Bitumen Emulsion Plant


Bitumen Emulsion is processed by emulsification of heated Bitumen with a soap solution, which is formed by creating a mix of mainly water with certain concentration of Calcium chloride, Hydrochloric acid, and an Emulsifier. The emulsification process of Bitumen Emulsion is done by the Multi-Stage High Shear Colloid Mill which produces equivalent high shear to produce the emulsion; the mill breaks the bitumen droplets to an extent to emulsify the two and create a stable un-separable emulsion.

Factors for Bitumen Emulsion Plant Design:

Production Capacity: up to 50L, 1 TPH, 5 TPH, 10 TPH, 20 TPH

Type of Automation: Automatic/ Semi-Automatic

Type of Emulsion: Rapid Setting/Mild Setting/Slow Setting (RS/SS/MS)

Availability of bitumen heating tanks, raw material tanks, final product storage tank

General Classification of Bitumen Emulsion Plant:

Plant Type:

Pilot Unit

Comprises of Colloid mill along with feed pumps each for Bitumen and Soap Solution mounted on a single base-frame for capacities ranging from 1 TPH up to 20 TPH. The Bitumen feed tank, soap feed tank and emulsion storage are not in our scope

Continuous Unit

Comprising of suitable capacities Bitumen mixing tank and Soap solution preparation and feed tank with dosing units, colloid mill, and all intermediary pipeline, connections, etc. Suitable for capacities ranging from 5 TPH up to 20 TPH.

Laboratory Unit

A small unit comprising of a base-frame with feed tanks each for bitumen and soap solution and a mill to have the emulsion ready. Suitable for volumes ranging from 10 up to 100 Liters

Types of Colloid Mill:

Single Stage Colloid Mill

Most economical model comes along with options to have batches up to 100 Liters mostly for laboratory applications

Two Stage Colloid Mill

This mill is used for batching plants wherein the emulsion is prepared byre-circulating the mix through the homogenizer a number of times. Suitable for mid-range or lower capacity models of about 2.5 TPH

Four Stage Colloid Mill

This is the widely used mill having one of the best leading technologies in the world to have the best quality of emulsions in the industry. This is majorly used for continuous processes and shall need a single pass through the mill. Suitable for higher capacity range up to 20 TPH

Control Panel:

Semi-Automatic​

A control panel operated system with all design parameters being indicated in the panel and operated by the end user usually IP-55 panels are provided with starters, relays, etc. ​

Automatic​

A control panel operated system with all design parameters being indicated and controlled with the program fed into the panel usually the logic is fed into the PLC which controls the process and the parameters and other data is indicated in a HMI touch screen

Automation:

Automatic dosing station with dosing tanks/hoppers, flow-meters/load cells, actuated valves can be designed basis on the formulations fed into the system

Actuated valves to automatically Open/Close the valve

HMI touch panel to make possible changes in the process

Bitumen Emulsion Plant comprises of the following:

Heated Bitumen Processing Tank

Heated Bitumen Tank of suitable capacity as per production capacity comprising of suitable heaters to maintain bitumen temperature and an agitator for efficient miscibility of the heated Bitumen.

Soap Solution Preparation and Feeding Tank

Soap Solution tank of suitable capacity comprising of suitable heaters to maintain soap solution temperature and an agitator for efficient mixing of the soap solution.

Feed Pumps

A. Bitumen Feed Pump: for Pumping heated Bitumen to Bitumen Emulsion Colloid Mill

B. Soap Solution Feed Pump: for Pumping prepared soap solution to Bitumen Emulsion Colloid Mill

Bitumen Emulsion Colloid Mill

Multi-Stage High Shear Colloid Mill specially designed for emulsification of Bitumen into the soap solution by breaking droplets of Heated Bitumen into very fine droplets for perfect emulsification. The Colloid mill is the heart of the system ensuring a smooth and stable emulsion.

Piping, Valves, Base-frame & Connections

Intermediatory pipeline with ANSI Flanged connections and ball valves are used for the connection. The complete unit is mounted on a skid mounted frame suitable for easy installation and relocation.

Control Panel

The complete unit is operated with a centralized panel comprising of suitable starters, relays, switches, etc. The panel may be Semi-Automatic or Automatic basis on the process requirement.