CO & 18-20, SR

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1 101 Ideas to Improve Efficiency of HMA Production 36 th Annual Rocky Mountain Asphalt Conference & Equipment Show February 18-20, 2009 Crown Plaza, Denver, CO Respectively Submitted Meeker Equipment, Inc. Bill Garrett Partner 5602 SR 655 Belleville, PA Office # ext 6 Mobile # Bill@meekerequipment.com

2 OUR GROWING INDUSTRY

3 Good Old Days Cheap Energy Less Regulation Lower Production Easier Binders Working Workers Fewer Mix Designs More Roads to Build

4 Aggregate Crushing Wear Changes Shape & Particle sizes

5 Aggregate Crushing & Stock Piling Wear changes particle shape & size Size & shape of piles, Segregation Pile dividers Loader & Material handling

6 Aggregate Crushing & Stock Piling Size & Shape of Piles Segregation

7 Aggregate Crushing & Stock Piling Stock Pile Dividers

8 Aggregate Crushing & Stock Piling Loader & Material Handling

9 Stock Piling at Asphalt Plant Pile Configuration Dozer Usage Testing

10 Stock Piling at Asphalt Plant Covered Piles Size of Piles

11 Stock Piling at Asphalt Plant Silos Dividers Covered Size of Piles Configuration Dozer usage Testing!!

12 Loader Operator Where to pick from on the pile Pile Maintained Drained properly

13 Transportation Truck Loaders Off Road Trucks Trains

14 Trains

15 Transportation Trains Off Road Trucks

16 COLD FEED SYSTEM Moisture Censors Covered Bins Moisture: Drain it out Keep it out Evaporate it out Calibration Non Stick Liners

17 COLD FEED SYSTEM Covers, (1% moisture increase cost or reduces production 12%) VFD, increased torque, less energy Proper Bin Draw (3 to 5 % Taper) Tensions Maintained

18 Heat Recovery Bins Removes Aggregate Moisture Reduces Emissions

19 Conveyors Covered Tension Maintained Supports Truss framed for stability Elevated tail pulleys

20 DRUM Insulated Seals Maintained Inlet & Discharge Dampers in place & functional Trunnion Adjustment Dryer & Mixer RPM s

21 Before Drum Insulation 600 tph Counter Flow, 650 deg F

22 After Drum Insulation Same 600 tph Counter Flow, 100 Deg F

23 Benefits of Dryer/Drum Insulation Before After

24 Hot Trunnion Detected

25 FLIGHTING Combustion Flighting Dryer Flights RAP protection vale

26 HEAT BALANCE or Loose $$ Know where the heat goes Equal breaching temperatures No opening in the veil

27 BURNERS Clean regularly; fuel delivery system: nozzles, strainers, traps, fans Tune ups often with monitoring Pressures monitored as equipment wears, especially with coal and recycled fuels Total controlled combustion systems, simultaneous combustion

28 WMA Technologies SAVE ENERGY Regardless of the technology typically only minor modifications are made to the plant. What really doesn t change for each of the technologies is the need for sound plant operation practices. Lowering the average temperature of a high production asphalt plant degrees Fahrenheit requires thought.

29 Drum Operations Due to lower temperatures and addition of RAP, buildup on the flights and in the drum can occur more rapidly Frequent starts and stops can be more of a problem with warm mix in cooler temperatures Excessive buildup will affect mix quality

30 Maintaining Bag House Inlet Temperatures are critical & Exhaust gas heaters can help

31 Maintaining Bag House Inlet Temperatures are critical & Indexing slingers can help especially when RAP is used

32 Even Batch Plants can save energy with WMA & MEEKER s AQUAFOAM BATCH

33 SAVE ENERGY with a MEEKER AQUAFOAM BATCH

34 WMA Foam Illustrations 311 F 230 F

35 Notice the visual difference at lower operating temperatures HMA F WMA F

36 Optimizing HMA Facility for WMA Saves $$ Proper insulation: piping, liquid storage, calibration, baghouse, ductwork, dryer/drum Proper flight adjustments for heat balance & utilization. Proper baghouse temperatures (above dew point) Proper moisture removal & control in aggregates Properly tuned burner Proper testing of materials for maximum results Proper injection equipment as specified by the manufacturer

37 RFO Filter and Heat

38 RFO Filter and Heat

39 Exhaust Filtering & Handling No holes 1. Ducts 2. Bags Cleaning cycles Insulation Damper functioning Door Seals

40 EXHAUST FAN VFD Dual vs. Single motor Dampers functional & controlled Impeller clean and balanced Backward Incline Fan Power Monitoring

41 Variable Frequencey Drive on 600 tph Counterflow Drum Mixer

42 Mix Handling Conveyor & Equipment Lubricate Clean (Release agents) Proper chain tension Gates & Batchers sealed

43 Liquid Storage & Handling Insulate Low Temperatures Clean Level Instrumentation for Spill Quantification

44 BTUH HEAT LOSSES IN ASPHALT TANKS AT 300 DEGREES F (WITH OUTSIDE AIR TEMPERATURE OF 50 DEGREES F) INSULATION THICKNESS IN INCHES TANK SIZE IN GALLONS 10,000 15,000 20,000 25,000 30, , ,406 1,012,011 1,232,616 1,453, ,597 65,951 84, , , ,784 32,976 42,167 51,359 60, ,856 21,948 28,111 34,239 40,367 BTUH HEAT LOSSES PER FOOT IN HEATED PIPELINES AT 300 DEGREES F (WITH OUTSIDE AIR TEMPERATURE AT 50 DEGREES F) INSULATION THICKNESS IN INCHES NOMINAL PIPE SIZE IN INCHES

45 Piping & Pumps Insulate, settling Safety

46 Asphalt & Fuel Heating Systems Time clocks WE DELIVER TOO Zone thermal fluid Temperatures set low Coking a NO NO

47 Controls Calibration Communication Information

48 1.4 GPT

49 100% Recycled Plants Cyclean Company Features 170 tph and a decade of experience in Los Angeles Speco Heavy Industries Mendenhal RAP Master Alex-Sin Manufacturing Rotary Screw Korean 90 TPH plant Portable 20 tph 35 tph indirect dryer Indirect/direct dryer Bracegirdle & Reliable

50 Cyclean LA

51 S P E C O O H E A V Y

52 Mendenhal Eagle

53 RAP Master

54 70-80% Recycle Swiss Ammonn Plant European Scanning Tour

55

56 SCHEDULING TRANSPORTATION

57

58 Classification of 8-hour Nonattainment Ozone Areas OTC / MRPO CATEGORY/CLASSIFICATION Severe 17 Los Angeles Serious - Riverside Co (Coachella Valley), San Joaquin, Sacramento, CA Moderate Moderate EAC Greensboro, NC Marginal Subpart 1 (Basic) Subpart 1 EAC (Basic) Beware of other state-specific initiatives

59 Regulatory Authority Regional Planning Organizations taking lead Super state air pacts to help meet SIP requirements OTC (13 states) / MRPO (5 states) most active re ozone (precursors) including NOx... for now Central, Western, Southeastern RPOs less active re ozone More interest in pristine area visibility (Nat l Parks) Other standards will dictate interest level, e.g. PM2.5 OTC / MRPO proposed LNB mandates Existing and future HMA plants LNB mandate

60 WHY ASPHALT IS BETTER Most recycled product in the world Smoothest & long lasting Immediate traffic even for our Hero's

61 ?? Questions?? THANK YOU 36th Annual Rocky Mountain Asphalt Conference & Equipment Show Bill Garrett Meeker Equipment, Inc SR 655 Belleville, PA Mobile # Office # ext 6 Bill@meekerequipment.com