Kleemann — Asphalt Recycling Power

The combination of machines and digital solutions in a powerful process chain enables efficient recycling of reclaimed asphalt in accordance with the relevant standards.

A central role in this was played by a Kleemann plant train, which enabled the processing of the milled material. At the same time, users can benefit from the comprehensive, full-service package offered by the Wirtgen Group.

From Reclamation to New Product

The new Kleemann plant train, made up of a MobiScreen MSS 502 Evo scalper, a MobiRex MR 100 Neo impact crusher, and a MBT 20 stacker, enables the processing of homogeneous fractions — producing aggregates in line with the requirements of the relevant standards for the use of reclaimed asphalt pavement (RAP) in the production of asphalt mixes.

The plant train plays an important role in the cycle: the interlinked processes in asphalt recycling begin with selective milling. Surface layers, binder courses and base layers are removed selectively with Wirtgen milling machines, which increases the quality of the reclaimed asphalt pavement material. After screening and crushing with the Kleemann plant train, the material is delivered to the asphalt mixing plant. Here, the processed material becomes a part of the new asphalt mix. Machines from Vögele and Hamm then complete the cycle with paving and compaction. This results in a coherent, efficient cycle from reclamation and processing to reuse.

The Kleemann Plant Train

Construction contractor Kutter in the Allgäu region near Memmingen works with the new plant train from Kleemann. In the first step, the reclaimed asphalt is fed to the scalper. Occasional large slabs of milled material with an edge length of 17.69 in. resulting from concretion during stockpiling are first crushed to a manageable size.

The overall process consists of a series of individual steps: Milled material with grain sizes of 0-4.7 in. are fed into the scalper. The MSS 502 Evo delivers an immediately usable final product containing the highest proportion of bitumen, according to Kleemann. The second product delivered by the MSS 502 Evo bypasses the MR 100 Neo via the middle grain conveyor and the MBT 20 stacker and is mixed with the final product from the MR 100 Neo.

The third product from the MSS 502 Evo, the oversize grain, is passed to the MR 100 Neo, which produces a further final product. The process thus produces a series of homogeneous final products that can be fed into the asphalt mixing plant with a maximized feed rate. A second MBT 24 stacker provides additional material stockpiling capacity.

Simone Eichiner, asphalt mixing plant manager of Kutter, is very satisfied with the performance of the plant train.

"The crusher and the screens deliver a material that contains a lower proportion of fines and better fulfills the requirements of the desired grading curve," he said. "That's important when it comes to the production of asphalt mixes in line with the relevant standards. On top of this, the low fuel consumption and simultaneously increased hourly output reduce the operating costs."

As the company works at a number of different locations, it also is advantageous that the mobile Kleemann plants can be quickly relocated and adapted to the different conditions on the individual construction sites.

Recycling Performance

The Kleemann plant train processes up to 264.5 tons per hour. After crushing in the impact crusher, the material is separated into two predefined final grain sizes: 0-0.43 in. for surface and binder courses and 0-0.87 in. for base layers and binder courses. Both fractions are delivered to the asphalt mixing plant and used there in the production of new asphalt mix.

Crusher operator Thomas Guggenmoser particularly likes the handling of the machine and the Lock & Turn quick access function.

"The system enables quick and safe opening of the crusher for maintenance and checking and has proved to be very useful in our daily operations," he said. "It reduces idle times to a minimum and saves us a lot of time and stress. All told, the access to the central service and maintenance points is really very good."

Spective Connect also has proved to be a valuable asset on-site. The digital application provides real-time information on consumption, production performance, use rates and possible faults. The precise fault localization enables significantly faster remediation of interruptions in ongoing operations. It also allows Thomas Guggenmoser to visually check the plant status at any time. "That makes everything more efficient and avoids unnecessary service callouts and interruptions."

Benefits of a Comprehensive Overview

Not only the performance of individual machines, but also the comprehensive overview of all processes from reclaiming the RAP material to the finished asphalt is decisive. The Wirtgen Group and its Wirtgen, Vögele, Hamm, Kleemann and Benninghoven product brands offer the complete machine and plant portfolio from a single source, according to Wirtgen.

Kutter has above all come to appreciate the application consulting services provided by the group's individual brands.

"This interaction optimizes the overall process," said Eichiner. "The consultants also look outside the box. The focus is on the applications, not on the individual products. That has proved to be an enormous advantage. The technical support, the fast delivery of spare parts and the training courses for digital tools — everything meshes so well."

For more information, visit wirtgen-group.com.

(The opinions expressed in this article are those of Kutter Construction. Results may vary.)