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ASPHALT

Asphalt Production
Use Case for the Asphalt Production

Coaters/Saturators

The manufacture of asphalt roofing products requires the application of hot asphalt to the underlying substrate. This results in the lighter fractions of the asphalt being vaporized which then condenses to form a blue haze in the exhaust from the ventilation system. Fiber Bed Filters have been accepted as meeting the Generally Available Control Technology (GACT) requirements.

In some areas, more stringent emission controls are required, such as thermal oxidation or carbon adsorption of the VOC emissions from the roofing manufacture. For these systems, Kimre B-GON® Mist Eliminators and Kimre Fiber Bed Filters have proven to be ideal pre-filters to reduce the loading and fouling of the VOC control device by removing the condensible materials.

Storage Tanks

Kimre offers complete solutions incorporating both B-GON® Mist Eliminators and Fiber Bed Filters into systems to handle emissions from asphalt storage tank vents. We can accommodate a variety of flow rates from 50 CFM up to 1500 CFM in small, self-contained packages. These systems include prefiltration with B-GON® Mist Eliminators to provide long life and minimize maintenance. Optional air blower and instrumentation can be provided to complete the system and meet the customer requirements.

Use Case History: Asphalt Production

  • Asphalt Production
    • Importance: Asphalt is essential for road construction, paving, and roofing, supporting
      infrastructure development and enhancing transportation efficiency.
    Production Methods
    • Batch Mix Process:
      • Heating and Mixing: Aggregates are heated and mixed with asphalt binder in
        batches, allowing for precise control over the final product's quality.
      • Cooling: The mixture is cooled before being transported to job sites or stored.
    • Continuous Mix Process:
      • Streamlined Production: Aggregates and binder are mixed continuously for higher
        production rates and efficiency.
      • Direct Loading: The finished product can be loaded directly onto transport
        vehicles.
    • Recycling:
      • Incorporating RAP: Reclaimed asphalt pavement (RAP) is added to reduce costs
        and minimize environmental impact.
    Key Products
    • Hot Mix Asphalt (HMA): Durable road surfaces resistant to wear.
    • Warm Mix Asphalt (WMA): Produced at lower temperatures, reducing energy consumption and emissions.
    • Cold Mix Asphalt: Ideal for patching and maintenance in cooler conditions.

  • Pollutants
    • Volatile Organic Compounds (VOCs): Emissions from heating asphalt can significantly impact air quality.
    • Particulate Matter: Dust and fine particles generated during production pose health risks.
    • Odors: Strong odors from asphalt production may affect nearby communities.
  • Regulatory Compliance
    • Emissions Standards: Compliance with strict regulations governing emissions from asphalt plants.
    • Waste Management: Meeting regulations for waste disposal and material recycling.
  • Process Efficiency
    • Energy Consumption: High energy use during heating necessitates energy-efficient technologies.
    • Quality Control: Maintaining consistent product quality while managing costs is a challenge.

  • Asphalt Shingle Manufacturing Process
    • Raw Material Preparation:
      • Fiberglass or Organic Felt: Base material is prepared, typically made of fiberglass or organic felt.
      • Coating: The base is coated with asphalt, which provides waterproofing.
    • Granule Application:
      • Surface Coating: Colored granules are embedded in the hot asphalt to provide UV protection and aesthetic appeal.
      • Cooling: The coated shingles are cooled before cutting.
    • Cutting and Packaging:
      • Trimming: The shingles are trimmed to size and packaged for distribution.
      • Quality Control: Each batch is tested for consistency and durability.

  • Coaters/Saturators

    The manufacture of asphalt roofing products requires the application of hot asphalt to substrates, resulting in the vaporization of lighter fractions that condense into a blue haze in exhaust from the ventilation system. To address this, Kimre™ Fiber Bed Filters meet the Generally Available Control Technology (GACT) requirements under 40 CFR 63.11559 (NESHAP for Area Sources: Asphalt Processing and Asphalt Roofing Manufacturing).

    For areas with more stringent emission controls, thermal oxidation or carbon adsorption of VOC emissions is often required. Kimre’s B-GON® Mist Eliminators and Kimre™ Fiber Bed Filters serve as ideal pre-filters, effectively reducing the loading and fouling of VOC control devices by removing condensable materials.

  • Storage Tanks

    For emissions from asphalt storage tanks, Kimre provides comprehensive solutions that integrate both B-GON® Mist Eliminators and Kimre™ Fiber Bed Filters. These systems can handle flow rates from 50 CFM to 1500 CFM in compact, self-contained packages. Pre-filtration with B-GON® Mist Eliminators ensures long service life and minimizes maintenance needs. Optional air blowers and instrumentation can be tailored to meet specific customer requirements.

  • Dust and Particulate Management:
    • Dust Suppression Systems: Utilize water sprays or chemical suppressants to control dust emissions during production and transport.
    • Electrostatic Precipitators: Capture fine particulate matter from emissions.
  • Energy Efficiency:
    • Heat Recovery Systems: Capture waste heat to reduce energy consumption.
    • Low-Energy Mixing Technologies: Innovations aimed at reducing energy use during production.
  • Quality Control Measures:
    • Real-Time Monitoring: Sensors and analytics for continuous quality and process monitoring.
    • Material Testing: Regular testing of raw materials and products ensures compliance with standards.

  • Compliance: Facilitates adherence to environmental regulations, minimizing legal risks and potential fines.
  • Efficiency: Enhances production efficiency, resulting in significant cost savings and improved productivity.
  • Protection: Extends the lifespan of equipment by reducing exposure to pollutants and corrosive substances.
  • Community Relations: Reduces odors and emissions, fostering better relationships with local communities.

  • Recommended Products:
    • Kimre B-GON® Mist Eliminators: Effective in capturing vaporized materials in roofing and storage applications.
    • Kimre™ Fiber Bed Filters: High-efficiency filters that improve air quality by capturing fine particulates.
  • Custom Solutions:
    • Tailored Systems: Custom-designed solutions to address specific production challenges and compliance needs in asphalt facilities.
  • Integration:
    • Seamless Integration: Solutions can be incorporated into existing production systems with minimal disruption.
    • Operational Continuity: New systems enhance production efficiency and regulatory compliance without impacting operational timelines.

This use case history outlines the critical aspects of emission control and process efficiency in asphalt production and shingle manufacturing, emphasizing the importance of tailored solutions for roofing and storage applications while providing a comprehensive approach to addressing challenges and implementing effective solutions.

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