WELCOME
ASPHALT AND AGGREGATE EVENT AND
MARKETS
Visitors in Indianapolis next
week will see lots of examples
of the ability of the Industrial
Internet of Wisdom (IIoW) to
empower the Industrial Internet
of things (IIoT) resulting in
higher quality granular products
at lower costs.
A hot mix asphalt plant
with just one operator is able
to blend the optimum percentages
of sand, asphalt, RAS, and RAP
based on continuous moisture
level analysis of the sand and
other parameters.
Guidance is provided not
only by the process management
software but by a tier of
subject matter ultra-experts who
have 24/7 access as needed. This
includes suppliers of major
components and consumables. A
bag expert is periodically
assuring that bag pressure drop
and energy consumption is
balanced with bag life extension
and emission limits.
He is continually
assessing the data analytics and
through
video camera feedback is
evaluating bag inspection and
maintenance procedures. With
more than 20 cameras located in
strategic positions bin conveyor
positioning, belt tracking and
other processes are assessed.
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The Show
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The IAC-Example
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The Markets
THE SHOW
Indianapolis, Indiana will host
the World of Asphalt Show &
Conference and co-located AGG1
Aggregates Academy & Expo February
12-14, 2019. Over 450 of the
industry's leading manufacturers
and service providers in the
aggregate, asphalt, pavement
maintenance, and traffic safety
industry sectors will showcase
their latest products and
technologies.
The program will include many
relevant combust, flow, and
treat ( CFT)
discussions such as a
round table with Mclanahan and
Superior on fines recovery.
http://review.nssga.org/NovemberDecember2018/index.php#/24
Lots of CFT Products on Display
(Here
are some of the 450 exhibitors)
Albarrie Environmental Services
manufactures a range of
filtration products from bags,
cages, door seals, dryer drum
seals and leak detection powder
to baghouse inspections,
maintenance and high-efficiency
filter bag cleaning.
American Fabric Filter has been
supplying filter bags for to the
asphalt industry for more than
15 years
BWF Envirotec
is a leading supplier of filter
bags for the asphalt industry.
As both a needle-felt producer
and bag fabricator, BWF has the
ability to design felts to meet
the individual requirements of
each application.
It provides dust
collector bags, baghouse
maintenance, lab services, parts
and accessories.
Derrick®
manufactures fine-separation
technologies for the aggregates
industry. Including dewatering
equipment and long-lasting
urethane panels.
Duechting Pumps
specializes in the manufacturing
of suction dredgers and solids
handling pumps for the sand and
gravel industry.
Eagle Crusher Company
Incorporated
manufactures a complete line of
heavy-duty impact crushers,
portable crushing and screening
plants, jaw crushers, and
conveyors for the concrete,
asphalt, aggregate, and recycle
markets.
FLSmidth AFT
is a supplier of baghouse filter
bags, APC replacement parts and
baghouse services It provides
complete bag installations,
changeouts and dust collector
rebuilds
Gorman-Rupp
rotary gear pumps are built to
handle all asphalt applications
including clean, blended,
emulsion or filled asphalts
including abrasive,
limestone/silica sand roofing
material.
Haver & Boecker
has launched the Tyler F-Class
portable plant that includes
several new technologies to
improve setup time and extend
equipment longevity in quarry
and mining operations.
HAZEMAG
offers a range of products such
as: impact crushers, drying
technology, hammermills, sizers,
roll crushers, horizontal impact
crushers, apron feeders and
roller screens.
Industrial Accessories Company
(IAC)
designs, fabricates, and
installs plants and equipment
systems. As an Engineering,
Procurement and Construction
contract provider serving
numerous industries, IAC has
delivered equipment, services,
and turnkey systems. IAC
specializes in baghouses for in
plant dust control, material
handling equipment, both
pneumatic and mechanical
conveying, and bulk storage
systems throughout the US,
Canada, Mexico, the Caribbean,
and Latin America.
Kolberg-Pioneer, Inc. (KPI),
Johnson Crushers
International, Inc. (JCI)
and Astec Mobile
Screens, Inc. have served
the aggregate, mining,
industrial, construction and
recycling industries for the
past 90 years. These divisions
of Astec Industries offer
a complete line of crushing,
screening, conveying, washing
and classifying, and track
equipment.
McLanahan Corporation
manufactures equipment that
ranges from primary crushing to
sand processing to water
management.
Metso
products range from mining and
aggregates processing equipment
and systems to industrial valves
and controls.
PHOENIX Process Equipment
provides custom system solutions
and equipment for liquid/solid
separation in aggregate, mining
and other minerals production
processing.
PSG® a Dover company
manufactures
pumps, systems and
related flow-control solutions
Schurco Slurry®
manufactures heavy-duty slurry
pumps, pump parts, and provides
pump services to a wide array of
markets worldwide. Heavy-duty
centrifugal slurry pumps are
used in industries like
hard-rock mining, mineral
processing, power generation,
aggregate processing, or any
type of slurry pumping
application.
Superior
which became a public company in
2017 supplies crushing,
screening and washing equipment.
These products are in addition
to a conveyor and custom plant
portfolio for a complete product
offering from Rock Face to Load
Out.
SWECO
is a manufacturer of round and
rectangular vibratory separation
equipment, gyratory sifters,
decanting centrifuges, and a
full complement of aftermarket
parts and screens. For the
aggregate market, SWECO offers a
complete line of Gyratory
Sifters.
Terex
crushing & screening equipment
includes the Terex® Cedarapids,
Terex® Simplicity, Terex® Canica
& Terex® Jaques lines.
Weir’s
product range incorporates
brands such as Warman®
centrifugal slurry pumps,
Linatex® rubber products and
hose, Vulco® wear resistant
linings, Cavex® hydrocyclones,
Enduron® comminution equipment,
Isogate® slurry valves, Delta™
Industrial knife gate valves,
Multiflo® mine dewatering
solutions, and Trio® equipment,
including crushers, screens,
washers and conveyors.
Wirtgen
utilizes IIoT and Remote O&M.
Among many others, the main
innovation of the asphalt plant
Cyber UACF iNova 1200 P1 is the
possibility of remote
monitoring. The Ciber
engineering manager, Bernard
Ronchetti, explains that -
through a simple software
supplied by the factory - the
customer can access information
in real time on your computer
and manage the process online.
"The engineer in charge of the
plant can see the same screen as
the operator. With that, he is
able to check the operation in
real time, 24 hours a day.
Access the historical production
and consumption of commodities
is also possible, "he explains.
Another novelty is the
possibility of computer
processing Recycled Asphalt
Pavement (RAP) through the
installation of optional
components. "Recycling can reach
up to 50%," explains the
engineer. The percentage is
quite significant, since in the
United States – reference in
recycling asphalt - the average
is 17%.
Another innovation of Ciber UACF
iNova 1200 P1 is related to fuel
economy and environmental
concern during the production
process of the asphalt: it is
possible to produce WMA (Warm
Mix Asphalt). "By setting up the
equipment’s system it is
possible to reduce the
temperature 15% and maintain the
quality of the mix. In addition
to reducing fuel consumption,
the process also reduces carbon
generation”, explains
engineering manager at Ciber.
IAC EXAMPLE
One of the exhibitors seeking to
leverage IIoW is IAC.
The company recognizes
the advantage of offering a
range of services to owners
which span the life of the
plant.
These can be summarized
as Advise –Design-Supply
-Construct- Guide- Maintain.
Advise:
The company prioritizes the
ability to understand the
customers goals and to advise
from project inception.
IAC has pursued this
approach by hiring as its new
president, a senior executive
from one of the sand and
aggregate operating companies.
In one recent
presentation
IAC Frac Sand Plant
Optimization
Bob Carter described
a multi-step process to
achieve an understanding of the
various control points and the
impact or change each introduces
to a sustained operation. The
six steps are: 1)
characterization of each type of
optimization. This would include
water related processes such as
filtering, settling and spill
management. 2) Operate the plant
and gather data compared to
original design para. 3) Model
impact of operational parameters
like feed gradation on control
points. 4) Develop Operational
SOP's around control point
optimization. 5) Measure and
report results and progress at
all levels of the organization.
6) Approve capital expenditures
around advanced control,
retrofit, design modifications,
etc., targeted toward specific
control point optimization.
Design:
With its extensive process
knowledge IAC is designing large
systems for a number of
manufactured sand plants as well
as for clients in aggregate,
cement, and steel.
Understanding of
components and their impact on
total cost of ownership is
critically needed by the
designer. If there is a better
fan or pump for the application
it should be selected by the
designer. Since these components
last for a decade or more the
initial design is a major factor
in long term operation and
maintenance.
Supply:
The
company has its own designs of
dust collectors, pneumatic
conveyors and a newly patented
dual fired rotary dryer/cooler.
Developments such as high
temperature catalytic filter
elements are routinely assessed.
IAC has decades of experience in
selecting and supplying all the
components. The company has a
number of electrical engineers
creating motor control centers
and is poised to take advantage
of all the new IIoT
opportunities.
Construct:
The company has a subsidiary
construction company, Adelphi
which has a long proven record
of delivering on time and at
competitive prices. For this
reason IAC has been the firm of
choice for a number of owners of
frac sand plants who needed
accelerated construction to take
advantage of the in basin trend.
Guide:
The company has strong
expertise and guidance programs
for many components but also in
meeting environmental emissions
requirements.
It helps with permit
applications and can send a team
to the site to measure fugitive
emissions and help institute
hardware and operational changes
to achieve the desired results.
The company has test rigs to
help determine locations for
sorbent injection
for plants needing to
reduce acid gas. Subject matter
ultra-experts are supported by
organized decision systems and
are available for those clients
with process management and
remote monitoring systems who
need advice such as the above
example of bag pressure drop,
life, and performance.
Maintain:
The need for quick delivery of
critical parts is addressed with
an efficient system decades in
the making which supplies 20,000
different parts and components
such as valves, hose, cages,
bags, and blowers.
Service includes complete
programs for monitoring and
replacement as needed. Service
includes training
and operations. A program
is in place to organize and rely
on the continuing flow of
evidence regarding component
performance. As IIoT and data
analytics provide even greater
quantities of evidence the
company is organized to utilize
it.
IAC is a good example of a
company who recognizes the power
of IIoW to enhance IIoT and is
taking advantage of the trend
with a full life cycle program
including Advise, Design,
Supply, Construct, Guide,
Maintain.
MARKETS
Asphalt
The asphalt industry represents
the 4th largest
market for fabric filters behind
stone and cement, power, and
steel.
Bag sales are in excess
of $300 million worldwide.
World Asphalt
Fabric Filter
Market - $
Million
The global asphalt market is
expected to grow at a CAGR of 4
percent during the period
2019-2021.The demand for porous
asphalt is expected to increase
as it not only channelizes water
to flow in a desired way but has
proven to be a cost-effective
material. Another significant
trend in the global asphalt
market is the recycling of
asphalt materials in highways
for resurfacing.
The importance of the
manufactured frac sand on the
U.S. CFT market is shown in the
following chart. The tons of
manufactured frac sand is small
but the CFT expense per ton is
high. Also the growth rate will
be much higher than other
granular categories. As a result
most of the revenue growth in
2019 will be in manufactured
sands.
The total production of frac
sands in the U.S. will exceed
100 million tons this year at an
average selling price of over
$60 ton creating a $6 billion
market. The revenues for CFT
suppliers are much higher per
ton of product because much of
the production is shifting to
local manufactured sands. So the
big cost is in the processing
and not the freight.
This fundamental shift in U.S.
frac sand production is away
from the Midwest, home to the
highest quality Northern White,
to lesser-grade sands which are
then upgraded (manufactured). As
a result, Northern White’s
market share is expected to be
43 percent in 2019, down from 75
percent in 2014,
Various granular products
require dry or wet processes.
Some require both. These involve
some combination of pneumatic or
mechanical conveyors, pumps,
valves, scrubbers, fabric
filters, precipitators, filter
presses, centrifuges, dryers,
classifiers, fans, controls, and
instrumentation.
In 2017, 890 million tons of
construction sand and gravel
valued at more than $7.7 billion
was produced by an estimated
3,600 companies operating 9,400
pits and 360 sales/distribution
yards in 50 States. Leading
producing States were, in order
of decreasing tonnage,
California, Texas, Minnesota,
Michigan, Arizona, Colorado,
Washington, Ohio, Wisconsin, and
New York, which together
accounted for about 52 percent
of total output. It is estimated
that about 44 percent of
construction sand and gravel was
used as concrete aggregates; 25
percent for road base and
coverings and road
stabilization; 13 percent as
asphaltic concrete aggregates
and other bituminous mixtures;
12 percent as construction fill;
1 percent each for concrete
products, such as blocks,
bricks, and pipes; plaster and
gunite sands; and snow and ice
control; and the remaining 3
percent for filtration, golf
courses, railroad ballast,
roofing granules, and other
miscellaneous uses.
Crushed stone, the other major
construction aggregate, is often
substituted for natural sand and
gravel, especially in more
densely populated areas of the
Eastern United States. Crushed
stone remains the dominant
choice for construction
aggregate use. Increasingly,
recycled asphalt and Portland
cement concretes are being
substituted for virgin
aggregate, although the
percentage of total aggregate
supplied by recycled materials
remained very small in 2017.
Dredging may or may not involve
more than just controls, pumps
and valves. In many cases
sediment is contaminated and
must be cleaned with filters and
separators. In the U.S. the
amount of dredged material is
around 200 million m3 or
400 million tons.
The McIlvaine Company provides
market forecasts, total cost of
ownership analyses, and project
databases on the range of
combust, flow, and treat ( CFT)
subjects.
You can find out more at
www.mcilvainecompany.com
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