Comparison of energy and environmental performance between warm and hot mix asphalt concrete production: A case study

The use of additives to produce warm bituminous mixtures in asphalt pavements gives the possibility to decrease temperatures with positive implications on energy consumption, and on emissions of greenhouse gases and airborne pollutants. This study investigates the changes in energy and environmental performance of an asphalt plant switching from hot to warm asphalt concrete production. A full-scale trial section was constructed in an Italian motorway with recycled bituminous mixtures containing SBS polymer modified bitumen. Reference hot mix asphalts (HMAs) mixed at 170 °C were compared with warm mix asphalts (WMAs) mixed at 130 °C with different chemical additives. Calculations and analysis were performed considering three production phases during which the production technologies (HMA and WMA) and the mixture types varied in temperatures, mixing duration, and quantity of virgin materials employed. Energy performance was calculated through values provided by the asphalt plant operator and thermodynamic equations. Emissions of CO2 were calculated based on energy consumption and emission factors reported in the literature for the Italian energy mix. Airborne pollutants were measured at the stack of the dryer drum. The results showed that for each mixture type, a reduction of 40 °C in the production temperature corresponds to 15% lower thermal energy values for the drying/heating of the aggregates, with consequent lower consumption of fuel oil. The drying/heating of aggregates for WMA lead to lower emissions of particulate matter, NOx, and VOCs compared to HMA. •Hot mix asphalt production is energy- and emissions- intensive.•Chemical additives in recycled bituminous mixtures allow lower temperature processes.•HMA and WMA differ in aggregate and mixing temperatures and in mixing duration.•WMA production leads up to 15% lower energy and fuel consumption and CO2 emissions.•Lower emissions of PM, NOx, and VOCs at the drying drum for WMA production.