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Bitumen emulsion factories operated by Denimo Tech A/S at 2001
The history for bitumen emulsion application on road construction and maintenance gets back to 1920. The bitumen emulsion application have been promoted on since 1953 in order to be used on freeway, highway, main road subways and country road construction by using of cold asphalt, different types of protecting asphalt, surface covering, road maintenance and improvement.
The bitumen emulsion has lots of advantages like more safety, providence in expense, diversity on application, providence in energy consumption, reduction of air pollution and saving the living environment. The products also can be used in wet surface. The bitumen emulsion without losing it's adherence can spread on stony surface etc…
The bitumen is rigid or semi rigid within ambient temperature which has NO sufficient application but can be used through any of following ways:
  1. Bitumen heating.
  2. Mixing of bitumen with petroleum solvent (solvent bitumen) .
  3. Mixing of bitumen with water to get the emulsified bitumen.
The 1 st option is normally is used for high capacity tasks.
The second option is normally expensive as it causes wasting of petroleum solvents, pollution in living environment with hydrocarbon especially in cities. Implementation of stated option has to be fulfilled in suitable seasons by using dry sands but NOT wet.
The application of bitumen emulsion as per to consumption is different whereas should have special specification. For example there is difference in between bitumen emulsion which is used among two layers of asphalt and the bitumen emulsion to be used for preparation of cold asphalt compound.
Bitumen emulsion structure and specification
The emulsifier are contained of two un-mixable materials one granule type in liquid nominated as internal un-continuance phase whereas the other one as continued external phase.
The emulsifiers in terms on types of the phase are divided in two branches as water in oil and oil in water.
There are different ways to identify which one is continued phase and which one in un-continued phase.
To provide balance in between internal as well as external phases on emulsifiers or in other word to produce the emulsifier and maintain of their stability in suspending situation, some additives will be added to compounds. This additive is called emulsifier or emulsion producer.
Some time may look necessary to increase the permanency of emulsifier; hence to achieve, another type of material called resistant gets added to emulsifier.
The bitumen emulsion is a compound consists of water and bitumen gets produced by emulsifier. The bitumen in fact does not get solvent in water turns in to very small granule particular suspender in water.
The bitumen emulsion granule particulars diameters are variable from 0.01 – 0.001 mm which are bigger than real liquid suspenders .
The emulsifier color is brown before usage whereas gets black after breakage.
The bitumen emulsion is basically known as oil in water which the bitumen gets suspender in water.
In such kind of bitumen emulsifiers, the amount of bitumen depends upon the consumption which usually in production manuals differs from 55 to 65%.
When the amount of bitumen in emulsion reaches to max. Margin, the bitumen granule particular get close together without any change on particular which then stick to each other so as the water in between turns the to act as globule providing water in oil type bitumen emulsion. Such kind of emulsion has same reaction as other bitumen and the amount of bitumen is between 70 – 80 percent.
The bitumen emulsion in terms of breakage speed and suspender particular's electrifying divided in 3 followings:
  1. Un-stable bitumen emulsion .
  2. Semi-stable bitumen emulsion .
  3. Stable bitumen emulsion.
1. the Un-stable bitumen emulsion turns to break very quickly and leaves a thin layer of bitumen. The most application are leakage prevention using stoney construction material, sand, surface asphalt and penetrable material.
2. The semi-stable bitumen emulsion does not break after contacting with stoney whereas keeps it's configuration for several minutes which then turns into effect. Such a kind of semi-stable bitumen emulsion normally gets produced in mobile factories.
3. The stable bitumen emulsion when gets ethereal can be used for surface coverage, surface leakage prevention, stone less covering and dust pacifying.
In term of electrifying, the bitumen emulsion has been divided in two parts as cationic and anionic.
The bitumen emulsion applications are as follows:
  1. Warm asphalt compound .
  2. Cold asphalt compound .
  3. Site produced compound asphalt .
  4. Securing and leakage prevention asphalt .
  5. One layer surface covering asphalt.
  6. Multi layer surface covering asphalt.
  7. Stoney asphalt for Leakage prevention .
  8. Sandy asphalt for Leakage prevention .
  9. Penetrating material with small and large space.
  10. different types of bitumen spraying.
  11. Coverage without stoney bitumen.
  12. Surface coverage .
  13. Dust pacifying .
  14. Desert sand pacifying.
  15. Crack filling.
  16. Instant & un-instant renovation .
The emulsifier is a chemical material in which gets used as an additive item in bitumen emulsion production line. The material can be blended with bitumen meanwhile provides temporary mixing possibility in between bitumen and water up to spreading phase and providing surface layer of bitumen and enabling water to get evaporated.
The main parts of equipment can get fitted in 1X20' container. It basically mixes water , chemical material and bitumen in booth ways either automatic or batch line.
The bitumen normally stored in tanks adjacent to the factory and gets stored after production in emulsion tankers or could be drained in truck to be used at site.
The process could be automatic or batch line. The operator can select any defaulted one to pump out the expected product.
The required area for factory establishment is about 7000 Sq. m whereas the out put capacity is around 48000 ton/one working shift per year.
The equipment software is well programmed for 8 formulas to produce automatically or manually the 8 different products which in fact are changeable and extendable .
The other advantage of the factory is enabling the bitumen emulsion to be kept at least for 4 next months in tank whereas covers all problems and limitation in which were used to raise on transportation of warm asphalt.
The considerable point is the amount of emulsifier that is going to be mixed with the bitumen which depends upon the type of emulsifier for Products like PRIMAKT.   
This compound is approved by affiliated sources in Iran like ASPHALT AND BITUMEN ASSOCIATION. It's relation to raw material importation will be too low whereas reduces approximately less than 1% per ton on emulsion production .
To know about price list and chemical formulation, please contact with Iran Office
 
CHEMICAL ITEM PRODUCER
BITUMEN EMULSION EQUIPMENT MANUFACTURER
PREFABRRICATED CONCRETE ITEMS
ROAD CONSTRUCTING MECHNERY MANUFACTURER
IRAN PRODUCTION COMPANIES' BUSINESS INFORMATION CENTER
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