Asphalt production Asphalt production in Hafnarfjörðurin HafnarfjörðurOur vision is zero impact Our vision is zero impact (not zero vision)(not zero vision)

Problems needing a Problems needing a solutionsolution

Existing plot too small for activitiesExisting plot too small for activitiesNot designed to adequately handle and treat Not designed to adequately handle and treat runrun--off off DustDustActivities not commensurate with Activities not commensurate with neighbourhoodneighbourhoodAsphalt plant not efficient & not able to meet Asphalt plant not efficient & not able to meet coming environmental regulations coming environmental regulations Not reliableNot reliableCapacityCapacity

The view from Hringhella The view from Hringhella 6, Hafnarfjörður6, Hafnarfjörður

AmbitionsAmbitions

Minimize environmental impact of asphalt Minimize environmental impact of asphalt production (be a good neighbour)production (be a good neighbour)

Eliminate dust problemEliminate dust problemTreat all runTreat all run--offoffRecycle asphaltRecycle asphaltBe innovative in our use of ressources, Be innovative in our use of ressources, development and new technologydevelopment and new technology

Some main principles of Some main principles of asphalt productionasphalt production

Drum MixDrum MixStone and binder mixed Stone and binder mixed in rotating, heating drumin rotating, heating drumAdvantages includeAdvantages include

Simplicity (=>reliability)Simplicity (=>reliability)MobilityMobility

Problems includeProblems includeEmission can (depending Emission can (depending on type) include partly on type) include partly combusted binder => combusted binder => more load on filtermore load on filterSegregation in mixSegregation in mix

Batch mix plantBatch mix plant

Advantages includeAdvantages includeBinder added after heating Binder added after heating of aggregates => emission of aggregates => emission only contains moisture only contains moisture and dustand dustMore flexibility viz More flexibility viz productionproduction

Disadvantages includeDisadvantages includeNot mobileNot mobilePerhaps not as energy Perhaps not as energy efficient as a drum mix efficient as a drum mix principleprinciple

The batching towerThe batching tower

Iceland´s biggest asphalt plantIceland´s biggest asphalt plant

KVM Asphalt Plant type KVM Asphalt Plant type 4000/2504000/250

Max capacity 240 tph @ 5.5% moistureMax capacity 240 tph @ 5.5% moisture8 cold feed hoppers8 cold feed hoppersRAP hopper and elevator to mixerRAP hopper and elevator to mixerDrying drum with 24MW burner for LFODrying drum with 24MW burner for LFOBagfilter Bagfilter -- Reverse jet. Filter area 1040m², emission < 10mg/m³ at Reverse jet. Filter area 1040m², emission < 10mg/m³ at 20m/s 17%O2 using Nomex 400g/m2 bags20m/s 17%O2 using Nomex 400g/m2 bagsFiller storage 2 x 50m³ (imported & reclaimed)Filler storage 2 x 50m³ (imported & reclaimed)33½½ screening decks (4 sizes)screening decks (4 sizes)5 Hot aggregates silo for 85ton5 Hot aggregates silo for 85ton4000kg batch mixer4000kg batch mixer5m³ additive (fibres/colour) silo5m³ additive (fibres/colour) siloHorizontal skip, self propelledHorizontal skip, self propelled500ton hot mix storage in 5 silos500ton hot mix storage in 5 silos2 x 70m³ bitumen silos, heated with blending facility2 x 70m³ bitumen silos, heated with blending facility

240 ton / hour240 ton / hour

34 metres tall, horizontal 34 metres tall, horizontal skipskip

Cold feed hoppersCold feed hoppers

The drier & burnerThe drier & burner

8012016

020024

0280

2% 3% 4% 5% 6% 7%

0

500

1000

1500

2000

2500

3000

Brænderkapacitet kg/h

Tørrekapacitet t/h

Vandindhold i %

Choosing the right burnerChoosing the right burner

Good air/fuel mixingGood air/fuel mixingShort, dense flame Short, dense flame Good heat radiationGood heat radiationEfficient combustionEfficient combustionFit for available fuel typesFit for available fuel typesLow excess of airLow excess of air

Increased drum Increased drum efficiency efficiency Decrease CO & NOx Decrease CO & NOx emissionsemissionsReduce air volume Reduce air volume through baghouse through baghouse (extend bag(extend bag--life)life)

Bitumen, Filler and Aggregate Bitumen, Filler and Aggregate scales scales –– each with 3 load cells for each with 3 load cells for accuracy (=>quality, efficiency)accuracy (=>quality, efficiency)

New paddle design New paddle design –– less less energy, shorter mixing timeenergy, shorter mixing time

The baghouse The baghouse

Main purposes includeMain purposes include filler is recycled, not wasted filler is recycled, not wasted (as in wet scrubbers)(as in wet scrubbers) effcient removal of dust from effcient removal of dust from emission emission –– especially with especially with latest filter materiallatest filter material

Keywords:Keywords:Effective filtrationEffective filtrationMeet environmental regulations Meet environmental regulations

viz emissionsviz emissionsMinimimal temperature gradient Minimimal temperature gradient

across filter (heat loss & across filter (heat loss & condensation)condensation)

Minimal pressure gradient across Minimal pressure gradient across filterfilter

The Filter bagsThe Filter bags

Filter bags (cont.)Filter bags (cont.)

Total of 572 bagsTotal of 572 bagsMaterial is Nomex Material is Nomex 400g/m2400g/m2New types & fabrics New types & fabrics being developed all being developed all the timethe time

Cleaning the filterCleaning the filter

Remove some, not all Remove some, not all the dust cakethe dust cakeTwo methods commonTwo methods common::

PulsePulse--jetjetReverse AirReverse Air

Filler transported to Silos Filler transported to Silos from where excess is from where excess is processed (sludged) to processed (sludged) to waste containerwaste container

Land considerationsLand considerations

Wind directions prevailingWind directions prevailingGeology & seismologyGeology & seismologyDrainage, runDrainage, run--off, waste water treatmentoff, waste water treatmentSurfacing & dust controlSurfacing & dust controlLayLay--outout

Logistics Logistics Internal transportInternal transportSafety Safety SpaceSpace

Other environmental requirementsOther environmental requirements

43000 fm

Sand traps

18000 ltr

Oil separators with sand traps

22000 ltr5000 ltr

FutureFuture

Ambitions / goalsAmbitions / goals

Reduce temperatureReduce temperatureReduce CO2 emissionsReduce CO2 emissionsAlternative bindersAlternative binders

«« 3E3E » ASPHALT» ASPHALT

1. 1. EEnvironmentallynvironmentally--friendlyfriendly2. 2. EEconomicalconomical--savingsaving3. 3. EEnergynergy--savingsaving

Objectives Objectives withwith

3E 3E AsphaltAsphalt

ReduceReduce mixingmixing temperaturetemperature by 40°Cby 40°CTo To achieveachieve

LessLess

emissionsemissionsReducedReduced

fuel fuel consumptionconsumption

andand

therebythereby

reducedreduced

CO2 CO2 emissionemission

WhilstWhilst maintainingmaintaining//improvingimproving workabilityworkability ofof thethe mixmix

WhilstWhilst preservingpreserving//improvingimproving mixmix propertiesproperties

3E 3E Methods in ColasMethods in Colas3E LT : 3E LT : Use of additivesUse of additives

3E DM: 3E DM: Mixing with soft bitumen first Mixing with soft bitumen first followed by hard, foamed bitumenfollowed by hard, foamed bitumen

3E DB: 3E DB: Mixing with soft bitumen first Mixing with soft bitumen first followed by hard bitumenfollowed by hard bitumen

Future (cont.)Future (cont.)

Filtration technologyFiltration technologyHeat exchanging in productionHeat exchanging in productionIncreased recycling of asphaltIncreased recycling of asphalt

Thank youThank you