XLS-5 Bitumen Cutback Production Plant

XLS-5 Cutback Bitumen Plant at a Glance

How the XLS-5 Bitumen Cutback Plant Works

The XLS-5 is designed around controlled metering of two material streams: heated base bitumen and a diluent such as paraffin, subject to the approved production formulation.

The general process is:

Base Bitumen Storage → Heated Bitumen Supply → Diluent Supply → Metering → Mixing / Homogenization → Finished Cutback Bitumen Storage

Each material is supplied through its own pumping and metering arrangement. Flowmeters and frequency converters allow the operator to adjust the individual flows according to the required production ratio.

1. Heated Base Bitumen Supply

Base bitumen is supplied from a heated storage tank to the XLS-5 production section.

Because bitumen viscosity changes with temperature, the supply line must remain within the required operating temperature range for reliable transfer.

The XLS-5 uses a dedicated bitumen supply pump with a nominal flow of 4 m³/h and a rated motor power of 3 kW.

The actual operating flow and process temperature should be matched to the selected bitumen grade and project formulation.

2. Diluent Supply and Filtration

The diluent is supplied independently from the bitumen stream.

The XLS-5 uses a nominal 3.3 m³/h paraffin pump com um 1.5 kW motor. An in-line filter is used to help protect downstream metering and mixing components from impurities.

The actual diluent type must be selected according to the target cutback formulation, local regulations and project requirements.

3. Controlled Ratio Adjustment

One of the key functions of the XLS-5 is independent flow control.

Flowmeters allow the operator to monitor the material streams, while frequency converters provide pump-speed adjustment.

This arrangement makes it possible to control the relative flow of bitumen and diluent according to the required formulation.

The exact blending ratio should be established from the approved product specification rather than from a universal ratio.

4. Mixing and Homogenization

After the two material streams are metered, they enter the mixing section.

The XLS-5 incorporates a grinding mill to promote mixing and homogenization of the bitumen and diluent stream.

The purpose is to produce a more uniform finished material before it is transferred to the downstream storage or loading system.

The actual process conditions should be adjusted according to the properties of the finished cutback bitumen and the applicable production specification.

5. Finished Product Transfer

After blending and homogenization, finished cutback bitumen can be transferred to a dedicated finished-product storage tank or another downstream loading system.

For larger continuous production systems, FEITENG can configure the XLS-5 together with heated storage tanks, pumps and pipeline systems according to the project layout.

Why Use the XLS-5 for On-Site Cutback Production?

Producing cutback bitumen on site can be useful when a road construction or maintenance project needs a controlled supply of project-specific material and has suitable access to the required raw materials.

Controlled Material Proportion

The bitumen and diluent streams are independently metered, allowing the production ratio to be adjusted according to the approved formulation.

Compact Process Layout

The XLS-5 has an overall footprint of approximately 2.6 × 1.1 × 1.5 m, making it suitable for projects where installation space is limited.

Integration with Existing Bitumen Storage

The production unit can receive heated base bitumen from an existing storage tank and transfer finished material to a dedicated storage or loading system.

Produção contínua

With a nominal production capacity of 5 t/h, the XLS-5 is intended for continuous production rather than manual batch blending.

Metered Process Control

Flowmeters, flow totalization and frequency conversion provide a controlled method for monitoring and adjusting the two material streams.

XLS-5 Main Components

Bitumen Supply Pump

The bitumen supply section uses a nominal 4 m³/h pump with a 3 kW motor for transferring heated base bitumen into the production system.

Paraffin Supply Pump

The paraffin supply section uses a nominal 3.3 m³/h pump with a 1.5 kW motor and an in-line filtration arrangement.

Medidores de vazão

Flowmeters are used to monitor the individual material streams and support controlled ratio adjustment.

Frequency Converters

Frequency converters allow the pump speed to be adjusted to help control the actual material flow according to the process requirement.

Grinding Mill

The grinding mill provides mixing and homogenization of the bitumen-diluent stream before finished-product transfer.

Thermal Oil Heat Tracing

The process system uses thermal oil heat tracing to help maintain the required temperature in the heated bitumen supply and process sections.

XLS-5 Thermal Management

Temperature management is important in any hot-bitumen process.

The XLS-5 is designed to work with thermal oil heating for the heated bitumen supply and process pipeline sections. The current FEITENG configuration specifies a thermal oil temperature range of approximately 200-250°C.

The required thermal conditions should always be confirmed against the actual bitumen grade, diluent, process formulation, pipeline length and ambient conditions.

For related heating-system information, see:

Como calcular a capacidade do aquecedor de óleo térmico para tanques de armazenamento de betume

XLS-5 and Cutback Bitumen Production

Cutback bitumen is produced by reducing the viscosity of base bitumen through controlled blending with a suitable volatile or less viscous component, depending on the specified cutback grade and applicable standards.

For example, project specifications may cover medium-curing or slow-curing cutback grades such as MC-type or other approved formulations.

The XLS-5 provides the equipment platform for controlled blending, while the final formulation must be determined from the required product specification.

For more technical information about cutback bitumen and MC-30 / MC-70 production, see:

How to Make Cutback Bitumen MC-30 / MC-70 On Site

XLS-5 in a Complete Cutback Bitumen Production System

The XLS-5 normally operates as one part of a larger bitumen handling system.

A typical configuration can include:

• Base bitumen storage tank
• Sistema de aquecimento a óleo térmico
• Heated bitumen transfer pipeline
• XLS-5 cutback production plant
• Diluent supply and filtration system
• Finished cutback bitumen storage tank
• Finished-product transfer and loading system

The complete arrangement should be designed according to production capacity, raw-material supply, required storage volume, pipeline layout and the final product requirements.

XLS-5 vs. Buying Finished Cutback Bitumen

The decision to produce cutback bitumen on site or purchase finished material depends on project logistics and the local availability of raw materials.

On-site production may be attractive when:

• The project has regular cutback-bitumen demand
• Base bitumen and suitable diluent are available locally
• The project requires a controlled production schedule
• Finished cutback transportation creates logistical challenges
• The contractor needs flexibility in production quantity

Purchasing finished cutback bitumen may remain preferable where the required material is readily available, project consumption is low, or local regulations make on-site blending unsuitable.

Aplicações

Prime Coat Production

The XLS-5 can be configured for projects requiring controlled production of cutback material used in prime-coat applications, subject to the applicable project specification.

Road Maintenance

Maintenance contractors may use on-site cutback production where the project requires regular supplies of lower-viscosity bituminous material.

Highway Construction

Large road projects can integrate the XLS-5 with storage and transfer equipment to establish a dedicated cutback production and supply system.

Remote Projects

Where finished cutback material is difficult to transport reliably, on-site production may provide an alternative when suitable raw materials and utilities are available.

Installation Requirements

Before installing an XLS-5 system, the project should confirm:

• Base bitumen storage capacity
• Required bitumen operating temperature
• Diluent storage and supply arrangement
• Electrical power availability
• Thermal oil supply
• Finished product storage capacity
• Pipeline route and length
• Drainage and maintenance access
• Local fire and process-safety requirements

The equipment layout should provide safe access to pumps, filters, flowmeters, valves, electrical components and other service points.

Technical Data

Perguntas mais frequentes

What is the XLS-5 used for?

The XLS-5 is designed for continuous production of cutback bitumen by blending heated base bitumen with paraffin or another approved diluent under controlled process conditions.

What is the capacity of the XLS-5?

The nominal production capacity is 5 tonnes per hour.

Does XLS-5 require heated bitumen?

Yes. The base bitumen supply must be maintained at a suitable process temperature so that the material can be transferred and blended reliably.

Can the blending ratio be adjusted?

The system uses independent flow measurement and pump-speed control for the bitumen and diluent streams. The actual blending ratio must be established according to the required cutback grade and approved formulation.

Does the XLS-5 include finished-product storage?

The XLS-5 is the production unit itself. A separate finished cutback bitumen storage tank can be configured as part of the complete production system according to project requirements.

Can XLS-5 be connected to an existing bitumen tank?

Yes. The production unit can be integrated with an existing heated base-bitumen storage system when the tank, pump, pipeline and heating conditions are compatible with the XLS-5 process requirements.

What information is required for an XLS-5 quotation?

For project-specific configuration, provide the required production capacity, bitumen grade, target cutback product, diluent type, blending ratio, base-bitumen storage temperature, available thermal oil system, power supply, finished-product storage requirement, pipeline layout and destination country.

Conclusão

The XLS-5 Bitumen Cutback Production Plant is a compact 5 t/h continuous production unit for controlled blending of heated base bitumen with paraffin or another approved diluent.

Its process combines independent material supply, flow measurement, pump-speed control and mixing in one integrated production system.

For a complete project, the XLS-5 should be matched with the appropriate base-bitumen storage tank, thermal oil heating system, pipeline, finished-product tank and transfer equipment.

FEITENG can configure cutback bitumen production systems according to project capacity, raw-material availability, heating method, storage requirements and site conditions.

For an XLS-5 quotation or complete cutback bitumen production system, send us:

• Required production capacity
• Grau de betume
• Target cutback grade
• Diluent type
• Target blending ratio
• Base bitumen storage temperature
• Finished-product storage requirement
• Project location

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E-mail: [email protected]
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