emulFALT
Bitumen Emulsion Plant
TEKFALT emulFALT is the reliable, highly efficient, compact, easy to use, economic bitumen emulsion plant which is engineered for bitumen emulsion production for all road construction projects, asphalt applications and other special applications.
- emulFALT’s colloid mill guarantees perfect results that can provide preferred particle size by adjustable gap setting between rotor/stator discs for all types of bitumen emulsions (even with low PEN bitumen or modified bitumen).
- Divided inlet for WAE and bitumen at the colloid mill in order to prevent foaming and ensure perfect particle size.
- Reliable and controlled production with thermal oil or electrically heated mill, inverter controlled bitumen and WAE pump, flowmeters, valves and piping.
- Trouble-free and precise production with robust plant structure equipped with stainless steel water-acid-emulsifier (WAE) tank and acid-emulsifier weighing hopper on loadcells, thermostatic controlled stainless steel heating coils.
- Corrosion resistant (stainless steel) gear type WAE (Water-Acid-Emulsifier) pump and flow meter are suitable for use with highly corrosive acidic and basic liquids.
- Ease of operation by accurate continuous control via bitumen, WAE and kerosene flowmeters in accordance with receiptbased manufacturing.
- Container type compact design for easy transportation and installation.
- Optional; Bitumen Flowmeter can be added to the mill’s bitumen feeding line.
- Optional; kerosene dosing system consists of a gear type kerosene pump with ex-proof electric motor including flowmeter and specially designed static mixer for premixing in order to reach desired dosing quality.
- Optional; latex dosing system and optional heat exchanger for modified bitumen emulsion applications.
- Optional; integrated bitumen tank (IBT) for special bitumen processes and flexible production opportunities for various project needs.
- Optional; twin WAE tanks to provide continuous production.
- Optional; PLC & SCADA control system with control panel or control cabin option with PC.
Colloidal Mill
emulFALT’s emulMILL with its adjustable milling gap provides <6 μm particle size and guarantees the best quality of final product even with low penetration bitumen. Thermal oil or electrically heated mill is suitable for the production of both anionic and cationic emulsions and also modified bitumen emulsions.
Emulsifier and Acid Pumping System
WAE Preparation Tank
emulFALT’s water-acid-emulsifier preparation tank’s body and heating coil pipes are constructed with 316L stainless steel and tank is covered with rockwool insulation. 3kW, direct coupled with a gear-motor agitator with 316L stainless steel shaft and blades, equipped with protected bearing housing at the bottom of the tank.
Acid and Emulsifier Weighing Hopper
Acid & emulsifier weighing hopper (316L stainless steel) is equipped with a loadcell.
Bitumen Pump & Circulation Pump
emulFALT’s special design helical gear type bitumen pump with inverter ensures stable bitumen flow and prevents performance loss in the colloidal mill, so mill can focus its whole production capacity on milling process. Hot oil circulation pump is a 1,5kW ALLWEILER centrifugal pump for thermal oil heated version of the plant.
Control System
Control system of the emulFALT is manual as a standard. However, PLC & SCADA control system with control panel or control cabin with PC options are available.
Kerosene Dosing System (OPTIONAL)
There are two options for the kerosene dosing system.
1- High flow rate for cut-back (MC) production (25-60%).
2- Low flow rate for bitumen softening (3-10%).
Bitumen Mass Flowmeter (OPTIONAL)
Bitumen mass flowmeter to produce high-quality emulsion. Thanks to bitumen flowmeter; the actual amount of bitumen flow, total amount and other parameters can be checked and adjusted properly.
Latex Dosing System (OPTIONAL)
Latex Dosing System is an external part of the emulsion plant that feeds the plant with latex through a dosing pump which is equipped with an inverter for perfect dosing rates. Latex Dosing System can be easily positioned according to worksite layout thanks to its flexible hoses and compact size. Dosing rate can be adjusted in accordance with the recipe.
Twin WAE Tanks (OPTIONAL)
The integration of Twin WAE Tanks reduces the batch intervals, thus provides continuous production. While WAE mix is being prepared in one part of the tank, ready WAE mix is being fed into the system.
Integrated Bitumen Tank (OPTIONAL)
Integrated Bitumen Tank (IBT) is a perfect solution to keep small amounts of bitumen at required temperature without heating up/cooling down the whole bitumen storage to operational values; and therefore, reducing heating costs. Additionally, it provides production flexibility by allowing to add & mix (with agitator) solid and liquid additives directly into the bitumen prior to milling process.
