Manufacture of Anionic Bitumen Emulsion MS-2 from UAE and Turkey

Anionic bitumen emulsion MS-2 Definition

Anionic Bitumen Emulsion MS-2 is an anionic water-based medium setting emulsified asphalt containing minimum 60% Bitumen.
For anionic and emulsions, there are several grades of different breaking characteristics. Rapid-setting emulsions are used for surface dressing, while medium or slow-setting emulsions are used for ‘mixtures’, that is mixed with aggregate either in concrete-type mixers or in situ. Rapid-setting emulsions are not used for mixtures because they would tend to set during the mixing process and clog the mixer. Generally, in making mixtures, the finer the aggregate used, the slower setting the emulsion that has to be used. Therefore, stone mixtures require medium-setting emulsions and sand mixtures require a slow-breaking emulsion. With anionic emulsions, the breaking process is predominantly by evaporation of the water in the emulsion continuous phase. Because of this, anionic emulsions are susceptible to temperature and humidity in terms of their breaking properties.

An Anionic emulsion has a negative charge, most of the things in the world are Anionic and that is why the majority of Research and Development, formulating, and lab testing has been done in the Industrial Coatings Industry to make coatings from Anionic systems. When an Anionic emulsion is mixed with a Cationic emulsion a strong bond develops and the result is the changing of the substance to a solid. This result is not ideal to be used as a coating because it cannot be applied to substrates.

Anionic bitumen emulsions MS-2 Applications

Anionic bitumen emulsion MS-2 is commonly used in road construction and maintenance for various applications, including:

• Surface treatments: MS-2 emulsion is often applied as a surface treatment to rejuvenate and protect existing pavements. It can be used in chip sealing, micro-surfacing, or slurry sealing applications to seal cracks, restore surface texture, and improve skid resistance.
• Pavement preservation: By applying MS-2 emulsion as part of a pavement preservation program, agencies can extend the service life of roads and reduce the need for costly rehabilitation or reconstruction projects. MS-2 emulsion helps seal the surface, preventing moisture ingress and reducing oxidation of the asphalt binder.
• Pothole patching: MS-2 emulsion can be used for patching potholes and other localized pavement distress. It provides a durable and cost-effective solution for repairing damaged areas, restoring ride quality, and preventing further deterioration.
• Prime coating: MS-2 emulsion can be applied as a prime coat to prepare the base surface before laying new asphalt layers. It helps improve bonding between the existing pavement and the new asphalt layer, enhancing overall stability and longevity.
• Tack coat: MS-2 emulsion is also used as a tack coat to promote adhesion between asphalt layers during construction or maintenance activities. It ensures a strong bond between pavement layers, preventing delamination and extending the life of the road.

How is bitumen emulsion produced?

Bitumen emulsion is produced through a process called emulsification, which involves mixing bitumen with water and emulsifying agents to create a stable suspension of bitumen droplets in water. The production process typically involves the following steps:

1. Selection of Bitumen: The type and grade of bitumen used depend on the desired properties of the emulsion and the intended application. Bitumen is typically heated to reduce viscosity and facilitate mixing.
2. Preparation of Water Phase:  Water is heated to a specific temperature, depending on the emulsification process and the desired characteristics of the final emulsion. Some emulsification processes may require the addition of specific additives or chemicals to the water phase.
3. Emulsification:  Bitumen is slowly added to the heated water phase while mixing vigorously to form a homogeneous mixture. Emulsifying agents, also known as surfactants, are added to stabilize the mixture and prevent the bitumen droplets from coalescing.
4. Homogenization: The bitumen-water mixture is further processed using high-shear mixing equipment to break down larger droplets and ensure uniform distribution of bitumen throughout the emulsion. This step helps improve the stability and performance of the emulsion.
5. Quality Control: The emulsion is subjected to quality control tests to ensure that it meets the specified requirements for viscosity, particle size distribution, stability, and other properties. Adjustments may be made to the formulation or production process if necessary.
6. Storage and Packaging: The finished bitumen emulsion is stored in tanks or containers under controlled conditions to maintain stability and prevent separation. It is then packaged into drums, totes, or bulk containers for transportation to the end-users.

Composition and Different Types of Bitumen Emulsion

The bitumen emulsion is classified into two types:

 1- Based on Setting Time

When the bitumen emulsion is applied on the aggregate for the road works the water evaporates leaving behind the bitumen droplets. These droplets spread on the aggregate and bind with each other and gains strength eventually.

Based upon the time taken by the vitamin emulsion to evaporate the water and between particles to separate from water, bitumen emulsion is further classified into 3 types based on setting time:

1. Slow setting emulsion
   In this type of emulsion, a special type of emulsifier is used to slow the process of water evaporation. This type of emulsifier are relatively stable.
2. Medium setting emulsion
   This type of bitumen emulsion doesn’t break as when applied on aggregate. The process of evaporation starts when the fine dust of mineral are mixed with the aggregate emulsion mix.
3. Rapid setting emulsion
   This type of bitumen emulsion breaks down rapidly as it comes with contact with aggregate helping in fast setting and rapid curing.

 2- Based on Surface Charge

Bitumen emulsion is a combination of water and bitumen. As the mixture of water and oily products quickly separate, a third component is normally added to the mixture, in order to make it more stable.

Known as an emulsifier, this third component is used for making a mixture of water and oil dispersed in each other. In addition to their ability to reduce the tension between oil and water molecules, emulsifiers have an electronic charge that affects the molecules of bitumen emulsion and lead to the categorization of it into Cationic and Anionic.

• Anionic Bitumen Emulsion
• Cationic Bitumen Emulsion

In anionic bitumen emulsion, the tiny droplets of bitumen are electronegatively recharged. In Cationic bitumen emulsion, the tiny droplets of bitumen are electro positively charged.

The average and commonly used emulsions is cationic between emulsions.

Selection of positive or negative recharge between emulsions depends upon the mineral composition of aggregate on which it is used

Ex: In the case of silica-rich aggregates the surface of silica is aggregate is positively charged therefore cationic bitumen emulsion is used which helps in better spreading and binding of bitumen with aggregates.
The electronic charge of bitumen emulsion decides on what kind of surface it should be used. Some aggregates (such as marble aggregates) mix better with anionic bitumen emulsion and some others are a better solution to cationic bitumen emulsion (such as granite aggregates).

Both cationic and anionic bitumen emulsions are categorized according to the setting time. Look at the table below to find the various categories of bitumen emulsion and their globally standard names.

MS-2 Packing

Packing of anionic bitumen emulsion MS-2 is in the new thick steel drum on the pallet to prevent any leak inside of container also bulk in bitutainer and tanker.

Advantages and Limitation of Bitumen Emulsions

Bitumen emulsions offer several advantages in road construction and maintenance:

Advantages:

1. Versatility: Bitumen emulsions can be used in a wide range of applications, including prime coating, tack coating, surface treatments, and patching, making them versatile for various road maintenance needs.
2. Ease of Application: Emulsions can be applied using standard equipment such as spray trucks or hand sprayers, making them convenient for both large-scale construction projects and smaller maintenance tasks. They can also be applied at ambient temperatures, reducing energy consumption compared to hot-mix asphalt.
3. Improved Adhesion: Emulsions provide excellent adhesion between asphalt layers and pavement surfaces, enhancing the overall durability and longevity of the road. They can also improve bonding between existing and new pavement layers.
4. Environmental Benefits: Emulsions typically contain fewer volatile organic compounds (VOCs) compared to hot-mix asphalt, reducing environmental impact and improving air quality during application. They also require less energy and resources for production and application, contributing to sustainability efforts.
5. Cost-Effectiveness: Bitumen emulsions offer cost savings compared to traditional asphalt binders, as they can be applied at lower temperatures and with less specialized equipment. Additionally, their versatility and ease of use contribute to lower labor and equipment costs.

However, there are also some limitations to consider:

Limitations:

1. Curing Time: Emulsions generally have longer curing times compared to hot-mix asphalt, which can result in longer traffic disruptions during construction or maintenance activities.
2. Weather Sensitivity: Emulsions are sensitive to weather conditions, particularly temperature and humidity, which can affect their performance and curing time. Extreme weather conditions may require adjustments to application procedures or delays in work.
3. Storage Stability: Emulsions have a limited shelf life and require proper storage conditions to maintain stability and prevent degradation. Storage facilities must be equipped to handle emulsions safely and effectively.
4. Compatibility: The compatibility of emulsions with aggregates and other materials used in road construction must be carefully considered to ensure proper bonding and performance. Compatibility testing may be necessary, especially when using new materials or mix designs.

Anionic bitumen emulsion MS-2 Specifications

 

T.D.S of Anionic Bitumen Emulsion MS-2