Energy-efficient Bitumen Tanks

09 August, 2024

KVM bitumen systems can be delivered as part of complete KVM asphalt plant installations or as a retrofit on any plant

First published in the July 2024 issue of Quarry Management as Top Tanks

Energy-efficient bitumen systems with strong focus on safety

Energy is costly, making it crucial to store bitumen in energy-efficient tanks. KVM offer a comprehensive range of storage, dosing, and processing equipment for bitumen, designed and optimized to minimize energy consumption. KVM’s bitumen systems can be integrated into a complete KVM asphalt plant or retrofitted to any plant needing modifications, expansion, or new technology.

Continuous material temperature ensures energy savings

KVM bitumen tanks are designed to store bitumen at temperatures around 160–180°C. When storing bitumen, heat loss due to ambient temperature must be considered. KVM address this effectively by applying 300mm thick insulation material and an external flush alu-zinc cladding. This highly efficient insulation minimizes heat loss through the tank walls and maximizes durability. Additionally, the insulation is mounted without radial support rods, reducing the risk of thermal bridging.

KVM have developed an external electric heating system. The system consists of heating elements mounted in channels welded evenly across the entire tank bottom, providing easy access for maintenance, simplifying troubleshooting, and facilitating the replacement of heating elements. This design also allows for optimal insulation, as access to the heating elements does not require interference with the tank’s insulation. The tanks can be equipped with bottom- or side-flange drainage.

The heating elements are connected in series, providing 9kW standby heat. During thawing or heating, parallel connection is possible, giving each heating element 36kW. A single temperature-control system ensures a constant temperature in the tank, using only the necessary energy in the heating process. Additionally, the temperature can be time controlled to heat only at night when electricity is cheapest, ensuring efficient energy consumption.

KVM fully conform to the industry recommendations on the safe handling of bitumen as defined by Eurobitume and the Refined Bitumen Association (RBA)

Top priority: operator and personnel safety

Handling 180°C bitumen is extremely dangerous, especially during filling from a tanker, where there is human-material close proximity. This necessitates many measures to ensure operator safety. Standard bitumen systems come with built-in sensor equipment for measuring temperature and levels, enhancing safety during tank filling. For further operator protection, a central filling pump can be installed at ground level next to the bitumen tanks, preventing spills during connection and disconnection via a check valve and a shut-off valve.

Odour emissions from displaced air are eliminated either through an activated carbon filter or by a pipe connection returning the air to the bulk tank. Each tank also features a weather-resistant control panel made of stainless steel, containing controls for connecting and disconnecting tank heating elements.

Bitumen tanks for other applications

In addition to the asphalt industry, KVM supply bitumen tanks to related industries such as the roofing felt industry and manufacturers of special insulation materials. The tanks’ applications range from bitumen with various penetrations to polymer-modified types. Examples include deliveries to Danish BMI/Icopal and Swedish Isodrän AB. While the delivery to BMI/Icopal is a standing tank with various pumps and valves from the standard programme, the delivery to Isodrän is tailored to special needs, with a horizontal tank featuring an integrated pump and valves for mobility.

KVM vertical tank series with further insulating measures to maintain material temperature and minimize heat loss, resulting in energy efficiency

Bitumen tanks with flexible construction

KVM bitumen tanks are available as vertical, horizontal, and semi-mobile, each with unique advantages. Limited installation space and the need for improved access roads are challenges on sites where factory expansions complicate traffic on original access routes. Vertical tanks save space, making them an ideal choice for sites where space constraints are critical. Additionally, vertical tanks have a smaller surface area, providing the advantage that the amount of usable liquid bitumen is relatively larger.

High tank capacity offers increased flexibility and can be beneficial to avoid shortage situations. KVM offer tanks with a nominal capacity of up to 135m3, equivalent to 116m3 Safe Working Capacity, as defined by Eurobitume.

Semi-mobile tanks are used where mobility and flexibility outweigh tank capacity. Whilst tank design and product quality are maintained, their smaller dimensions make them easier to place and install on site. Besides horizontal and vertical configurations, flexible design allows semi-mobile tanks to be used for transferring bitumen from one tank to another. Their transport-friendly dimensions also make them significantly cheaper to transport.

KVM 24/7/365 online service

KVM provide everything from project design to mechanical installation, including electrical and control systems, installation, and operator training. Experienced project designers, project managers, and engineers ensure optimal handling during the design, installation, and commissioning of new machines and equipment.

Through the KVM Service Hotline, automation engineers and service teams are fully available 24h a day, seven days a week, 365 days a year to provide advice and guidance or arrange a service visit on short notice if necessary to ensure uninterrupted operation.