HINDUSTAN COLAS LTD Technical Note: TKS01/2011

Hot Mix Vs Cold Mix: Economic Comparison

Summary:
In the asphalt industry a lot of energy is consumed to heat up aggregates and sand. Very often, these
materials are wet from contacting with water (rain) or humidity from air. The economic comparison is
evaluated on this aspect since one of the key proposition for Cold Mixes are enhanced working
window.

In asphalt plants, typically aggregates and sand are stored in open areas, which could lead to
contamination with water. The amount of water depends on the size and porosity of the aggregates
as well as climate/season and the influence of geographical locations. The water content can vary
between 0% to 6% for aggregates and for sand it can go up to 10%. The influence of water content is
calculated on extra energy consumption per kg of aggregates using the specific heat capacity of
minerals. The calculations are based on 100% aggregates with water contents of 2, 4 and 6%
respectively.
- A reduction of energy can be achieved based on the choice of aggregates/sand and their heat
capacities
- Every percent of water in the aggregates increases the energy consumption of an asphalt plant
by ~13 to 15% depending on the specific heat of the aggregate
- The cost of construction with emulsion can be cheaper by about 5 - 6 % than the conventional
bitumen
 Technical Note: TKS01/2011

1. Specific Heat Capacity of various Aggregates:

There is a great variation of specific heat capacities of minerals. The specific heat capacities
of minerals and non-porous rocks increase substantially at higher temperatures.

Sp Heat Vs Temp - Aggregates

1500
Specific Heat

1300

1100 Granite
900 Basalt
700 Quartz
500
Temp 20 75 125 175 225

2. Energy Consumption to heat aggregates at varying % moistures:

In asphalt plants, typically aggregates and sand are stored in open areas, which could lead to
contamination with rainwater. The amount of water depends on the size and porosity of the
aggregates as well as climate/season and the influence of geographical locations. The water
content can vary between 0% and (in extreme circumstances) 6% for aggregates and for
sand it can go up to 10%. The energy that is needed to evaporate water is normally
independent from the specific heat capacities of the minerals; in the calculations the influence
of particle size, porosity, natural water and chemical reaction is not included. It can be
deduced from below that aggregates with low specific heat capacities need more energy.
This is caused by the lower amount of required energy, which is needed to heat the minerals
with a low Cp; therefore the percentage of extra energy needed to heat up the water is
relatively higher

Granite Basalt Quartz

Cp (J/Kg/C) 950 899 740
Energy required (30C - 160C) 123500 116870 96200
Extra Energy @ 2% Water 172921 166424 146167
Extra Energy @ 4% Water 222342 215978 196134
Extra Energy @ 6% Water 271764 265531 246102

Hot Mix Vs Cold Mix: Economic Comparison

2
 Technical Note: TKS01/2011

% Increase in Energy (to heat from 30 - 160 C)

% Increase in Energy
200
Extra Energy @ 2%
150
Water
100 Extra Energy @ 4%
50
Water
Extra Energy @ 6%
0
Water
Granite Basalt Quartz

3. Cost of Heating
The drying process in an asphalt installation is done in three stages:
o Aggregate mix (trapped with water) are heated to the water evaporation temperature
o The moisture is evaporated, starting from as low as perhaps 40-50C
o The aggregates mix heated up to the required temperature

Basis:
1 Ton of Asphalt Mix; 30 to 160C 130 Granite Basalt Quartz
950 899 740
930 kg of Aggregates 114855 108689.1 89466
20 kg of Lime 2470 2337 1924
50 kg of Bitumen
KJ 117325 111026.5 91390
Kcal 27935 26435 21760
Fuel required for
aggregates 4.4 4.1 3.4
Fuel for Bitumen 0.4 0.4 0.4
Total Fuel 4.7 4.5 3.8
Cost of Energy @40 Rs/Kg 189 179 150

@2% Water 930 kg of Aggregates 114855 108689.1 89466

20 kg of Lime 2470 2337 1924
50 kg of Bitumen
20 kg of water 56073 56073 56073
KJ 173398 167100 147463
Kcal 41285 39786 35110
Fuel required for
aggregates 6.5 6.2 5.5
Fuel for Bitumen 0.4 0.4 0.4
Total Fuel 6.8 6.6 5.8
Cost of Energy @40 Rs/Kg 272 263 234

Hot Mix Vs Cold Mix: Economic Comparison

3
 Technical Note: TKS01/2011

@4% Water 930 kg of Aggregates 114855 108689.1 89466

20 kg of Lime 2470 2337 1924
50 kg of Bitumen
40 kg of water 112146 112146 112146
KJ 229471 223173 203536
Kcal 54636 53136 48461
Fuel required for
aggregates 8.5 8.3 7.6
Fuel for Bitumen 0.4 0.4 0.4
Total Fuel 8.9 8.7 7.9
Cost of Energy @40 Rs/Kg 356 346 317

@6% Water 930 kg of Aggregates 114855 108689.1 89466

20 kg of Lime 2470 2337 1924
50 kg of Bitumen
60 kg of water 168220 168220 168220
KJ 285545 279246 259610
Kcal 67987 66487 61812
Fuel required for
aggregates 10.6 10.4 9.7
Fuel for Bitumen 0.4 0.4 0.4
Total Fuel 11.0 10.7 10.0
Cost of Energy @40 Rs/Kg 439 430 400

Significant energy is consumed due to presence of moisture in the aggregates. From these
calculations, it is clear that every 1% of water increases the energy consumption of the asphalt plant
by ~13 to 15% depending on the specific heat of the aggregate.

Hot Mix Vs Cold Mix: Economic Comparison

4
 Technical Note: TKS01/2011

4. Cost Comparison of Hot Mix Vs Cold Mix

Basis:
31000 Rs/Ton Bitumen Hot Mix Cold Mix
25000 Rs/Ton Emulsion Granite Basalt Quartz Granite Basalt Quartz
Cost of energy @ 0% Moisture 189 179 150
Cost of Bitumen 1550 1550 1550
Wastage @ 2% 31 31 31
Cost of aggregates @800Rs/Ton 744 744 744 744 744 744
Cost of Emulsion 1923 1923 1923
Antistripping agent @ 150Rs/Kg at 0.5% 38 38
Transportation, Laying and Compaction 200 200 200 200 200 200
Total 2751 2704 2713 2867 2867 2867
% Cost Reduction with Cold Mix -4 -6 -6

Cost of energy @ 2% Moisture 272 263 234

Cost of Bitumen 1550 1550 1550
Wastage @ 2% 31 31 31
Cost of aggregates @800Rs/Ton 744 744 744 744 744 744
Cost of Emulsion 1923 1923 1923
Antistripping agent @ 150Rs/Kg at 0.5% 38 38
Transportation, Laying and Compaction 200 200 200 200 200 200
Total 2835 2788 2796 2867 2867 2867
% Cost Reduction with Cold Mix -1 -3 -3

Cost of energy @ 4% Moisture 356 346 317

Cost of Bitumen 1550 1550 1550
Wastage @ 2% 31 31 31
Cost of aggregates @800Rs/Ton 744 744 744 744 744 744
Cost of Emulsion 1923 1923 1923
Antistripping agent @ 150Rs/Kg at 0.5% 38 38
Transportation, Laying and Compaction 200 200 200 200 200 200
Total 2918 2871 2879 2867 2867 2867
% Cost Reduction with Cold Mix 2 0 0

Cost of energy @ 6% Moisture 439 430 400

Cost of Bitumen 1550 1550 1550
Wastage @ 2% 31 31 31
Cost of aggregates @800Rs/Ton 744 744 744 744 744 744
Cost of Emulsion 1923 1923 1923
Antistripping agent @ 150Rs/Kg at 0.5% 38 38
Transportation, Laying and Compaction 200 200 200 200 200 200
Total 3002 2955 2963 2867 2867 2867
% Cost Reduction with Cold Mix 4 3 3

Hot Mix Vs Cold Mix: Economic Comparison

5
 Technical Note: TKS01/2011

Benefits of Cold Mix System:

Bituminous road construction using conventional paving grade bitumen (i.e hot mix technology) is
sometimes not technically feasible and logistically in high rainfall areas, as intermittent rains
throughout the year affects the production and laying of these mixes. Similarly, at high altitude and/ or
in snow-bound areas, very low pavement temperatures make laying of hot mixes rather impossible.
Use of Bitumen emulsion eliminates the need to heat bituminous binder and aggregates; coats damp
aggregates, prevents degradation of environment and thus conserves energy. Cold Mixes enable
construction of roads using emulsion based cold mix technologies in wet and inclement weather.
These cold mixes can be produced either by using concrete mixer or in hot mix plant without heating
facility. The paver and other construction machineries, as in normally employed for hot mixes, can be
used for execution of these works.

The field trials have been carried out by HINCOL on Jammu-Srinagar Highway on NH-1A near
Patnitop (J&K) under cold and snow bound areas; Jowai - Badarpur Road on NH-44 near Silchar
(Assam), Mizoram (N.E. region) under heavy rainfall ; and on H-S Road near Hanumangarh
(Rajasthan) under desert climate.

The main advantages of cold mix technologies for construction of roads are given below:
Construction of binder course and wearing course, using bitumen emulsion in various
specifications is feasible in all weather including wet condition. The working window is
enhanced significantly by this.
Environment friendly technology due to elimination of heating process.
Cold Mix performance is not mixing/laying temp dependant. The mix can be transported to longer
distances easily. Failures which are common in case of hot mix due to nonadherence to temp
requirements are eliminated
The requirements for Anti Stripping agents are eliminated in Cold Mixes
The cost of construction with emulsion can be cheaper by about 5 - 6 % than the conventional
bitumen

Hot Mix Vs Cold Mix: Economic Comparison

6