Strategic Alliance Workshop EME Demonstra7on project in Q 02 Ge&ng the mix design to work – Dis6n 1 Supported by Delivering the job Produc4on Chris Lange Boral Asphalt
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Strategic Allia
nce Worksho
p EM
E De
mon
stra7o
n project in Q
02 Ge&ng the mix design to work – Dis6n 1
Supported by
Delivering the job -‐ Produc4on
Chris Lange Boral Asphalt
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Overview • Plant • Materials management • Process control • Mixing • QA
Aggregate Stockpile Management
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Plant
160tph Batch Plant • 6 Cold Feed Bins
• 2.4m dia counter flow drum
• 2.25t mixer
• 3 filler silos
• 3 x 100t finished product silos
• 4 bitumen tanks – electric heated
• Computerised mixing system
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Schema4c of Plant
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Materials Management Aggregate • Careful a?en@on to
aggregate quality – mee@ngs with
Quarries – stock pile gradings
checked • High percentage
crusher dust (90% higher than DG20HM)
• No natural sand • High percentage
passing the 75 micron
Aggregate Stockpile Management
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Materials Management Bitumen – EME Binder • Ensure tank able to heat and maintain temperature of 1850C
• Electrically heated (thyristor control to ensure slow rise)
• Tank flushed prior to taking load of EME binder
EME Binder Temp: 1850C
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Process Control Aggregate • Calibra@on of cold feed
bins • High % crusher dust – ran
two feeders to ensure accuracy
• Baghouse fines quan@@es required -‐ checked
• Blend sheets reviewed and checked
• Plant trials to check gradings / binder contents
• Plant scales calibrated
Aggregate Stockpile Management
Cold Feed Calibration: Bin 1 - 10mm Aggregate
0102030405060
1 2 3
Belt Speed
tph
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Process Control • Bitumen
– Tank selec@on – Circula@on – Temperature during
mixing – Inline samples taken
during produc@on – Samples taken at
supplier depot and on delivery from tanker
Aggregate Stockpile Management
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Mixing and Batching • Operators briefed on ITP • Mixing temperature monitored closely: target 1850C and then 1800C
• 75 micron target 8.4% • Batching cycle @mes 50sec • Bitumen temperature maintained at 1850C
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Grading Achieved
0
10
20
30
40
50
60
70
80
90
100
0.075 0.15 0.3 0.6 1.18 2.36 4.75 6.7 9.5 13.2 19 26.5 37.5
Sieve size (mm) (not to log scale)
% P
assi
ng
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Compliance tes4ng Sieve size Max tolerance spec Actual 13.2mm +-‐ 6 % 4
9.5mm +-‐ 6 % -‐1
6.7mm +-‐ 6 % -‐2
4.75mm +-‐ 6 % -‐2
2.36mm +-‐ 3 % 2
1.18mm +-‐ 3 % -‐1
0.6mm +-‐ 3 % -‐1
0.3mm +-‐ 3 % -‐1
0.15mm +-‐ 3 % 0
0.075mm +-‐ 1 % +1.1
Binder content +-‐ 0.5 % -‐0.1
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