IKA mixing technology for the bitumen industry

IKA mixing technology for the bitumen industry


Bitumen is a natural product which can be produced, processed, and used without any environmental disadvantages. Bitumina are thermoviscous (moldable with the influence of heat) mixtures of materials from various organic substances that are generally used as binding agents. Bitumen becomes a thin fluid at a temperature between 150 and 200°C and can then be mixed with other substances. Indispensable products for the preservation and improvement of our quality of life are therefore created: streets, road surfaces, airport runways, construction and roof sealings, bituminous building protection agents and more.

The production of high-quality, polymer modified bitumen (PMB) is the main responsibility of the distributors for street and airport construction companies. Continuous process PMB production is a completely new method exclusively developed by IKA. The inline system DISPAX-REACTOR DR 2000-PB heralds a new era for the bitumen industry: The polymer is placed perfectly inside the bitumen and the chemical cross-linking is therefore ensured.

When compared to traditional batch processes, significant advantages arise for the manufacturer:
  • better product quality based on a steady mixing technology
  • fewer process steps: The polymer/bitumen premixing can be left out completely!
  • less time-consuming: 50% reduction possible compared to a batch process
  • less space required for machines and storage
  • more flexibility when it comes to production amounts
  • smaller energy costs
The biggest PMB machine developed by IKA achieves a flow-rate of up to 35 tons per hour.

IKA also offers innovative and efficient solutions for bitumen emulsions. A bitumen machine intended for continuous operation is used to mix two non-mixable phases: bitumen and water. The heart of this machine is IKA colloid mill MK. It steers and secures the drop crushing within a tight particle size range. This enables flexible reactions to fluctuating raw material characteristics. The use of specific materials allows for the production of cationic and anionic bitumen emulsions without having to convert the bitumen machine.

With IKA mixing technology are produced:
  • Bitumen emulsions
  • Polymer modified bitumen


The most popular equipment

ProductgroupMachines and plants
 
Inline dispersers / Mills Colloid Mill MK 2000/05 Flow rate (max.) : 2500 l/h
Colloid Mill MK 2000/20 Flow rate (max.) : 20000 l/h
Colloid Mill MK 2000/10 Flow rate (max.) : 7500 l/h
 



Applications

Polymer modified bitumen


Polymer modified bitumen
Production in an inline process
Bitumen is an extremely viscous, black mass at room temperature. It slowly starts flowing when it is heated. To achieve a homogeneous mixture of bitumen and polymer, the bitumen has to be heated to temperature exceeding 160°C.

Until now, this was normally done in a batch mode (big vessel including ineffective dissolver-agitator). When the bitumen reached the necessary temperature, the polymer is added and is mixed by stirring. This process needs much time. The process becomes much faster by using an inline homogenizer. It accelerates the solving process and reduces the mixing time considerably.

The most efficient way of solving polymers in bitumen is to mix them inline. The new IKA® high-performance mixer DR 2000/.. -PB makes this new process possible. Polymers can be added and solved in one step. The up to now necessary mixing vessel is no more needed.