-In the late 1800’s - industrial revolution was in full swing-Asphalt was economical and quick-Need for larger production of asphalt
One of the first asphalt plants in AmericaPicture taken 1912Served purpose but many drawbacks – pollution, slow, very inefficientNotice horse in picture
Through 1900’s, Demand gave rise to increased productionStill no modern features such as accurate blending, fuel efficiency, pollution controls AND SAFETY
Today’s plants are clean, efficient, automated and SAFE
They handle various levels of demand and products.
Drums plants are most popular currently but still account for only 40% of total plants - Parallel Flow - Counter Flow - Double BarrelBatch Plant
Some of the various components of an asphalt plant from bird’s eye view.
Burner from early plant – pipe with a nozzle-very inefficient-no control of emissions and pollutants-usually only diesel fuel or propaneModern Burner – traits similar to jet engine-fuel is sometimes heated/pressurized/atomized/mixed with air/ignitedTypes of Fuel
Dust Collection – Environmental Compliance
In the old days no concern for pollution-released dust and pollutants in the air-Affecting the surrounding environment and the employees-Need for improved controls
Baghouse – Modern baghouseold plants utilized wet scrubber/washer
Air flow through baghouse. Some utilize cyclone or knock down boxAir flows below and up through bags and into top of baghouseBag pulse to release built up dust materialDust augured back to drum and blended with mix
Mix dumped directly out of plantDrawbacks-No trucks equal plant shut down-One type of mix at a time.-Dangerous
First Modern Silo System-allowed storage of asphalt-lack of trucks didn’t require shut down of plant
Modern Silo System-Multiple silos allow plant to continue production while waiting on customers-Allow production/sale of multiple mixes
Plant Control-Heart of plant (the brain)Sophisticated controls-Control blending system-Updated Status & Control-Process Management and Diagnostics-Inventory ControlLoading and TicketingTime Entry
Cost breakdown of Asphalt from 1950 to 2012Largest component cost are materials drivenModern control system manages materials within tolerance of .5%Accounts for variations in specific gravities, temperatures, moistures and waste.
Asphalt Plant Presentation - Guest Speaker
AN OVERVIEW OFASPHALT PLANTS
Introduction• Shawn A. Riley – VP of APAC Kansas City & Missouri• Career – Hall & Riley Construction – APAC – Oldcastle
Who is APAC?• Until 2006 – Leading Construction Company in U.S. • #1 Asphalt • #5 Quarry
History of APAC• 1900 Warren Brothers Company, the forerunner of APAC, was founded February 5, 1900 in Nashville, Tennessee.• 1900 Frederick J. Warren filed a patent for "Bitulithic" pavement, a mixture of bitumen and aggregate.• 1901 The first modern asphalt production facility was opened by the Warren Brothers in East Cambridge, MA.• 1968 Ashland Oil, Inc. acquired Warren Brothers and the name changed to Ashland-Warren, Inc.• 1980 the Ashland-Warren name was changed to APAC, Inc. still under the ownership of Ashland.• 2006 APAC was acquired by Oldcastle Materials Group.
Who is Oldcastle?• Subsidiary of CRH, Inc. – Dublin, Ireland• 2 Division – Oldcastle Products Group • Oldcastle Glass • Oldcastle Architectural Products • Oldcastle Distribution • Oldcastle Precast • Oldcastle Merchants Metals – Oldcastle Materials Group
Oldcastle Materials Group• Supplies aggregates, asphalt, and ready-mix concrete, and provides paving services.• Over 1200 locations• Employees 17,500• 44 states• Over $6 billion Revenues