dm3/h	1…20*
6 Emulsifier consumption, dm3/h	1…20*
7 Adhesive additive consumption, dm3/h	1…20*
8 Maximum input bitumen pressure, MPa	0,2
9 Pressure of bitumen supplied the blender, MPa	14…16
10 Water phase pressure supplied to blender, MPa	0,2
11 Input bitumen temperature, оС	140-160
12 Input water temperature, оС	40-60
13 Maximum emulsion output lift, (m)	15
14 Maximum power consumption, kW	17
15 Power circuit voltage at 50Hz, V	380
16 Compressed air pressure, bar	4…6
17 Air consumption, dm3/min	100
18 Maximum dimensions, mm:
-length	2250
-width	1750
-height	1840
19 Maximum weight, kg	1050

* Depending on the formula of produced emulsion!

DESIGN AND OPERATION PRINCIPLES

Plant UVB-1 (hereinafter init) designed for production of bitumen emulsions (see figure 1 and 2) is a semiautomatic unit, which consists of several sections mounted on a common frame and connected by means of pipelines:

Figure 1 – Unit general view (control panel side)

Figure 2 – Unit general view (pump side)

Item	Description	Item	Description
1	Frame		Valves for
2	Blending tank		Water
3	Pumping unit	14.2	Blending
4	Mill	14.3	Flux
5	Water pump		Flow indicator (rotameter) of
		15.2	Water
7	Flux pump
8	Hydrodynamic mixer	15.3	Flux
9	Blending mixer	16	Pneumatic bitumen three-way valve
10	Water phase mixer	17	System of heated bitumen pipelines
12	Control panel (CUU)	18	Pipelines of oil heating
	Gauging tanks section
13.1	Acid
13.2	Emulsifier
13.3	Adhesive additive

Frame (item 1) is a space frame, which holds:

• blending tank, item 2;
• bitumen pumping unit, item 3;
• mill, item 4;
• water pump, item 5;
• blending pump, item 6;
• flux pump, item 7;
• hydrodynamic mixer, item 8;
• blending mixer, item 9;
• water-phase mixer, item 10 ;
• control panel (CUU), item 12;
• gauging tank section: item 13.1 – acid; item 13.2 – emulsifier; item 13.3 – adhesive additive;
• faucets: item 14.1 – water; item14.2 – blending; item14.3 – flux;
• flow indicators: Item 15.1 – water; item15.2 – blending; item 15.3 – flux;
• pneumatic three-way bitumen valve, item 16;
• heated pipeline system , item17;
• oil heating pipeline system, item18.

Our unit is also equipped with temperature and pressure sensors.

Temperature is gauged in points:

• water supply;
• blending supply;
• bitumen inlet;
• bitumen inlet to mixer;
• emulsion outlet.

Pressure is gauged in points:

• before unit;
• after bitumen pump;
• before mill.

Emulsifier tank heater (figure 3).

Figure 3 – Emulsifier tank heater

Heater has a flat pipe-welded design, with heat-transferring fluid circulating inside. 200 liter emulsifier tank is placed on the top of this heater.

Composite control panel (CUU) (figure 4) has a hermetical metal structure, which encloses: controller «Schneider zelio»;multifunctional measuring regulators ТРМ1-Щ2.У.Р and 2ТРМ1-Щ 2.У.РР; protective and starting equipment.

Principle electric diagram, its description and specification are presented in appendix А.

Figure 4- Composite control panel (CUU)

Item	Description	Note	П       Item	Description	Note
1	Operating controller	A11	16	LED function control button «Check»	SB8
2	Mnemocircuit		17	Emergency button «Emergency Stop»	SB1
3	Bitumen temperature gauge before pump «Т1 temperature»	A1	18	Pump М1 «Bitumen forward» control button	SB2
4	Bitumen pressure gauge before pump «Р1 pressure»	A6	19	Pump М1 « Bitumen reverse » control button	SB3
5	Bitumen temperature gauge after pump «Т2 temperature»	A2	20	Mill С4 control button	SB7
6	Bitumen pressure gauge after pump «Р2 pressure»	A8	21	Pump М3 «Water» control button	SB4
7	Emulsion temperature gauge before mill «Т3 temperature»	A3	22	Pump М4 «Blending» control button	SB5
8	Emulsion pressure gauge before mill «Р3 pressure»	A7	23	Pump М5 «Flux» control button	SB6
9	Water and blending temperature gauge «Т4, Т5 water/blending temperature»	A4	24	Automatic mode «Start» control button	SB9
10	Manual phase disconnecting switch	SD1	25	Mode select switch «Mode»	SA1
11	Valve К1 «Butumen» control switch	SA6	26	Automatic mode «Stop» control button	SB10
12	Valve К2 «Solution» control switch	SA3
13	Valve К3 «Flux» control switch	SA5
14	Valve К4 «Blending» control switch	SA4
15	Switch for operation with kerosene (for automatic mode) «Flux»	SA2

Plant principle of operation is given on process layout (figure 5)

Figure 5 – Plant process layout

PROCESS LAYOUT AND EQUIPMENT REQUIREMENTS

Figure 6 – Process layout of water-bitumen emulsion production: 1-bitumen boiler; 2-bitumen pump; 3- heat-transfer fluid pumping section (centrifugal pump); 4-water tank; 5-flux tank; 6-emulsion tank; 7- acid tank; 8-emulsion supply tank; 9-compressor; 10-bitumen emulsion plant UVB

Process layout of bitumen emulsion production (figure 6) consists of plant UVB-1, bitumen boiler 1, bitumen filter 12; flux tank 5, water tank 4, acid tank 7, emulsifier tank, adhesive additive tank, readymade emulsion tank 6, oil section 3, compressor 9, bitumen lines and pipelines (water, emulsion, flux, heat-transferring fluid and compressed air).

Bitumen boiler 1 is a tank with capacity up to 30 m3 equipped with heating system (any type of fuel), which can reach and keep bitumen temperature up to 160…180^оС. Boiler shall be heat-insulated and equipped with gauges which control bitumen temperature and volume and also shall be equipped with bitumen pumps, bitumen valves and bitumen pipelines, which allow bitumen inlet, outlet, mixing and drainage.

Flux tank 5 with capacity 1 to 5 м³ and shall be equipped with stop valves and pressure vent valves which provide explosion-fire protection.

Water tank 4 with capacity 5 to 30 m3 equipped with heating system (any type of fuel), which can reach and keep water temperature up to 40…60^оС.

Acid tank 7 is a translucent polypropylene tank with capacity 1m3 equipped with stop valves. Acid tank shall be placed on platform not lower than 1,3m.

Tanks for emulsifier and adhesive additive are standard metal drums with capacity 200 liters each, which these components are supplied in.

Readymade emulsion collection tank 6 is a vertical heat-insulated tank with capacity up to 30m³, which is equipped with heating system which keeps emulsion temperature within 40…60^оС, sensors which control temperature and volume and also is equipped with pump for emulsion mixing and pumping out.

Oil section 3 is a unit for circulation and heating of thermal oil for heating of bitumen pumps, valves, bitumen pipelines and plant UVB-1. This section heats the oil up to 140…160 ^оС, and is equipped with control and measuring tools.

Bitumen pipelines shall have flow section not less than Du50, heating and heat-protection.

Water pipelines shall have flow section ton less than Du40.

Installed compressor shall have capacity not less than 250l/min and create pressure up 8 bar.

Plant UVB-1 is to be located either inside the manufacturing premises equipped with ventilation, or on open site under tent 6х6m.