Session 2. EMULSIONS: The COLAS DNA 2.3. THE NEW EMULSION PLANT IN GALWAY An integrated business model Alan Kavanagh Technical Manager
CONTENT 1. Introduction the Colas Ireland business model 2. New Emulsion Plant in Galway 3. Quality Control 4. Our strengths 5. Proposals 6. Conclusion
Introduction the Colas Ireland business model
Galway Rotterdam Antwerp Bitumen import: 70/100 pen and 160/220 pen 100 % naphthenic since 2012 (i.e. crude from Middle East) Port Jerome Colas Dunkirk
Bitumen Terminal at Galway Six storage tanks Total capacity is 18,000 tonnes
Introduction the Colas Ireland business model Emulsion Manufacturing facility Emulsifiers
Introduction the Colas Ireland business model The emulsion market: 10,000 km of motorway and National Roads; - Surfaced with hot-mix asphalt 100,000 km of local and regional roads - Surfaced with surface dressing, i.e. tar and chips Colas Ireland market = 55,000 tonnes of emulsion per annum = 16 million m 2 of surface dressing per annum
Introduction the Colas Ireland business model First route to market: Cold Chon supply and spray emulsion for local agencies in west of Ireland
Bond coat and Surface Dressing (Tar & Chip)
Introduction the Colas Ireland business model Second route to market: Contracting arm performs road maintenance works for local agencies throughout island
Surface Dressing (Tar & Chip)
Microsurfacing
Emulsion bound cold mix asphalt
Cold in-situ recycling using emulsion
Introduction the Colas Ireland business model
New Emulsion Plant at Galway Galway
New Emulsion Plant at Galway Designed by Colas Installation began in November 2014. First emulsion produced on 16 th January 2015. (Old plant was in place for 17 years) Consists of both a Colas Mill and a Charlotte Mill; Output is 40 tonnes/hour; Manufactures emulsions and fluxed bitumens; Automated Continuous & Batch System for emulsion manufacture using Ermiis Software; 5 tonne batch tank to make concentrate water-phase;
New Emulsion Plant at Galway High and low flow solvent and additives pumps; High and low flow latex pumps for the addition of latex. Separate emulsion and fluxed bitumen lines; Emulfix process installed; In-line viscometer and ph readouts; Heat exchanger to cool emulsions and heat hot water; In-Line Static Mixers for the production of fluxed bitumens; Endress & Hauser state of the art meters.
New Emulsion Plant at Galway Emulsions manufactured: Cationic Emulsion: Polymer Emulsion: 70 % for surface dressing (CSR) 65 % for velocity patching (CSR) 62 % for cold-mix asphalt (CMS) 76.5 % for surface dressing (CRS) (Cohesion >1.2 or >1.4 J/cm 2 ) 65 % for bond coat (CRS) Fluxed Binder: For delay set macadam
New Emulsion Plant at Galway Raw materials: Paraffinic bitumen: Polymer modified bitumen 6 storage tanks Hot and cold water Hydrochloric Acid Calcium Chloride Flux oil Adhesion agent (Chemoran TPH)
New Emulsion Plant at Galway Emulsifiers: X2TDC(R) for rapid setting emulsions; TNB for polymer emulsions; GAP for cold-mix asphalts and in-situ recycling; TLC for SBS modified micro-surfacing emulsion; CPM-H for latex-modified micro-surfacing emulsion; X2DL for patch-mix emulsion; All Chemoran emulsifiers are liquid at ambient temps. Typical storage temp = c. 30 C.
New Emulsion Plant at Galway Temperatures: Bitumen phase temperatures: 150 C for cationic emulsions 160 C for SBS polymer emulsions Water phase temperatures: 5 to 20 C for cationic emulsions 13 to 20 C for SBS polymer emulsions Emulsions temperatures: 80 C for cationic emulsions 85 C for SBS polymer emulsions
New Emulsion Plant at Galway New plant features: Water-phase Batch Tank In-Line ph Meter
New Emulsion Plant at Galway New plant features: Charlotte G125 Mill Used for polymer emulsions Colas Mill Used for standard emulsions
New Emulsion Plant at Galway New plant features: Heat Exchanger Cools polymer emulsions from 100+ C down to 85 C and also heats water, if required
New Emulsion Plant at Galway New plant features: In-Line Viscometer for Emulsions In-Line Emulsion Sampling Point
New Emulsion Plant at Galway New plant features: Computer screen for water-phase
New Emulsion Plant at Galway New plant features: Computer screen for bitumen-phase
New Emulsion Plant at Galway Emulsion storage tanks: 12 emulsion storage tanks Total capacity is 560 tonnes
New Emulsion Plant at Galway Time Flow BITUMEN Flow EMULS Flow ACID 2 LF % BITUMEN Emulsion Viscosity Plant production reports: Records values every 10 seconds; 94 parameters recorded including: a) the flow, speed, quantity and temperature of the: soap, latex, solvent, bitumen, bitumen additive, emulsifier, acid, Calcium chloride, cold water, hot-water b) the pressure, speed and amperage of the mill; c) the emulsion viscosity, temperature and output quantity; d) bitumen content; and e) destination tank
New Emulsion Plant at Galway Energy savings, thanks to: a) very efficient motors; b) on demand electric trace heating; and c) All motors are controlled by soft start invertors. 45 27
New Emulsion Plant at Galway Energy savings, thanks to: a) very efficient motors; b) on demand electric trace heating; and c) All motors are controlled by soft start invertors. 40 % reduction in energy demand during production; and 53 % reduction in energy demand when on standby!
Quality Control Bitumen QC includes pen value, softening point, acid value and salt content; This allows us to adjust emulsion formulations, if required. For QC of emulsions, the following steps are taken: 1. Initial sample taken from the plant; 2. A second sample is taken from the filled storage tank; 3. QC tests include binder content, breaking index, sieve test, ph, particle size analysis and viscosity; 4. Once approved, the product is released for delivery;
Quality Control
Quality Control Bitumen QC includes pen value, softening point, acid value and salt content; This allows us to adjust emulsion formulations, if required. For QC of emulsions, the following steps are taken: 1. Initial sample taken from the plant; 2. A second sample is taken from the filled storage tank; 3. QC tests include binder content, breaking index, sieve test, ph, particle size analysis and viscosity; 4. Once approved, the product is released for delivery; 5. QC testing also performed by National Authority; 6. Lab is ISO and CE certified.
Quality Control The product is ready for dispatch:
Our strengths Fully integrated business model of Colas Ireland: Importing bitumen, manufacture of emulsifiers, manufacture of emulsions, supply of emulsions to customers and performing road maintenance contracts for customers; Leads to close relationship with customers/users of our emulsions; R&D performed in partnership with Chemoran, Cold Chon and road maintenance contracting division supported by CST and local university; We can anticipate our customer needs and develop solutions for them.
Proposals 1. Make use of bitumen storage: a) to control you own supply and ensure quality; and b) to increase buying capacity when bitumen prices are low 2. Have close relations with your customers to anticipate product demands; 3. Consider starting/growing your contracting/road maintenance division; 4. Integrate R&D of emulsions with R&D of end-products; 5. Use Chemoran emulsifiers
Conclusions Modernization can lead to increased productivity and reduced fuel costs; Your emulsion plant can be at the heart of your business model Please contact us if you have any questions: alankavanagh@colas.ie
How to install a new emulsion plant in 50 seconds
THANK YOU Alan Kavanagh Technical Manager