USB-3 Continuous Bitumen Modification Unit (12 m3/hour)

GlobeCore / Products / Bitumen Modification Plant. Modified Bitumen Production / USB-3 Continuous Bitumen Modification Unit (12 m3/hour)
polymer modified bitumen plant
USB-3 unit is designed for continuous production of modified bitumen (continuous operation unit). The rated capacity of the unit is...
    Advantages
    • continuous operation;
    • use of any modifiers which can be fed in the form of granules, powder, or liquid;
    • possibility to make products in any quantity and in various concentrations of additives;
    • high quality of the product made with little time consumed;
    • ease of operation and maintenance;
    • compactness – the unit is transported in a standard twenty-foot container;
    • implemented system for heating with thermal oil;
    • modern control system

USB-3 unit is designed for continuous production of modified bitumen (continuous operation unit). The rated capacity of the unit is 12 cubic meters per hour.

When preparing modified bitumen, USB-3 unit allows using any modifiers known as of today, including crumb rubber and various special additives along with all known SBS-polymers which can be fed in the form of granules, powder, and liquid.

The unit makes it possible to implement new formulations of modified bitumen which involve adhesion additives and plasticizers.

The unit can be optionally completed with the following components:

  • sulfur feeder;
  • polyphosphoric acid feeder;
  • Big-bag monorail hoist;
  • weighing batcher;
  • compressor;

the mill can be completed with a mechanical seal including a support system.

Principle of operation

Figure 1 — Design of USB-3 unit

  1. Polymer is fed into the hopper.
  2. The operator sets the polymer modified bitumen formulation (percentage of polymer and additives in bitumen) on the control cabinet.
  3. The unit is started.
  4. Bitumen is fed and batched into the intermediate tank. Polymer is fed and batched into the same tank.
  5. Liquid additives (plasticizers, adhesion additives, etc.) are preliminarily fed and batched into bitumen.
  6. A high-speed mixer inside the tank preliminarily mixes polymer and bitumen.
  7. A gear pump supplies this mixture to the mill where polymer modified bitumen (PMB) is ground and homogenized.
  8. Upon completion of operation, the unit automatically flushes itself with clean bitumen (to avoid the formation of plugs in assemblies and pipelines).
  9. The unit is ready to be engaged at any time thereafter.

Technical features

  1. USB-3 unit is installed inside a spatial structure the dimensions of which allow transporting the equipment in a standard 20-foot container.
  2. The spatial framed structure of increased rigidity makes it possible to quickly assemble and disassemble the unit in the field which is very important when changing the location of an asphalt and concrete factory.
  3. USB-3 is equipped with a high-speed colloid mill the cutters of which have a special profile allowing to grind, cut, and homogenize polymer-containing bitumen, as well as to obtain a finished product of excellent quality in a single run.
  4. The mill cutters have a symmetric profile allowing to double their service life. It is just required to change the rotation direction. Furthermore, the mill allows changing the gap between the cutters from 0.1 to 1 mm (depending on the tasks).
  5. The pumping equipment of the unit is completed with a frequency converter which allows the premixed bitumen and polymer to be supplied to the mill at a specified capacity. Therefore, the mill is relieved of suction and discharge functions and the entire power is spent on homogenizing the product only.
  6. A polymer batching system is a hopper equipped with a spiral conveyor the drive of which contains a frequency controller. The input polymer (either from regular bags or from Big-bags) is fed from the hopper into the intermediate tank through the spiral conveyor in accordance with the percentage ratio to bitumen which is set by the operator on the control panel.
  7. An intermediate tank is designed for preliminary mixing of polymer with bitumen and increases the bitumen-polymer contact time which will allow unloading the mill. The intermediate tank is equipped with a high-speed mixer which ensures uniform mixing of bitumen and polymer.
  8. Liquid additives such as plasticizers and adhesion additives are supplied by self-priming, gear-type, and dosing pumps; the percentage in PMB is set and adjusted by the operator from the central control panel. Each pump of the kind has its own mixer and blends additives into bitumen in front of the intermediate tank and the mill.
  9. The unit is completed with electro-pneumatic valves, and compressed air can be supplied thereto from a compressor installed on the unit (optional); it allows the unit to be independent on an external source of compressed air.

All the bitumen pipelines, pumps, the mill, and the intermediate tank are heated with thermal oil. Heating with thermal oil is the “mildest” and most efficient heating of assemblies and bitumen lines.

Bituminous grouts — field of application

  1. Bituminous grouts are classified both by fields of application and by methods of use (cold and hot coating).
  2. Some grouts require preliminary surface preparation with primers. A primer is a bituminous priming material containing a bitumen and a solvent and having a high penetrability and a short drying time.
  3. Types of grouts and their uses:

а) Coating grout (cold application):

  • waterproofing of surfaces;
  • treatment of joints and cracks;
  • puttying of surfaces;
  • attaching of rolled bitumen materials;
  • anticorrosive protection of metal structures.
  1. b) Coating grout (cold application). It can be used at sub-zero ambient temperatures. It is used for repair and forms an ultrastrong waterproof coating on the steel, concrete, and wood structures sunk deeper into the ground.

с) Bituminous-rubber grout (cold application) is used for waterproofing of foundations, walls, tanks, pipelines, etc.

  1. d) Adhesive grout (cold application). Designed for attaching the extruded polystyrene to bituminous, bituminous-polymer insulating materials in foundation insulation systems.

Modified bitumen — Fields of application

  1. Road construction:
  • production of asphalt concrete which is used for new construction and repair of first-class roads, bridges, overpasses, road junctions, etc.;
  • production of stone matrix asphalt concrete (SMA) for pavement topping of first-class highways and roads;
  • production of porous asphalt concrete;
  • plaсing of crack-stopping membrane interlayers.
  1. Hydraulic engineering facilities:
  • production of PMB-based grouts for coating of water storage facilities, swimming pools, water supply pipe linings.
  1. Roofing:
  • production of PMB-based rolled roofing materials (Ruberoid, Euroruberoid).
  1. Bitumen shingles:
  • production of grouts for laying and repair of roofing surfaces.

Parameter

UOM

Value

 Capacity

m3/h

8… 12

Amount of polymer

%

1… 5

 Amount of plasticizer per 1m³ of bitumen

kg

0…100

Amount of adhesion additive per 1 m³ of bitumen

kg

0…10

 Operation mode

continuous

 Required power

-mill, kW

75

-overall, kW

110

Electric current

-voltage, V

customizable

-alternating current (AC) frequency, Hz

customizable

 

 

 Dimensions, not more than:

         -length, mm

5,400

         -width, mm

1,620

         – height (operating position), mm

2,650

 Weight, not more than, kg

3,500

Equipment configurations that are not included in this configurator can be implemented via a separate request to [email protected].

  • continuous operation;
  • use of any modifiers which can be fed in the form of granules, powder, or liquid;
  • possibility to make products in any quantity and in various concentrations of additives;
  • high quality of the product made with little time consumed;
  • ease of operation and maintenance;
  • compactness – the unit is transported in a standard twenty-foot container;
  • implemented system for heating with thermal oil;
  • modern control system
Equipment configurations that are not included in this configurator can be implemented via a separate request to [email protected].

Application Fields of GlobeCore Polymer-Based Bitumen Modification Plants

GlobeCore polymer-based bitumen modification plants can be used for:

  • creating special-purpose polymer mixes which are put to use in the automotive industry, in construction, packaging, etc.;
  • production of special-purpose lubricants with different types of additives blended in;
  • production of composite materials which are put to use in making road pavements, sports surfaces, as well as in the construction industry;
  • production of modified construction materials, such as waterproof coatings and materials, asphalt mixes,;
  • production of anticorrosive coatings for metal structures;
  • production of special insulating materials or covers for packing which require a high stability and flexibility;
  • production of polymer coatings which are used for protection of cables and pipes against exposures, including humidity, chemical corrosion, and mechanical damage;
  • production of coatings which enhance the wear resistance of various surfaces, for example, as applicable to industrial floors, parking areas, warehouses;
  • production of special polymer mixes which ensure more effective soundproofing in the construction or automotive industry;
  • production of coatings which are used on sports grounds, ensuring enhanced safety and comfort;
  • production of polymer mixes which are used for road surface markings, ensuring a better visibility and durability;
  • production of special coatings which protect marine craft from water, salt and other exposures to marine environment;
  • production of polymer mixes which are used as insulating materials in electronic and electrical industry, particularly in the production of wire and cable insulation;
  • production of modified polymer mixes for creation of coatings which improve the thermal insulation and energy efficiency of buildings, pipelines, and other structures;
  • production of geotextiles which are used in the construction industry for waterproofing, drainage, soil reinforcement, and other applications;
  • production of special coating and composite materials which are used in the automotive industry for vehicle interior, dashboard, door panel design, etc.;
  • production of coatings which are used in solar panels, wind turbines, and other renewable energy components;
  • production of special coatings for moisture protection of agricultural facilities;
  • production of coatings which enhance the wear resistance of sports equipment, for example skis, snowboards, bicycles;
  • production of waterproof and chemically stable coatings for internal and external surfaces of swimming pools, water slides, etc.
Equipment configurations that are not included in this configurator can be implemented via a separate request to [email protected].

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Equipment configurations that are not included in this configurator can be implemented via a separate request to [email protected].

Equipment configurations that are not included in this configurator can be implemented via a separate request to [email protected].

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Cost ingredients for bitumen emulsion production
USB-3 (12 m3/hour)
USB-3 (16 m3/hour)
Equipment configurations that are not included in this configurator can be implemented via a separate request to [email protected].