Bitumen emulsion production lines

Alexandria Engineering Industries designs and manufactures fully automated, high-efficiency bitumen emulsion production lines for the road construction, waterproofing, and infrastructure sectors. These systems produce stable oil-in-water (O/W) bitumen emulsions—used in cold mix asphalt, surface dressing, tack coats, prime coats, and soil stabilization—without requiring high-temperature application, reducing energy consumption and emissions.

Our lines support the production of anionic, cationic, or non-ionic emulsions, tailored to project specifications and climate conditions.

Key Components & Process Stages

1. Bitumen Melting & Storage

• Indirect heating tanks (thermal oil or steam) to melt solid bitumen (e.g., penetration grades 40/50, 60/70, 80/100) to 140–160°C.
• Temperature-controlled storage with agitation to prevent aging.

2. Emulsifier Solution Preparation

• Stainless steel mixing tank for preparing aqueous phase:
  • Water (softened or demineralized)
  • Emulsifying agent (cationic: e.g., amine salts; anionic: soaps)
  • Additives (pH adjusters like HCl or NaOH, stabilizers, polymers)

3. Colloid Mill (Core Unit)

• High-shear rotor-stator colloid mill (3,000–6,000 rpm) to disperse hot bitumen into microscopic droplets (1–10 microns) within the water phase.
• Precision gap control ensures uniform droplet size and long-term stability.

4. Cooling & Stabilization

• Heat exchangers rapidly cool the emulsion to <80°C to halt further reaction and prevent coalescence.
• Optional inline homogenizer for enhanced stability.

5. Storage & Maturation

• Insulated agitated storage tanks with slow-speed mixers to maintain homogeneity during the 24–48 hour maturation period.

6. Control & Automation

• PLC + HMI system for:
  • Automatic dosing of bitumen, water, and chemicals
  • Real-time monitoring of temperature, pH, flow rates
  • Recipe management (e.g., rapid-set, medium-set, slow-set emulsions)
  • Data logging and batch reporting

Key Features

✅ High Stability & Uniformity: Emulsions meet ASTM D977 / EN 13808 standards.
✅ Flexible Formulations: Switch between cationic/anionic emulsions with quick cleaning.
✅ Capacity Range: From 2 to 30 tons/hour (customizable).
✅ Energy Efficient: Lower operating temperatures vs. hot-mix asphalt.
✅ Eco-Friendly: Enables cold-application techniques—reducing CO₂ emissions by up to 30%.
✅ Robust Construction: Food-grade stainless steel (SS304/316) for all wetted parts.
✅ Low Maintenance: Self-cleaning colloid mill options and minimal moving parts.