Reducing carbon footprint in the asphalt pavement industry

3/9/2024
1
CONFIDENTIAL. This document contains Cargill Confidential information. Disclosure, use or reproduction outside Cargill or inside
Cargill, to or by those who do not have a need to know is prohibited. © 2024 Cargill, Incorporated. All rights reserved.
How can we reduce our Carbon
Footprint - Mix Design
Rejuvenators and Warm Mix Asphalt Technology
Dan Staebell
North America Business Development Leader
Cargill Asphalt Solution
Dan_Staebell@cargill.com
© 2023 Cargill, Incorporated. All rights reserved.
Cargill’s history
2
Cargill's rich heritage
begins with W. W.
Cargill's first grain storage
facility on the American
frontier in 1865.
Cargill became one of the largest, privately-owned
businesses, providing food, agricultural, risk
management, financial, industrial products and
services around the globe.
Cargill Bioindustrial Asphalt Solutions
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3/9/2024
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Cargill: our foundation
Cargill Bioindustrial Asphalt Solutions 3
Our priorities are focused on:
4
Cargill Bioindustrial Asphalt Solutions
Protecting
the planet
Working to improve land use,
advance climate solutions and protect
water resources.
Nourishing
the world
Improving food security and nutrition,
innovating safety in our food system,
strengthening farmer livelihoods and
preparing the next generation of food
and agriculture leaders.
Enriching communities
Strengthening our local operating communities
through economic development, education and
employee engagement.
3
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3/9/2024
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We’re harnessing
the power of nature-
derived ingredients
to help meet the
world’s needs for
renewable materials.
Cargill
Bioindustrial
is made for
this moment.
© 2023 Cargill, Incorporated. All rights reserved. 5
A Global Leader in Asphalt Chemistries
To empower a more sustainable life and
keeping people safe on the road through
high-performance and advanced bio-based
asphalt additives.
Rejuvenation Warm Mix
Cold Mix Emulsions
Rheology Stabilizers
Customer custom formulation services
Compositional and analytical evaluation
Advanced rheology and thermal analysis
State-of-the-art Asphalt Lab
155,000
employees
Working in
70
countries
155
years of experience
$165 billion
in annual revenue
BioIndustrial Research and Manufacturing Facilities
5
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3/9/2024
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Why this matters!
What do I need to know now?
How do we get there?
Diving into Rejuvenators
Utilizing WMA Technology to Reduce Emissions
Q&A
7
How Are We Going to Reduce our
Carbon Footprint – Mix Design
Why this matters!
Why this matters for
agencies and industry!
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3/9/2024
5
A pivotal time
Why is this important?
10
State of the Environment FHWA Sustainable Pavement
Technical Working Group
• Since 2011
• NAPA / AI
Engaged
• Determined to
make something
happen
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3/9/2024
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Why is this important?
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State of the Environment
• Administrations Change, emphasis on
making progress
• Public Companies Reporting and
Disclosures
– Investors driving
– Younger Workforce Interest
• NAPA Industry Road Forward.
– Net 0 2050
– Pathway starting today
– Immediate options
• Inflation Reduction Act
• Buy Clean Legislation
FOR IMMEDIATE RELEASE
2022-46
Washington D.C., March 21, 2022
Colorado
Add a footer 12
11
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3/9/2024
7
Oregon
13
Minnesota Path Forward
14
13
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3/9/2024
8
California Buy Clean
SHOW ME THE MONEY!..
Additional Federal Climate Funding Discussion
• IIJA Carbon Reduction Program – $6.4B over 5 years—agencies can use funds for
pavements if can show a substantial reduction in GHG emissions via LCA Pave
• Inflation Reduction Act-EPA received $41.5 billion in appropriations to develop and
support 24 new and existing programs that monitor and reduce greenhouse gas emissions
and air pollution, protect health and advance environmental justice.
• EXAMPLES:
• $100M to EPA for Low Carbon Labeling Program for Construction Materials (asphalt
included)
• $350M to EPA for Low Carbon Construction Materials Program (includes asphalt)
• $250M to EPA for EPD assistance program
• $300M to EPA for Air Quality Monitoring in Communities
EPA Funding Announcements from the Bipartisan Infrastructure Law and Inflation Reduction Act | US
EPA
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3/9/2024
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What do I need to know now?
Construction life cycle system boundaries
18
Reference: ISO 21930: 2017 Core rules for EPDs of construction products and services
A1-A3:
“Cradle to Gate”
A1-C4:
“Cradle to Grave”
Cargill Asphalt Solutions EPDs
B1-C4:
Use-EOL
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1.7
28.7
3.8
20.5
Aggregates Asphalt Binder Transporation (A2) Plant Operations (A3)
Example Asphalt EPD Values
Global Warming Potential of an Asphalt Mix (kg CO2 eq / ton)
*Data From Napa’s GHG Emissions Inventory For Asphalt Mix Production In The United States
Materials make
up majority of
the environmental
impact!
Total =
54.7 kg
CO2 eq / ton
Materials (55%)
Aggregates
Asphalt Binder
Transportation (7%)
22 miles by truck
Plant Operations (37%)
Burner Fuel
Electricity
Hot Oil Heater
19
Cargill’s EPDs
Two different EPDs are completed and verified
Both EPDs are included in NAPA’s Emerald
Eco-Label Tool so you can incorporate them
into the EPDs for your mix designs
Both EPDs conform to with the ISO 21930
standard, which is the standard used by NAPA
to produce EPDs for Asphalt Mix
1 Anova® 1815 rejuvenator
Anova® 1501 warm mix additive
2
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Use of Recycled Asphalt Pavement (RAP)
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*Data From NAPA’s Emerald Eco-Label Tool
Use of RAP and Overall GHG Emissions
21.3 21.3 21.3 21.3
9.27 7.79 6.03 5.1
30.33
24.4
19.96
17.01
0
10
20
30
40
50
60
70
No RAP 20% RAP 35% RAP 45% RAP
GHG
Emissions
(kg
CO
2
eq/ton)
Plant Operations (A3) Transportaion (A2) Materials (A1)
29% Reduction
13% Reduction
43.4
47.3
53.5
60.9
Total (A1-A3)
Increasing RAP
lowers total
environmental
impact of
asphalt mix!
22% Reduction
How do we get there?
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Summary - Mechanisms of Impact
Three broad mechanisms to treating aged asphalt are envisioned:
1. Softening through Dilution of Maltenes:
Adds to solvent phase and performs as diluents or “Fluxing”
2. Compatibilizing Asphaltene and “Gel” Structure:
Disrupt asphaltene associations
3. “Non-balancing” Softening:
Low viscosity additions to saturate fraction
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RAP Value –
Misunderstood!
• NAPA 11_2023 Benefits of Prioritizing RAP
As shown in Table 2, road owners save
three times more by using RAP in a mix
(valued at a cost equivalent to replacing
both virgin aggregate and virgin asphalt
binder in a new asphalt mixture)
compared to using it as aggregate alone.
How are Rejuvenators Used?
Typically, 1-3% wt. of the binder or 0.05-0.15% wt. of the mix, added via:
1. In-line into virgin binder using additive pump
2. Treatment of RAP (at collar or during processing)
3. Injection into pugmill or mixing drum
4. Pre-blended into virgin binder (least common)
RECYCLING AGENT
Drum Plant Example Batch Plant Example
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Performance Testing: Cracking
• Evaluates mix durability and resistance to fatigue and thermal cracking
• Involves modes of distresses and aging conditions
Beam
Fatigue
Overlay
I-FIT / SCB
IDEAL-CT
DCT
Varies 4-25⁰C
25⁰C
25⁰C or room
25⁰C or room
Low Temp PG +10
Slab compacted, cut
Cut sample
Cut and notched
Compacted to height
Cut and notched
27
Examples of other High RAM Specifications
28
MNDOT
(Proposed)
City of
Phoenix
ODOT
(Trial)
City of
Columbus
Virginia
DOT
City of
Janesville
Illinois
DOT
Illinois
Tollway
Chicago
DOT
New Jersey
DOT
Agency:
DCT
(IDEAL
companion)
IFIT to
approve
RA
IDEAL-CT
IDEAL-CT
IDEAL-CT
DCT + IFIT
IFIT
DCT + IFIT
DCT
Overlay
Tester
Cracking Test
HWT
HWT to
approve
RA
HWT
HWT
APA
Hamburg
Hamburg
Hamburg
Hamburg
APA
Rutting Test
None
Meet virgin
grade of
70-28
Extracted
pass
climate PG
+ 6
Extracted
pass
climate PG
+ 6
None
Extracted
pass PG
XX-16
None
None
Extracted pass
PG XX-22, ΔTc
> 5
None
Binder
Specification
IDEAL-CT
Basic VMD
QC
IDEAL-CT
IDEAL-CT
Surrogate
tests, TBD
Performanc
e test
TBD
Trial Strip +
Performanc
e test
Extracted
PG
Trial Strip +
performanc
e test
QC Process
Under
considerati
on
Trials in
2021
Trial in
2021
Implement
ation in
2022
Trial spec
as of 2019
Active as
of 2017
Active as
of 2019
Active as
of 2018
Active as
of 2018
Active as
of 2018
State of
Implementation
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3/9/2024
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Proven performance with Anova® rejuvenator
To demonstrate performance against
the typical 30% RAP mix, Cargill built a
test section on the NCAT track using
45% RAP and Anova rejuvenator.
After 10 million loadings,
zero cracks appeared in
the test section.
* Data provided and measured by NCAT using plant produced mix.
30% RAP Control
45% RAP + Anova®
rejuvenator
To demonstrate performance against
the typical 30% RAP mix, Cargill built a
test section on the NCAT track using
45% RAP and Anova Rejuvenator.
After 10 million loadings,
zero cracks appeared in
the test section.
0
50
100
150
200
0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000
Average
IRI,
in/mile
Traffic Loading (Equivalant Single Axle Loads, ESALs)
Maintaining
Smooth
Ride
0%
5%
10%
15%
20%
0 1,000,000 2,000,000 3,000,000 4,000,000 5,000,000 6,000,000 7,000,000 8,000,000 9,000,000 10,000,000
Cracking
(Percent
of
Lane
Area)
0 Cracking
0.000
2.000
4.000
6.000
8.000
10.000
12.000
14.000
0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000
Mean
Rutting
(Laser),
mm
No Rutting
30% RAP Control 45% RAP + Anova™
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Increased reflective
cracking resistance
Cycles to failure,
overlay tester*
Control
239
HiRAP +Anova
449
0
100
200
300
400
500
PASS
FAIL
Improved thermal
cracking resistance
Fracture energy
(J/m2), DCT*
Control
503
HiRAP +Anova
495
0
200
400
600
PASS
FAIL
Maintaining rutting
resistance
Rutting depth (mm),
Hamburg wheel*
Control
7.1
HiRAP +Anova
2.3
-1
4
9
14 FAIL
PASS
Target specification
* Data provided and measured by MnDOT using plant produced mix.
• To demonstrate performance against
the typical 25% RAP mix, Cargill built
a test section on MnRoad, using 45%
RAP and Anova Rejuvenator.
The test section
maintained great
cracking performance
through 2.5 MM ESALs
and 3 winters.
32
Utilizing Warm Mix to
reduce emissions.
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Anova® WMA is dosage efficient and multi-functional
33
Footer
Anova® WMA is a non-toxic liquid warm mix additive that
is added at a 0.25-0.75% dosage to bitumen
Anova® WMA allows up to 40ºC (80ºF) reduction in
compaction temperature
Anova® WMA does not significantly affect bitumen
rheology and grade at the recommended dosages
Definitions:
“Chemical” Warm Mix Additives
• Their use has become especially prevalent in
North America and parts of Europe due to the
ease of implementation and lack of impact
on standard bitumen grade.
• Such additives are believed to perform through
improving the combination of the following
mechanisms:
– Modification of the bitumen internal friction,
and
– Improve bitumen ability to coat the
aggregates through modification of surface
free energy, often also making such
additive “adhesion promotors”
Typical Performance Example:
34
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3/9/2024
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1.7
28.7
3.8
20.5
Aggregates Asphalt Binder Transporation (A2) Plant Operations (A3)
Example Asphalt EPD Values
Global Warming Potential of an Asphalt Mix (kg CO2 eq / ton)
Presentation title (Insert Tab > Header & Footer > [type presentation title in text area] Check the Box)
*Data From Napa’s GHG Emissions Inventory For Asphalt Mix Production In The United States
Materials make
up majority of
the environmental
impact!
Total =
54.7 kg
CO2 eq / ton
Materials (55%)
Aggregates
Asphalt Binder
Transportation (7%)
22 miles by truck
Plant Operations (37%)
Burner Fuel
Electricity
Hot Oil Heater
35
Sustainability: Warm Mix Additive
Lower costs and a safer
work environment.
With Cargill’s non-toxic Anova® Asphalt Warm Mix
additive, crews can reliably achieve density and
improve workability at lower temperatures while
reducing emissions and odor.
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3/9/2024
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*AASHTO T283 IDT Tensile Strength Ratio test,
after one freeze thaw cycle. **AASHTO T324-14 Hamburg wheel tracking.
Anova® WMA maintains high moisture resistance and
better rutting resistance
37
Cargill Bioindustrial
0
5000
10000
15000
20000
25000
Hamburg (Cycles to 12.5mm) Inflection Point
HMA
50%
55%
60%
65%
70%
75%
80%
85%
90%
HMA Anova WMA
Moisture resistance* Rutting resistance**
Target
Anova WMA
Proven Field performance: NCAT Facility
38
Cargill Bioindustrial
Asphalt mix design:
- 30% RAP
- PG64-22 Bitumen
- 0.5% Anova™ WMA
0%
5%
10%
15%
20%
0 1,000,000 2,000,000 3,000,000 4,000,000 5,000,000 6,000,000 7,000,000 8,000,000 9,000,000 10,000,000
Cracking
(Percent
of
Lane
Area)
0 Cracking
0.000
2.000
4.000
6.000
8.000
10.000
12.000
14.000
0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000
Mean
Rutting
(Laser),
mm
No Rutting
After 10 million ESALs: Zero cracks
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3/9/2024
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21.3 18.64 17.3 15.97
7.79
7.42 7.42 7.42
30.12
30.15 30.16 30.16
0
10
20
30
40
50
60
70
Hot Mix 40F Reduction 60F Reduction 80F Reduction
GHG
Emissions
(kg
CO
2
eq/ton)
Temperature Reductions
Plant Operations (A3) Transportation (A2) Materials (A1)
Use of Warm Mix Asphalt
39
*Data From NAPA’s Emerald Eco-Label Tool and NAPA report SIP-106: GHG Emissions Inventory for Asphalt Mix Production in the US
Use of Warm Mix Asphalt and Plant Operation GHG Emissions
Lowering asphalt
plant production
temperature lowers the
plant operations
environmental impact
Lowers overall GHG
emissions!
53.6
54.9
56.2
59.2
Total (A1-A3)
19% Reduction
in A3
13% Reduction
in A3
25% Reduction
in A3
© 2023 Cargill, Incorporated. All rights reserved. 40
Owner / Industry
Leadership
Leaders need to be
involved
What will it
take?
Partnership
Set Direction – Agree on
purpose
39
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3/9/2024
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Conclusions and Summary
• Lowering overall emissions in HMA Industry will be required.
– Warm Mix Asphalt Options available today! Begin Learning BMP.
• Implementation of high RAP + Rejuvenator by BMD is highly practical today,
with millions of tons produced every year.
• Process requires a framework that provides transparency and reliability for all
stakeholders:
• Begin process
Great resource for industry adopters of RA:
CONFIDENTIAL. This document contains Cargill Confidential information. Disclosure, use or reproduction outside Cargill or inside
Cargill, to or by those who do not have a need to know is prohibited. © 2021 Cargill, Incorporated. All rights reserved.
Thank You!
Dan Staebell
North America Business Development Leader
Dan_Staebell@cargill.com
42
March 2024
41
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Reducing carbon footprint in the asphalt pavement industry

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