Hot in-Place Recycling (HIR) in Canada

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Hot in-Place Recycling (HIR) in Canada




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Presentations text content in Hot in-Place Recycling (HIR) in Canada

Slide1

Hot in-Place Recycling (HIR) in Canada

Update on HIR - State-of-the ArtCUPGA 2009 Workshop, CTAA ConferenceDelta Beausejour HotelMoncton, New BrunswickNovember 15, 2009Presented by: Ken Fyvie

Slide2

Presentation Outline

Overview of Hot In-place Recycling (HIR) History in Canada (BC)Evolution of Equipment and ProcessToday’s Equipment / New TechnologyThe BC ExperienceQuestions / Discussion

Slide3

Overview of HIR History (Canada)

Heater scarification, Ontario, BC, etc.

Propane, open flame; fumes

/

burning

15 -30 mm maximum treatment depth

No integrated beneficiating

add-mix capability

N

o

ability to improve mix qualities

Smoothen surface /

“rework” crack sealant

Witco’s

Reclamite

® added to surface or in windrow or, no rejuvenating

additive

Open textured finish / limited service

life as surface

course; durability / raveling problems

Slide4

Past Equipment

Johnson Recycling /

Crupi

- heater scarification,

early

to late 1980’s – Demo’s

Taisei Rotec 1987 – 1989 demo’s and projects in BC, Ont., etc.

Rorison

-Wiley 2-stage HIR train, 1987 Williams Lake, BC

Pyrotech

Asphalt Equipment Manufacturing Co. Ltd., Kamloops (

Rorison

) 1990

Artec

Recycling Corp, Delta (Wiley) 1990

Martec

Recycling Corporation, Vancouver, 1994

Slide5

Johnson Recycling ~ 1984 Horsefly – Likely Road, BC

Slide6

Equipment – Yesterday

Johnson Recycling, Tofino, BC – Sept. 1987, BC MoTH Demonstration Project

Slide7

Equipment – Yesterday

Johnson Recycling, Tofino, BC – Sept. 1987, BC MoTH Demonstration Project

Slide8

Johnson Recycling / Crupi – Features

Single Stage Process, including:

Propane fueled heating; open flame, scarifying tines, strike-off

screed (

vib

)

Excess heat,

flames and smoke!

Depth limited to ~ 25 mm max.

Asphalt rejuvenator “could” be added – spray on hot material

surface –

health effects!

No add-mix addition / blending capability

Municipal roads,

lower

volume highways, Ontario, BC, etc.

Slide9

Taisei Rotec, Sechelt, BC – Sept. 1987, BC MoTH Trial

Equipment – Yesterday

Slide10

Taisei Rotec, Prince George Airport Runway 15-33 Overlay, 1988, Transport CanadaDetailed analysis, before and after (CTAA, 1989)Significant HIR mix quality improvements18 year life achieved with HIR and Overlay

Equipment – Yesterday

Slide11

Taisei Rotec - Features

Single stage processing

Propane fueled,

infra-red;

two, open flame pre-heaters

Followed by scarifying teeth, reformer and add-mix / remix unit, grade controlled lay-down / screed

Less flame, less smoke; no emission system

Processed

to ~ 40 mm + add-mix to ~ 50 mm

Rejuvenator by micro-processor

control

Add-mix addition / blending capability; lay-over scarified asphalt “option” with “strike-off”

screed

Slide12

Taisei Rotec - Features

Reformer / paver unit controls

Scarifying teeth

Slide13

The HIR Turning Point (in BC) - 1989

?

Slide14

The HIR Turning Point (in BC) - 1989

BC MoT called 50 mm HIR depth tender, 1988

Eastern CDN contractor bid with equipment incapable of 50 mm, “did their best”

BC HIR market was told by

MoTH

that no equipment would be allowed that could not achieve ≥ 50 mm (2”) depth

Market responded with better capability, and BC MoT responded by tendering more HIR,

Annual volume history summary to follow

Slide15

Equipment Features, Evolving

Pyrotech

,

Pyropaver

300 E

One pre-heater

Two-stage (A & B unit, ~ ½ depth each) milling with

propane fueled, infra-red heat

Variable width processing, 3.5 to

3.8

m wide

Emission control system (incineration)

Rejuvenating agent by micro-processor control

Beneficiating add-mix addition capability, ~ 25 % max; 50 mm plus 10-15 mm add-mix

Drag-slat conveyor pick-up to paver hopper

Slide16

Pyropaver 300 E

Pre-heater

“A” Unit

“B” Unit

Slide17

Pyropaver 300 E

One pre-heater

“A” Unit – 25 to 30 mm

“B’” Unit – 25 mm, with computer controlled asphalt rejuvenator addition

Metered, variable

add-mix addition

Slat conveyor pickup with on-board, pug-mill mixer

“B” Unit pushed by conventional paver, lay-down with standard automatic grade control

s

Slide18

Pyrotech / Pyropaver 300 E (cont’d)

Two Pyropaver users in BC todayGreen Roads Recycling (formerly RW Blacktop)ARC Asphalt Recycling (Ecopaver 400)Contractor rationalization and market consolidation, 2002 to 2006Pyrotech 300 E train users in:BCMexicoSwedenUSASouth Korea

Slide19

Artec Recycling Corporation

Developed four-stage HIR train, ~ 1989 +

Pre-heater followed by four-stages of heating and milling (¼, ¼, ¼, ¼ )

Processing,

3.5 to 3.8 m width

Rejuvenating agent by micro-processor control

Beneficiating add-mix addition capability, ~ 20 % max; 50 mm plus 10-15 mm add-mix

Cranbrook

runway

,

Namao

DND runway,

BC

MoT

projects, Pincher Creek AB, Johor

Barhu

runway, Malaysia, etc.

Receivership, 1993

Slide20

Martec AR 2000 Super Recycler

Martec

acquired

Artec

Recycling

Developed AR 2000 hot air, multi-stage system, 1994 as

Artec

->

Martec

BC demonstration projects: Abbotsford; Sumas;

Mission, BC, etc.

“Heat and stir” process

On board, twin shaft pug-mill mixer before discharge to paver hopper

Lower emissions due to hot air heat process

Propane or diesel option (foreign markets)

Slide21

Artec / Martec AR 2000

Slide22

New Technology - Highlights

Slide23

New Technology - Highlights

Pyrotech300 E = “Ecopaver 400”Two-stage systemInfra-red heatingEmission IncinerationWell-controlled rejuvenator and add-mix addition systemsOn board pug-mill mixerTri-grinder milling headsMore robust components

Martec

AR 2000 Super Recycler

Multi-stage system

Hot air heating

Emission Incineration

Diesel or propane fuel option

On board pug-mill mixer

Well-controlled rejuvenator and add-mix addition systems

More robust components

GHG Software

Slide24

Martec GHG Software

GHG emissions model uses scope 1, scope 2 and scope 3 energy use and emissions for road rehabilitation with process model of road repaving activities

Users enter key data on location of project, depth, lane width & length, distance to various resources, etc.

Model calculates GHG, fuel use and HMA needed for three alternatives:  Overlay, Mill & Fill and Hot in-place

Recycling

Carbon credits obtained

Slide25

The BC HIR StoryThe Long and Sometimes Winding Road

Slide26

Contractor & BC MoT Worked Together

Shared the risks:

Contractors invested in new technology

BC MoT made commitment for rapid implementation, subject to positive outcome

Overcame obstacles together, including:

Excess smoke

Lack of depth

Equipment control issues

Slide27

The BC HIR Story

Slide28

Quantity Trend

Backlog catch-up, early to late 1990’s

Peaked at ~ 625 lane

kms

(2.3 M m

2

), mid 1990’s

Tight budgets / limited or shrinking highway rehabilitation funding

Shrinking supply (coking) / increasing A/C costs may result in more HIR in future years

2009, approx. 1,700,000 m

2

(470 lane km)

Anticipating >10 % increase in 2010

Slide29

BC MoT HIR Project Selection Considerations

Pavement condition:

Structurally sound, > 80 mm thickness pavement, moderate or less rutting

Material properties:

AC content, penetration, aggregate gradation

Previous HIR treatment history

Pre-construction testing

FWD, cores, laboratory testing

Costs

Slide30

BC End Product Spec Approach

Contractor responsible for Project Mix Design, Quality Management & Quality ControlBonus / penalty adjustments for:GradationSmoothness (IRI)AC ContentSegregationCompactionLane Occupancy

Slide31

“Typical” HIR Treatment Regime

Varies by project based on pre-assessment, but generally, includes:

50 mm processing depth + add-mix

Range from 10 to 30 % add-mix

25 % add-mix “average” (20% of recycled mix)

Rejuvenator range, 0.2 to 0.4

litres

/m

2

Typically specify 0.3

litres

/m

2

Golden Bear Specialty Oil -

Cyclogen

“L” or approved equivalent (BC MoT Accepted Products List)

Slide32

BC’s HIR EPS Project Outcomes

Typically, BC HIR contractors achieve an average of 60 to 80% of maximum available bonus moneyLack of bonus success is usually due to a lack of allowance for pre-treatment leveling course paving7 to 12 year typical HIR pavement lifeGHG / Carbon Credit system starting

$$$

Slide33

BC MoT Performance / Relative Treatment Cost Data (per BC MoT)

Before major increase in crude / AC costs!

Slide34

Moving Forward With HIR

LEED for roads?GHG / Carbon CreditsInnovators need clear objectivesProgress needs to be measuredChampions need to be rewarded

Slide35

Moving Forward With HIR

Pavement rehabilitation / bitumen costs are skyrocketing

Aggregate resources

further

away,

more expensive to

process and transport

HIR is a proven solution (BC examples)

Canadian HIR growth (outside

BC) stagnant

USA moving ahead,

CalTrans

planning

$ 15 M for

HIR, 2010

Wash

DoT

projects in 2009, 2010

Slide36

HIR On Highways / Urban Arterials

Slide37

HIR On Airports

Slide38

If Any of This Information Was Deemed Incomplete or Inaccurate, My Reasons Are…

Renovation Chaos at Home, or …

I’m just not very smart, I’m getting old, and I’m leaving the CTAA Board (for the 2

nd

time)

Slide39

I’m Distracted By The Prospect Of the 2010 Winter Olympics and Vancouver Traffic!

Slide40

Thanks for Your Attention!

Any Questions…Ask Einstein, Lol

Ken Fyvie


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