1. Dipl. Ing. Ralf Port 28th of February 2013 C R O A T I A N A S P H A L T A S S O C I A T I O N O R G A N I S E S S E M I N A R RE-USE / RECYCLING OF CONSTRUCTION WASTE

2. Dipl. Ing. Ralf Port THE DEMAND OF THE TIME RECYCLING Cold - Warm - Hot Recycling RAP in Asphalt Production

3. Dipl. Ing. Ralf Port Advantages: - Reduction of Bitumen purchase - Deduction of Aggregate and Filler purchase - Deduction of Bitumen storage  deducted heating costs - Identical quality to standard Asphalt Mixes Disadvantages: - More technical components needed - Higher quality controls of the incomming RAP materials needed - Bigger storage space and additional logistics needed - Incoming RAP materials and RAP consumption might not be proportional at all Arguments for the use of RAP

4. Dipl. Ing. Ralf Port The process of recycling-material Location: Czech Republic Prag

5. Dipl. Ing. Ralf Port Recycling Granulator Single Shaft Granulator Controls Milling Shaft Push Bar

6. Dipl. Ing. Ralf Port Bypass Twin Shaft Granulator Screen Magnetic Belt Collector Recycling Granulator Double Shaft Granulator

7. Dipl. Ing. Ralf Port Recycling Granulator Location: St. Petersburg

8. Dipl. Ing. Ralf Port Schematic Drawing of MBRG 2000 / 2

9. Dipl. Ing. Ralf Port Operating on the highest level - The BENNINGHOVEN granulator control system

10. Dipl. Ing. Ralf Port Recycling Granulator Specification: MBRG 2000-2 Recycling End Product 8 - 22 mm 0 - 8 mm

11. Dipl. Ing. Ralf Port How works a Granulator ?

12. Dipl. Ing. Ralf Port Recycling Storage

13. Dipl. Ing. Ralf Port Environment protection Cost advantage due to RAW materials Image Advantage Innovation advantage against the competition Arguments for the RAP usage

14. Dipl. Ing. Ralf Port Regarding the technical scope of supply it is the cheapest solution. Smallest Area of space required. Capacities of adding:Approx.: 10-15 % at 3 % Moisture Essential Requirements:Enough Capacity of the Hot Stone Elevator Screen-Bypass Facility on the Hot Stone Elevator Bypass chute must be without wear angle plate within the Hot Bins Advantages:Cost No additional Moisture within the Mixing Tower Disadvantages:Lower percentages of RAP are added. Everything runs through bypass. Cold RAP into the Hot-Elevator

15. Dipl. Ing. Ralf Port Cold RAP into the Hot-Elevator

16. Dipl. Ing. Ralf Port Cold Rap Adding System into the Mixer via Cold RAP Elevator and Belt Weighing Conveyor Capacities of adding:Approx.: 25 % at 3 % Moisture Essential Requirements:Sufficient Volume in the mixer housing for steam expansion. Sufficient Filter Capacity Space for feed chute to be added Advantage:Accurate Dosing Control High percentages can be utlilised Disadvantages:Higher Capital Cost Higher Moisture in the system increases maintenance. Cold RAP into the Mixer

17. Dipl. Ing. Ralf Port Cold RAP into the Mixer

18. Dipl. Ing. Ralf Port Cold RAP into the Mixer

19. Dipl. Ing. Ralf Port Cold RAP into the Mixer

20. Dipl. Ing. Ralf Port Cold RAP into the Mixer

21. Dipl. Ing. Ralf Port Equal heat distribution due to the consistency of the added RAP material. Bigger Fractions which need more heat transfer stay longer in the drying process than the fines. Capacities of adding: Approx.: 25 % at 3 % Moisture Essential Requirements: The dryer need a separate ring, where the material is falling in. Sufficient space next to the burner Sufficient space between dryer and elevator. Mixing tower must be fitted with screen bypass facility. Advantages: Perfect Heat Distribution of the RAP No Humidity within the mixing tower High feed rate possible Low cost retrofit Disadvantages: Asphalt production with RAP only can bypass the screen. RAP Ring Dryer

22. Dipl. Ing. Ralf Port RAP Ring Dryer

23. Dipl. Ing. Ralf Port RAP Ring Dryer

24. Dipl. Ing. Ralf Port RAP Ring Dryer

25. Dipl. Ing. Ralf Port RAP Ring Dryer

26. Dipl. Ing. Ralf Port NEW DEVELOPMENT Multivariable Dosing System. The excellent performance of the cold-dosing- process into the mixer is achieved by the multivariable dosing system. This specialised system allows for the addition of 40 % of RAP-Material at 3 % humidity into the mixer whilst still ensuring high quality asphalt is produced. Another feature is that this system allows any kind of cold or warm mixes to be achieved. Standard Configuration 2 RAP hoppers with oversized grid for coarse / fine material Belt Feeder (Inverter driven) Cold Rubber Belt Elevator Bypass Change over chute (Buffersilo + Discharge chute) Buffer Silo with Level Indicator Dosing Belt (Inverter driven) Mixer Feeding Weigh Belt mounted onto 4 load cells Chute with creusabro liners into the mixer Steam Expansion ducting insulated

27. Dipl. Ing. Ralf Port Multivariable Dosing System. The excellent performance of the cold-dosing-process into the mixer is achieved by the multivariable dosing system. This specialised system allows for the addition of 40 % of RAP- Material at 3 % humidity into the mixer whilst still ensuring high quality asphalt is produced. Another feature is that this system allows any kind of cold or warm mixes to be achieved.

28. Dipl. Ing. Ralf Port Standard Configuration 2 RAP hoppers with oversized grid for coarse / fine material Belt Feeder (Inverter driven) Cold Rubber Belt Elevator Bypass Change over chute (Buffersilo + Discharge chute) Buffer Silo with min. / max. level sensor Dosing Belt (Inverter driven) Mixer Feeding Weigh Belt mounted onto 4 load cells Chute with creusabro liners into the mixer Steam Expansion ducting insulated Multivariable Dosing System.

29. Dipl. Ing. Ralf Port Multivariable Dosing System.

30. Dipl. Ing. Ralf Port Multivariable Dosing System.

31. Dipl. Ing. Ralf Port Capacities of adding:up to 100 % Essential Requirements:Sufficient stocks of graded RAP material Sufficient space next to the mixing tower Advantages:Perfect Heat Distribution of the RAP No Humidity within the mixing tower Highest possible feed rate Most efficient at operating with high ratio of RAP Fast return of investment Disadvantages:High capital cost Planning permission required Larger site area required Hot-Recycling

32. Dipl. Ing. Ralf Port Hot-Recycling

33. Dipl. Ing. Ralf Port Data: Two Coal-dust burner One for the Recycling Drum and one for the Dryer Drum Coal -dust Silo Asphalt Mixing Plant Typ BA 4000 + RA 180

34. Dipl. Ing. Ralf Port Hot-Recycling

35. Dipl. Ing. Ralf Port

36. RC-Cold Input: - up to 35% in Base Course - up to 15% in binding - none in Wearing Coarse RC-Warm Input: - up to 30% in BC by hot elevator - up to 30% in head plate dryer drum - up to 30% by middle drum input RC-Parallel Drum: - up to 100% possible (Hot-Input) - 50-80 % in BC is normal Input Quantities relative to various processes

37. Dipl. Ing. Ralf Port RC-Cold Input - Simplified Technical Plant - Possible to input small quantities - Flexible under stop/start working conditions - Steam extraction via the mixer/tower - Bitumen thermal overload - Water as “foaming agent” in mix process - Up to 30% additional input possible RC-Warm Input - Simplified Technical Plant - Possible to input small quantities - Steam extraction via the dryer - Up to 30% additional input possible RC-Parallel Drums - High investment on plant technology (Hot-Input) - Expensive to process small quantities - Steam extraction in the dryer - Easier to heat the RC material - Continuous processing of large quantities - Better emission control - Possible to process up to 100% RC material Pros and Cons of the three Processes

38. Dipl. Ing. Ralf Port Continuing efforts are being made by all Asphalt Producers to increase the input percentage of RC material. For example, in Bavaria at present the Regional Regulations are being worked out with a view to applying them nationwide. As a result there is a need for increased investment in this field. In addition costs are being inflated by higher energy prices which is leading to every opportunity to increase cost effectiveness being investigated. Target:Up to 80% in base course Up to 50% in binding Up to 30% in wearing course Up to 20% in mastic asphalt New Regulations covering the RC Input Levels applicationin all German States

39. Dipl. Ing. Ralf Port Outlook for RC Input 1. In Germany there is an increasing trend towards RC parallel drums as higher bitumen costs impact the industry. 2. The new installations now combine both cold and warm input. This gives the flexibility to input small or large quantities. 3. The following quality control and financial requirements are already the subject of discussion. - Lowering mixing temperature by adding RC material to all material mix combinations. - Preparation of acceptable quality bitumen even with inputs higher than 30% - It should be possible to continue this practice up to 100% input

40. Dipl. Ing. Ralf Port Thank you very much