INTERNATIONAL JOURNAL OF CIVIL ENGINEERING AND TECHNOLOGY (IJCIET) ISSN 0976 6308 (Print) ISSN 0976 6316(Online) Volume 5, Issue 7, July (2014), pp. 188-197 IAEME: www.iaeme.com/ijciet.asp Journal Impact Factor (2014): 7.9290 (Calculated by GISI) www.jifactor.com IJCIET IAEME PERCENTAGE REPLACEMENT OF BITUMEN WITH SUGARCANE WASTE MOLASSES K. Shyam Prakash 1, M. Phanindra 2, S. Ram Surya 3, J. Naresh 4 1 Asst. Professor Department of Civil Engineering, PVP Siddhartha Institute of Technology, Kanuru, Vijayawada 520007 India 2, 3, 4 Student, Department of Civil Engineering MVR College of Engineering-521180, India ABSTRACT Bitumen the residue left over from petroleum distillation is throughout the world the most significant bonding agent used for road way construction. Crude petroleum is a fossil mineral resources and fuel source that will be used up within next 50years. Increasing energy costs and the strong worldwide demand for petroleum has encouraged the development of alternative binders to modify or replace asphalt binders. The benefits of using alternative binders are that they can save the natural resources and reduce energy consumption, while maintaining, and in some cases improving pavement performance. Because of urgent need of infrastructure, rehabilitation and maintenance, the introduction and application of such sustainable and environmental friendly materials like sugar cane waste molasses are required. And today the demand lies around 200 million tons. Keywords: Bitumen, Molasses, Alternative Binders, Mixing Bitumen and Molasses, Eco- Friendly. INTRODUCTION General Energy plays a crucial role in growth of developing countries like India. In the context of low availability of non-renewable energy resources coupled with the requirements of large quantities of energy for materials like bitumen, the importance of using industrial waste cannot be under estimated. During the manufacturing of bitumen from the crude oil lot much amount of benzene, sulphur dioxide and nitrogen oxide are released this gases can be controlled to some extent in the company, but during the transportation and application process the bitumen is heated to high temperatures then the harmful gas carbon dioxide (co 2 ) is released into the atmosphere causing lung diseases and serious threat to the environment. In the Backdrop, the search for cheaper substitute to bitumen is a needful one. 188
Bitumen Bitumen is a mixture of organic liquids that are highly viscous, black, sticky, entirely soluble in carbon disulfide, and composed primarily of highly condensed polycyclic aromatic hydrocarbons. Naturally occurring or crude bitumen is a sticky, tar-like form of petroleum which is so thick and heavy that it must be heated or diluted before it will flow. At the room temperature, it is much like cold molasses. Refined bitumen is the residual (bottom) fraction obtained by fractional distillation of crude oil. It is the heaviest fraction and the one with the highest boiling point, boiling at 525 o C (997 o F).In British English, the word asphalt refers to a mixture of mineral aggregate and bitumen. In Australian English, bitumen is sometimes used as the generic term for road surfaces. Bitumen is primarily used for paving roads. Its other uses are for bituminous waterproofing products. Including the use of bitumen in the production of roofing felt and for sealing flat roofs. Why Replacement??? The topic replacement of bitumen with waste materials is the one thought that took life from reading the startling things about decaying of environment because of cement. There are some current issues globally which are threatening the environment! Being civil engineers it s our nominal duty to take care of mother earth. The problems with bitumen 1. Bitumen s release huge amount of carbon dioxide. 2. There will be 8 to 37 % of carbons in one gallon oil bitumen. 3. The surfaces of asphalt roads made from normal bitumen have a tendency of becoming greasy in wet road conditions; this is due to oil content of residue bitumen. 4. Black road surfaces made from bitumen absorb so much heat that heavy vehicles have been known to lift the road surface creating road safety hazards for the public and also for the motor vehicles. 5. Huge amount of heat is required to melt the bitumen during transportation and application 6. Aggregate and bitumen bond is attacked by the water reaction. SOLID WASTE FROM SUGAR INDUSTRY Molasses Molasses is the dark, sweet, syrupy byproduct made during the extraction of sugars from sugarcane and sugar beets. Molasses can vary in color, sweetness, and nutritional content depending on the variety or how much sugar has been extracted. Molasses has a rich history in the Caribbean and Southern United States, where sugarcane and sugar beets are heavily cultivated. Molasses was also a popular sweetener throughout the United States in the early 20th century. How Molasses is made During the sugar making process, juice extracted from sugarcane or sugar beets is boiled down until the sugars crystallize and precipitate out. The syrup left over after crystallization is referred to as molasses. Typically, sugar cane juice undergoes three cycles of boiling and crystallization to extract as much sugar as possible. With each successive cycle, the left over molasses contains less sugar. 189
Molasses varieties Light Molasses: This is the syrup left over after the first boiling cycle of sugarcane juice. This molasses is the lightest in colour, has the highest sugar content, and the least viscous. Texture Dark Molasses: Dark molasses is the by product of the second boiling cycle of sugarcane This molasses is darker and more viscous than light molasses, and contains less sugar. Black Strap Molasses: This is the final by product of the third boiling cycle in the sugar making process. This variety of molasses contains the least sugar and has the highest concentration of vitamins and minerals. Black strap molasses has a very dark colour and is extremely viscous in texture. Because this type of molasses is highly concentrated, it has a deep, spicy flavour. Sulfured vs. Unsulfured Molasses: Sulfured molasses refers to molasses that has been treated with sulfur dioxide as a preservative. Generally, only young sugarcane requires this treatment. Therefore, molasses made from mature sugarcane is often unsulfured. Unsulfured molasses may have a lighter, cleaner sugar flavour. Uses of molasses Baked Goods: In the United States, molasses is a common sweetener and flavouring in many baked goods such as gingerbread, Boston brown bread, and shoofly pie. Molasses is also responsible for the classic, sweet, rich flavour of baked beans. Alcohol: Molasses is the sugar used to make rum. Rum is therefore common in regions of the world where sugarcane or sugar beets are heavily cultivated because of the abundance of molasses. Molasses is also sometimes used to brew dark ales like stout. Brown Sugar: Molasses is responsible for the dark, rich flavour and texture of brown sugar. Brown sugar is produced by combining refined white sugar with approximately 5% molasses. Tobacco: Molasses is added to some tobacco products for flavour. Tobacco flavoured with molasses is particularly popular in the Middle East for use in hookahs. LITERATURE REVIEW ASPHALT BITUMEN FROM RENEWABLE RESOURCES BY SANDRA LAWSON (MELBOURNE JULY 5) An Australian research and development company has developed non-petroleum based, asphalt bitumen substitute for roads. It is made from waste material derived from sugar cane, molasses. It has taken more than 20 years to develop the road-grade substitute. Road safety and health are the main intensity to develop the substitute or alternative. What is really surprising to see is that the scientific community around the world has failed to address, pursue and support any alternatives to petroleum based bitumen, almost believing that it will be around forever. Ironically it took the change in the climatic condition said by overall. 190
ECOPAVE AUSTRALIA GEO320 TECHNOLOGY IMPROVES SHELL BITUMEN BY DAMIEN JOHNSON (MELBOURNE-DECEMBER21, 2005) The increase in non-toxic products was the key factor in eco pave choosing to completely replace the traditional hydrocarbon bitumen model in 1997. USE OF MOLASSES BY CAIRNS POST (Qld: 1909-1954), 17thSeptember 1941NATIONAL LIBRARY OF AUSTRALIA The experiments conducted in India have proved that distinct possibilities exist for the use of this material for roads as bitumen is mostly imported to Australia and concrete is regarded as expensive, any substitute that would provide a satisfactory road surface, and at the same time make the use of a by-product of the sugar industry is worthy of construction Interesting details regarding the Indian experiments are given in the report of the meeting of the Indian road congress, which stated that two series of experiments were done. PROPERTIES OF BITUMEN Ductility Penetration Test TABLE 1: Properties of Bitumen Flash& Fire Test Viscosity Specific Gravity Softening Point 46.333 52.33 198 C & 220 C 48 SEC 1.0 55.5 C RECOMMENDED VALUES FOR THE PROPERITIES OF BITUMEN: Recommended values for ductility test: Paving bitumen and Penetration grade Min ductility value Assam Petroleum A25 5 A35 10 A45 12 A65, A90 & A200 15 Bitumen from sources other than Assam Petroleum S35 50 S45, S65 & S90 75 Suitability of bitumen is judged depending on its type and proposed use. Bitumen with low ductility value may get cracked especially in cold weather. Minimum values of ductility specified by ISI for various grades are tabulated above. 191
Recommended values for penetration test Penetration test is a commonly adopted test on bitumen to grade the material in terms of its hardness. An 80/100 grade bitumen indicates that its penetration value lies between 80 & 100.Grading of bitumen helps to assess its suitability in different climatic conditions and types of construction. For bituminous macadam and penetration macadam, IRC suggests bitumen grades 30/40, 60/70, 80/100. In warmer regions, lower penetration grades are preferred to avoid softening whereas higher penetration grades like 180/200 are used in colder regions to prevent the occurrence of excessive brittleness. High penetration grade is used in spray application works. Recommended values for flash & fire test The minimum value of flash point by Pen sky- Martens closed type apparatus is 175 C for all grades of bitumen. Recommended values for viscosity test Cutback bitumen 0 1 2 3 4 5 Orifice size (mm) 4.0 4.0 10 10 10 10 Temperatures ( C) 25 25 25 25 40 40 Viscosity Ranges 25-75 30-250 10-20 25-75 14-45 60-140 Recommended values for specific gravity The specific gravity of pure bitumen ranges from 0.97 to 1.02. according to Indian Standard (BIS) minimum specific gravity of paving bitumen at 27 C shall be 0.99 for grades A25, A35, A45, A65, S35, S45 and S65, 0.98 for A90 and S90 and 0.97 for A200 and S200. Recommended values for softening point test: Softening point indicates the temperature at which binders possess the same viscosity. Bituminous materials do not have a melting point. Rather, the change of state from solid to liquid is gradual over a wide range of temperature. Softening point has particular significance for materials to be used as joint and crack fillers. Higher softening point ensures that they will not flow during service. Higher the softening point, lesser the temperature susceptibility. Bitumen with higher softening point is preferred in warmer places. REPLACEMENT OF BITUMEN WITH MOLASES The materials used for this investigation are bitumen, fine aggregates, coarse aggregates, molasses and lime. Fine aggregates and coarse aggregates are taken form the crushing industries which are located nearby. The size of coarse aggregates used must pass through 20mm sieve and retained in 4.75mm sieve and fine aggregates passing through 4.75mm sieve. The grade of bitumen used is having a viscosity grade-30. Molasses used is the waste obtained during the preparation of sugar in sugar factory. Tests are conducted for the materials collected. The tests conducted on aggregates are Aggregate Crushing Value, Aggregate Impact Value, Specific Gravity and Water Absorption Test, Los Angeles Abrasion Value, Flakiness index and Elongation Index of Coarse Aggregates. The 192
different tests conducted for bitumen are Penetration Value, Ductility, Softening Point, Viscosity Test, Specific Gravity and Flash & Fire point. By the tests conducted properties of aggregates, bitumen and molasses are obtained. The OBC test is conducted for bitumen to known the optimum bitumen content. The moulds which r used can hold the weight of 1200gms. The amount of aggregate to be taken is obtained by removing the bitumen weight from the mould weight. At first the specimen is prepared for 100% bitumen i.e.., free from molasses. Aggregates should be added to bitumen by melting the bitumen at a temperature of 200 C. The sample shouldn t be over heated because the sample may lose its properties Stir the mix thoroughly until the mix becomes uniform. Gently fill the mould by the mix and should be compacted on both sides, each side with 50 blows. If the specimen is broken and sticks to the mould then the sample are failed this is caused due to overheating of the sample. Keep the specimen undisturbed to make it dry & gently remove it from the mould. Apply grease or wax to the mould and kept in water bath for 24 hours. Weigh the sample before & after keeping in water bath. Specific Gravity test is conducted after 24 hours. Weigh the sample. Marshall Stability Test is conducted with a load of 25KN, after the specimen is completely dry. Note the flow value and dial gauge readings. By the same process this test is conducted for various specimens of 1 to 15% replacements of bitumen. Lime is added during mixing to control the water absorption when kept in water bath for 24 hours. Fig 1: samples of 13% Replacement of bitumen with molasses The above figure shows the 13% replacement of molasses with bitumen. This shows that molasses can be replaced with bitumen upto certain percentage. Fig 2: 4.20, 4.5,4.75 Pure Optimum Bitumen Bitumen Content Sample In the above shown the specimens are prepared to find the optimum bitumen content that should be used in the investigation. 193
Bitumen content (%) Table 2: Calculation of optimum molasses content after replacement Molasses content (%) Air voids (Vv) Voids in Mineral Aggregate Voids Filled With Bitumen (VFB) Stability Flow Value 100 0 4.6722 15.5233 69.9693 948.279 6.033 99 1 4.6569 15.37 70.4826 983.9922 5.367 98 2 4.6308 15.1978 70.1167 1142.6285 4.3 97 3 4.6119 15.0654 71.2375 1144.1405 4.077 96 4 4.6022 14.9236 69.94017 1230.746 3.967 95 5 4.5611 14.7449 69.528 1385.693 3.6 94 6 4.4889 14.5386 69.212 1435.89 3.33 93 7 4.3966 14.50344 69.6914 1624.343 3.25 92 8 4.2213 14.2233 70.3797 1762.779 3.033 91 9 4.1003 14.0066 70.881 1822.835 2.8233 90 10 4.0965 13.92938 70.65118 1907.59 2.633 89 11 3.5336 13.3252 73.5674 2028.705 2.443 88 12 2.6335 12.35439 78.8897 2045.276 2.25 87 13 2.79741 12.31331 77.2937 2102.157 2.067 86 14 4.0567 13.358346 69.71477 1914.975 2.15 85 15 5.47779 14.5539 62.45034 1793.867 2.233 GRAPHS STABILITY (KGS) 2250 2000 1750 1500 1250 1000 750 500 250 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 molasses (%) Graph no:-1: Molasses(%) Vs Stability(KGS) 194
Table 3: Values of Molasses Vs Stability Molasses 0 1 2 3 4 5 6 7 Stability 948.27 983.99 1142.62 1144.14 1230.74 1385.69 1435.89 1624.34 Molasses 8 9 10 11 12 13 14 15 Stability 1762.77 1822.83 1907.59 2028.70 2045.27 2102.15 1914.97 1793.86 In the molasses vs. stability graph the molasses content is taken over the x-axis and the stability is taken over the y- axis. In the above graph the stability goes on increasing up to the 13% and then the stability goes on decreasing, so it is recommended replace upto the 13%. If the stability increases the strength of the road increases and then the life of road increases. The minimum stability value is 840kgs. The peak point in the stability graph is taken as the optimum molasses content. When the stability increases the bonding nature between the aggregates is strong and resists the damaging of road. 16 15 VMA (%) 14 13 12 11 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 MOLASSES (%) Graph no:- 2: Molasses(%) Vs VMA(%) Table 4: values of Molasses Vs VMA Molasses 0 1 2 3 4 5 6 7 VMA 15.5233 15.3701 15.1978 15.0654 14.9236 14.7449 14.554 14.5034 Molasses 8 9 10 11 12 13 14 15 VMA 14.246 14.0066 13.9293 13.325 12.354 12.3133 13.3583 14.55 The above graph is plotted between the molasses content and the voids in mineral aggregate (VMA). the molasses is taken over the x-axis and voids in the mineral aggregate is taken over the y- axis.the voids in the mineral aggregate decreases upto the 13 % and then increases. Voids in the mineral should be as less as possible. The range of VMA should be less than 18%. When the VMA is decreased then the voids decreases and the stability increase that means strength is high at 13% and it goes on increasing so that the voids again increases and strength increases. Due to voids the sub grade soil and stabilized soil get affected. Sometimes the aggregates absorb the water and weight increases and wave shaped surface is formed 195
80 VFB (%) 75 70 65 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 MOLASSES(%) Graph no:-3: Molasses(%) Vs VFB(%) Table 5: Values of molasses Vs VFB Molasses 0 1 2 3 4 5 6 7 VFB 69.9693 70.4826 70.1167 71.2375 69.9401 69.5281 69.2123 69.6914 Molasses 8 9 10 11 12 13 14 15 VFB 70.3291 70.8818 70.6511 73.567 78.8897 77.2937 69.7147 62.4503 Above is a graph drawn between the molasses and voids filled with bitumen. The molasses content (%) is take over the x-axis the voids filled with bitumen is taken over the y-axis. it is observed that the voids filled with bitumen percentage increases up to the 13% and then decreases beyond this percentage. voids filled with bitumen percentage should be greater than 75% so that the bitumen mix will be in good condition. If the bitumen mix is not properly mixed and filled so that the strength decreases. If voids are not properly filled then the bonding nature between the aggregates, fillers decreases and the aggregates get dispersed away and the potholes get formed on the roads. When the heavy load vehicles travel on this roads then the damage of roads get increase. CONCLUSION Form the study the behaviour of molasses modified bituminous mix it was found that the modified mix posses improved Marshall Characteristics as method below.it was observed that marshal stability value increases up to 13% and then decreases and also flow value decreases upon addition of molasses. The parameters such as V v, Vb, VMA, and VFB are within the required specifications. Considering this we can assure we can obtain more stable and durable mix. The optimum bitumen content of mix is 4.7%. The small investigation not only utilizes beneficially, the solid waste molasses but also provides us improved pavement characteristics such as road safety, visibility, long life, strength, recycling, workability and another one that is environment. The temperatures are rising towards 50 0 c and rains are danger at these temperatures, so by using this molasses modified mix we can save environment, the main global environment objectives towards Zero emission. By using molasses to the bituminous mix amount of release of carbon dioxide decreases and also products of molasses also decreases which are very harmful to human health. By spraying this molasses over the aggregates increases binding characteristics. The molasses modified bituminous mix reduces the void present in the mix; this prevents the moisture absorption and oxidation of bitumen entrapped air. The road can withstand heavy traffic and better service. This modification not only add value to molasses but will also develop technology which is eco-friendly. 196
So it is recommended that more research regarding the topic should be done and more trial sections should be laid and their performance should be studied. REFERENCES Journal papers 1. Synthetic bitumen by ecopave Australia in the year 2002 2. Eco-road building for emerging economies: an initial scan for promising alternative technologies by global knowledge partnership(gtkp) 3. Asphalt bitumen from renewable resources by Sandra Lawson 4. Ecopave Australia GEO320 technology improves shell bitumen by Damien Johnson. 5. Paving towards future by Vivien cuttle. 6. Molasses road will head north by kirsty Ross (Tuesday 8 march,2005) 7. Uses of molasses for road building cairns post (qld: 1909-1954) September 1941. 8. Marshal Mix design NPTEL may 24, 2006 (introduction to transportation engineering by jom v. athev and k.v. Krishna rao). 9. Marshal method by main roads Western Australia. 10. R.Sathishkumar and Dr.S.P.Jeyapriya, Comparison of Strength Properties of Bitumen Mixed with Waste Materials as Modifier, International Journal of Civil Engineering & Technology (IJCIET), Volume 4, Issue 4, 2013, pp. 219-224, ISSN Print: 0976 6308, ISSN Online: 0976 6316. 197