This is a laboratory-sized emulsion plant with an output capacity of 30 – 60 gallons per hour (110 – 220 liters per hour). All pumps are variable speed/output so virtually any mix ratios of emulsion can be produced. Mix ratios are normally controlled by monitoring and controlling the various input and output temperatures. The laboratory plant is a self-contained unit, with all components fitted to a heavy-duty steel cart. The cart is equipped with lockable 4” (100mm) diameter caster wheels on all four corners. Overall dimensions are approximately 72” (1.83m) long, 29½” (0.75m) wide and 66” (1.68m) high.
The laboratory plant uses a Supraton S100 colloid mill with a stainless-steel rotor and stator, which have the same groove configuration as production-sized VSS emulsion mills. The mill is equipped with variable speed control for a step-less adjustable speed from 8,000 to 17,000 rpm to match the tooling speed in larger model mills and to achieve optimum asphalt particle size. A 3 hp (2.2 kW) 3 phase electric motor powers the colloid mill via a flexible coupling. The motor and speed control can be supplied in various 3-phase voltages, including 208-, 230- or 460-volt 60Hz and 380-volt 50Hz.
A stainless-steel asphalt feed tank of 5.25-gallon (20.0 liter) capacity is provided. Asphalt is circulated and then pumped into the colloid mill by a heat-jacketed gear pump of .20 - .60 GPM (0.8 – 2.3 LPM) capacity. The asphalt pump is flex coupled to a 3/4 hp (.56 kW) 3 phase electric motor. The motor can be supplied in various 3-phase voltages, including 208-, 230- or 460-volt 60 Hz and 380-volt 50 Hz. Motor/pump speed can be varied from 400 – 1200 RPM using a variable frequency drive controller.
Controller displays pump output in either GPM or LPM as well as amperage load, control frequency and voltage. A three-way valve is used to select asphalt re-circulation for temperature control or asphalt into mill for batch production. A check valve prevents back flow of other liquids into the asphalt line. The asphalt pump, as well as all of the asphalt circulation plumbing is maintained at circulation temperature using 110-volt heat-trace tape. Feed tank asphalt temperature control is by a supply voltage band heater with a thermostatic controller. Tank heating and blending is enhanced by use of a 110-volt, 50/60 Hz adjustable speed mixer. The asphalt feed tank and all of the asphalt circulation plumbing is insulated, with a jacket cover over the insulation. Asphalt temperature, in either Fahrenheit or Celsius, is monitored with a temperature gauge installed into the feed tank and by a digital display on the control panel which is connected to a thermocouple mounted in the asphalt tank output line.
A stainless-steel soap feed tank of 5.25-gallon (20.0 liter) capacity is provided. Soap is circulated through the colloid mill by a peristaltic pump of .05 - .60 GPM (0.2 – 2.3 LPM) capacity. The soap pump is powered by a 1/10 hp (.07 kW) 110-volt 50/60 Hz electric motor. Motor/pump speed can be varied from 6 – 600 RPM using the pump controller. The controller displays pump output in milliliters per minute as well as total volume pumped since last reset. A three-way valve, located on the mill output, is used to select soap re-circulation back to tank for temperature control or mill output out of mill for batch production or system flushing. A check valve prevents back flow of other liquids into the soap line. All soap piping is stainless steel, and the tubing is Tygon. Feed tank soap temperature control is by a supply voltage band heater with a thermostatic controller. Soap temperature, in either Fahrenheit or Celsius, is monitored with a temperature gauge installed into the feed tank and by a digital display on the control panel which is connected to a thermocouple mounted in the soap tank output line.
For polymer modified emulsions, a latex supply system is included. A stainless-steel latex feed tank of 0.5-gallon (2.0 liter) capacity is provided. Latex is pumped into the system by a peristaltic pump of .0001 - .13 GPM (.005 – .48 LPM) capacity. The latex pump is powered by a 1/10 hp (.07 kW) 110-volt 50/60 Hz electric motor. Motor/pump speed can be varied from 6 – 600 RPM using the pump controller. The controller displays pump output in milliliters per minute as well as total volume pumped since last reset. A check valve prevents back flow of other liquids into the latex line. All latex piping is stainless steel, and the tubing is Tygon.
A second three-way valve on the mill output is provided for selection of waste product or emulsion output. This valve directs the material into containers provided by the user. Mill output temperature, either Fahrenheit or Celsius, is monitored with a temperature gauge and by a digital display on the control panel which is connected to an RTD mounted in the mill output line. Resolution of the RTD and display is to 0.1 degrees. Mill output monitoring also includes a 0 – 100 psi (0 – 6.8 bar) pressure gauge.
All controls and displays are mounted in, or adjacent to, a NEMA 4 enclosure which is mounted to the laboratory mill cart.