Machinery & Plant Sourcing · Asphalt Plants

Bitumen emulsion plant

Colloid mill plants that produce cationic and anionic bitumen emulsions for tack coat, prime coat, chip seal, slurry and cold mix.

Product: Cationic and anionic emulsions
Bitumen content: Typically 55 to 75%
Core unit: Colloid mill
Operation: Batch or continuous (in-line)

Indicative figures based on manufacturer data. Capacity and specification are confirmed in each offer.

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What is a bitumen emulsion plant?

A bitumen emulsion plant disperses hot bitumen into water as very fine droplets, using an emulsifier and a high-speed colloid mill. The result is a brown liquid that can be sprayed or mixed at low temperature and later “breaks”, leaving a bitumen film on the road surface. Asphalt emulsions typically contain about 55 to 75% bitumen and 0.1 to 2% emulsifier, with water making up the rest.

Emulsions are used for tack coat, prime coat, chip seal, slurry seal and microsurfacing, cold mix, dust control and cold recycling. Because they are applied cold, they need less energy on site than hot bitumen.

Cationic or anionic emulsion?

The type depends on the emulsifier. Cationic emulsions (positively charged, usually amine-based) bond well with most aggregates, including siliceous stone, and are widely used today. Anionic emulsions (negatively charged) suit some limestone aggregates. Each type is made as rapid, medium or slow setting depending on how quickly it must break.

Production process

How emulsion is made

Step 01

Heat the bitumen

Bitumen is heated to lower its viscosity for milling.

Step 02

Prepare the soap

Water is warmed and mixed with emulsifier and acid or alkali to make the soap solution.

Step 03

Mill

Bitumen and soap are fed in exact ratio into the colloid mill, which shears bitumen into fine droplets.

Step 04

Store

Emulsion is cooled and pumped to storage tanks with gentle agitation.

Step 05

Test and load

Samples are checked for viscosity, residue and stability before loading into tankers or IBCs.

Key components

Main units

Bitumen heating tank

Heated tank that feeds bitumen to the mill at milling temperature.

Soap preparation tanks

Tanks with mixers and heating for emulsifier solution, often two for continuous production.

Colloid mill

High-speed rotor and stator that create the droplet size.

Dosing pumps and flow meters

Hold the bitumen to soap ratio constant.

Emulsion storage tanks

Tanks with slow agitation to keep emulsion stable.

Control panel

Recipe and ratio control with flow and temperature monitoring.

Technical data

Specifications

Typical values from manufacturer documentation. Final figures are confirmed in the manufacturer's offer for your project.

Emulsion types	Cationic and anionic; rapid, medium and slow setting
Bitumen content	Typically 55 to 75%
Emulsifier	Typically 0.1 to 2%
Mill	Colloid mill
Production mode	Batch soap or continuous in-line
Capacity	Selected to daily demand; confirmed per offer

Composition ranges from industry references. Plant capacity and options are confirmed in the manufacturer's offer.

Who it's for

Built for these buyers

Road maintenance contractors

Make tack coat, chip seal and slurry emulsions on demand.

Bitumen distributors

Add emulsion to the product range for local markets.

Public road agencies

Supply emulsion to maintenance teams across a region.

FAQ

Questions buyers ask

What is bitumen emulsion used for?

Tack coat and prime coat, chip seal, slurry seal and microsurfacing, cold mix asphalt, dust suppression and cold recycling.

How much bitumen is in an emulsion?

Typically 55 to 75% by weight, with 0.1 to 2% emulsifier and water making up the rest. The exact content depends on the grade being produced.

What is the difference between cationic and anionic emulsion?

Cationic emulsions carry a positive charge and use amine emulsifiers; anionic emulsions carry a negative charge and use fatty acid or lignin emulsifiers. Cationic types bond well with a wider range of aggregates.

What does a colloid mill do?

It shears hot bitumen into very fine droplets between a fast-turning rotor and a stator, so the emulsifier can keep them suspended in water.

How long can bitumen emulsion be stored?

Emulsion is stored in tanks with gentle agitation and protected from freezing and overheating. Storage life depends on the grade and the emulsifier; your emulsifier supplier gives the limits.