XD
XD
These mobile emulsion plants are built onto a rigid skid-mounted steel frame, rust protected and painted.
They are fully assembled and tested, ready for installation and connection to your plant plumbing and electrical system.
They may be mounted in a 20 ft or 40 ft container.
A laboratory room with windows and doors can be fitted into the 40 ft. container.
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SUPRATON COLLOID MILL
- 8 tons per hour or 1920 gallons per hour
- 16 tons per hour or 3840 gallons per hour
- 25 tons per hour or 6000 gallons per hour
- 40 tons per hour or 9600 gallons per hour
- 75 tons per hour or 18000 gallons per hour
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FLOW CONTROLLER
- Electrically actuated throttle valve controls soap flow
- Two control options available
- Temperature Control using emulsion temperature at the mill exit
- Flow Control using mass flow sensors on bitumen and soap lines
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INSTRUMENTATION
- Emulsion Exit Temperature
- Asphalt Temperature
- Soap Temperature
- Soap Flow
- Latex Flow
- Solvent Flow
- Mill Amps
- Asphalt Flow/Ratio Meter - HMI* *(flow controlled option)
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HEAT EXCHANGER
- High efficiency plate type heat exchanger capable of temperature reduction of 40C on maximum mill output
- An outlet temperature gauge is included
- This option is required for production of SBS, EMA emulsions
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FLOW CONTROLS
- Flow Control System uses mass flow sensors on asphalt and soap lines with PLC to control soap flow
- Touch screen HMI panel for residual asphalt percentage input and manual control of throttle valve
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BITUMEN LINE
- Pump capacity to suit output
- Jacketed bitumen pump for hot oil or steam heating
- Bitumen pump includes relief valve
- Motor to suit local power supply
- 2" or 3" valving for in-line circulation, with Teflon-lined 3-way valves
- Non-return (check) valve in-line
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LATEX LINE
- Progressive cavity pump w/capacity to suit output
- Variable speed drive controls flow output
- Flow meter w/gallon or liter totalizer
- Non-return (check) valve in-line
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SCHEMATIC FLOW DIAGRAM SHOWING ALL RELEVANT FLOW AND TEMPERATURE
- All motors are protected with auto fuses
- Mill motor electrical soft-start equipped
- This Fixed or Mobile Asphalt Emulsion Batch Plant is capable and fully equipped for producing a complete range of Anionic, Non-ionic and Cationic Emulsions. When equipped with latex injection and/or heat exchanger it can produce emulsions based on SBS, SBR, EVA, EMA. PE and other compatible polymers.
- The system comes complete with plumbing with all flow meters, check valves and temperature gauges installed in the system. All plumbing is flanged for immediate adaptability to your tank farm.
- Unit is completely wired and ready for immediate installation.
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CONTAINER MOUNTING
- 20 Foot standard container, rust-proofed, can be fitted with one door and window
- 40 Foot container, rust-proofed, can be fitted with lined office/lab area
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SOAP LINE
- Flow meter w/ gallon or liter totalizer
- 2" Stainless Steel pump w/water-cooled mechanical seal
- Motor to suit local power supply
- Non-return (check) valve in-line
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CONTROL PANEL
- Control panel mounted on the frame with following functions
- Mill and Pump Control
- Mill start/stop
- Bitumen pump start/stop
- Soap pump start/stop
- Latex pump start/stop/speed control
- Solvent pump start/stop/speed control
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SOLVENT LINE
- Pump sized to provide dosing into bitumen line of 1-10% solvent
- Electric motor and flowmeter/totalizer mounted on the control panel to set flow rates
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LABRORATORY EQUIPMENT
- Complete laboratory supplies for emulsion and aggregate testing
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ANCILLARY EQUIPMENT
- This Emulsion plant configuration does not include Water Tanks, Bitumen, Solvent, or any other type of finished product or holding tank. Tank farm to be furnished by customer. This unit does NOT contain tanks or external pumps of any kind.
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SPARE PARTS
- Small Maintenance Parts and Tools
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OPTIONS
- Complete Plant and Tank farm layout and design
- 2 Million BTU Hot Oil Heater with heat exchanger
- Emulsion Plant Controls - Temperature Controls
- Emulsion Plant Controls - Flow Controls
- The operator panel (HMI)
- Heat Exchanger Option
Emulsion Plant Controls - Temperature Controls
Consistent, quality emulsion production depends on maintaining the residual asphalt ratio in the mix. This ratio is commonly maintained by monitoring emulsion exit temperature and automatically controlling a throttle valve on the soap line. A loop controller constantly makes small adjustments to the throttle valve position to regulate the soap flow and hold the emulsion exit temperature to a set point. A heat equation is used to take the temperatures and specific heat factors of both the asphalt and the soap and calculate the emulsion exit temperature that will then result in a specified residual asphalt ratio. Controlling the residual asphalt ratio using the emulsion exit temperature relies on holding consistent temperatures on both the asphalt and soap supply lines.
Emulsion Plant Controls - Flow Controls
Instead of using the emulsion exit temperature, a flow controlled plant monitors both the asphalt and soap flows, calculates the residual asphalt ratio, and constantly makes adjustments to the throttle valve position to regulate the soap flow. This system is controlling the residual asphalt ratio based on actual mass flow measurements instead of calculated measurements based on temperatures and specific heat factors. It is not affected by any variation in the temperatures of the asphalt and soap lines. It still controls the ratio by varying the soap flow but the controller is driven by a different calculation. The flow controlled emulsion plants can be considered easier to operate since there is no need to make a calculation to convert the required residual asphalt ratio to an emulsion exit temperature.
The operator panel (HMI)
The operator panel (HMI) displays the residual asphalt ratio (AC%), asphalt flow and soap flow. The operator uses the touch screen to toggle between automatic and manual modes and to input the AC% set point. In the manual mode the operator can control the position of the throttle valve on the soap line. In automatic mode the PLC uses a PID loop calculation to control the position of the throttle valve.
Heat Exchanger Option
Some emulsion mix designs require mill output temperatures that exceed the boiling point of the emulsion. There are also conditions where the emulsion must be cooled for immediate transport or storage. Use of a heat exchanger will lower the emulsion temperature below the boiling point making the emulsion available for use without waiting for it to cool down. For making of emulsions that are above the boiling point, a back-pressure valve may or may not be needed depending on the piping and valving used in the installation (consult factory if required). The heat exchanger is rated for 250oF (120oC). It must be connected to a cool water supply of approximately 75oF (25oC) temperature at a flow rate approximately equal to the mill output.
Training and Technology Transfer
- VSS Macropaver will furnish the services of a service representative to supervise, assist and instruct the employees of the Purchaser in the start-up and check-out of the equipment furnished by VSS Macropaver for a period not to exceed 3 working days. All transportation (airline, train, car, etc) and living expenses are not included and are the responsibility of the Purchaser.
- VSS supplies a full technology transfer and formulation service. This includes formulation, trouble shooting, development, mix design and raw materials analysis.
- If the services of a representative are in excess of the time above, these services will be charged to the Purchaser per day plus all traveling expense enroute to and return from the installation site or work location. If the representative is required to work on Saturdays, Sundays, or holidays or for more than eight hours on any day, overtime rates shall be paid at 1.5 times daily rate by the Purchaser.
- Purchaser shall furnish the necessary facilities, labor and materials to properly test and start-up the equipment. Purchaser shall furnish the following at the equipment site prior to the arrival of VSS representatives:
- All piping and tank connections completed and tested
- All fuel and/or gas connected in the plant
- All electrical power wiring complete
- All raw materials ready for plant production
- Bitumen
- Hot Water
- Acid
- Emulsifiers and other additives
- Under normal conditions the installation takes 4 days
- Price for one supervisor during 4 days
