Germany’s bauma 2025 Showcases CO₂-Free Asphalt Production Using 100% Green Hydrogen

WPB: At the recently concluded bauma 2025 trade fair in Germany, Benninghoven introduced a groundbreaking solution for sustainable asphalt production. Unveiled in Munich, the new MULTI JET burner generation and the associated MULTI JET Control system represent a leap forward in fuel flexibility and emissions reduction. This innovative burner series is capable of operating with four fuel types simultaneously, regardless of whether they are solid, liquid, or gaseous. Importantly, this technology is not limited to newly constructed plants—it can also be retrofitted to existing facilities, irrespective of the original equipment manufacturer.

A standout characteristic of the MULTI JET system is its ability to handle mixed fuel operations. For instance, hydrogen, liquefied petroleum gas (LPG), hydrotreated vegetable oil (HVO), biogas, and natural gas can all be used at the same time via individually separated nozzles. Switching between fuels can occur during operation without any need for halting production, ensuring a steady energy supply. This adaptability offers plant operators the flexibility to opt for the most cost-effective and readily available fuel options, which contributes to significant savings, especially considering the future trajectory of CO₂ pricing.

Further enhancing its appeal, the new burner system reduces acoustic emissions by 5 decibels (dB(A)), effectively cutting the perceived sound level in half. Simultaneously, electrical power usage has been cut by 20%, all while maintaining consistent material throughput.

Efficient Dust Extraction Enhances Sustainability in Asphalt Plants

In addition to burner innovations, Benninghoven also presented a newly engineered dust collection system that plays a critical role in boosting sustainability and operational efficiency. Effective dust control is essential in asphalt production, as it helps extract and filter out particulates like stone dust and bitumen fumes, both of which are generated during the mixing process. Beyond process optimization, these emissions are increasingly subject to stringent environmental regulations in many regions, making reliable dust collection systems essential.

The new dust collection technology stands out due to its aerodynamic design, strong energy efficiency, minimal residual dust levels, high operational reliability, expansive filter surface, and straightforward maintenance access.

Optimizing Recycling: Benninghoven’s Recipe Generator Boosts Profits and Cuts Emissions

Benninghoven’s commitment to resource-efficient asphalt production continues with a focus on maximizing recycling. The goal is to reuse premium materials in a way that preserves—or even enhances—the original quality. Increased recycling rates also result in significant CO₂ reductions, with studies indicating that incorporating up to 60% reclaimed asphalt pavement (RAP) can lead to a 20% drop in emissions.

The recipe generator, a software extension for the Benninghoven BLS 4 control system, is central to achieving this objective. This digital tool supports plant operators in managing optimal recycling content by adjusting plant parameters based on the final product specification, operational constraints, and equipment setup. It allows for the blending of various RAP grades to closely match the desired aggregate gradation of the target asphalt type.

Additionally, the software facilitates automatic switching between bitumen types—from hard binders to softer alternatives—as RAP content increases, ensuring compliance with softening point specifications. These adjustments occur in 1% increments and are executed in real time, without interrupting production or requiring recipe changes, thereby streamlining operations and enhancing flexibility.

Lowering Production Temperatures to Reduce Energy Use and Emissions

Asphalt production’s most energy-intensive stages—heating and drying both raw and recycled materials—present opportunities for major energy savings. One solution gaining traction is the production of reduced-temperature asphalt, where the mixture is processed at approximately 120°C instead of the conventional 160°C. This 30% decrease translates into significant benefits: for instance, producing 2,000 tonnes of asphalt per day in this manner can save around 18,000 kilowatt-hours of energy and reduce carbon dioxide output by 6,000 kilograms.

Benninghoven offers three key methods for producing this lower-temperature asphalt: incorporating solid or liquid additives, or simply using water. These solutions can be easily integrated into both new and existing asphalt plants via the company’s Plug & Work system. One particularly promising technique is the use of foamed bitumen, which requires only water—already available at any plant—to activate. This approach enhances the binder’s ability to coat aggregates effectively at lower temperatures, achieving handling characteristics similar to hot asphalt. Importantly, this method also curbs the release of harmful PAHs (polycyclic aromatic hydrocarbons) during paving.

Mobile and Continuous Mixing Technologies from Ciber Also on Display

Visitors to Benninghoven’s area at bauma 2025 were also introduced to the latest developments from Ciber, a specialist in continuous asphalt production. At the event in Munich, Ciber showcased equipment designed to enable mobile and efficient continuous mixing processes, further expanding the Wirtgen Group’s portfolio of environmentally conscious and cost-effective asphalt production technologies.

Through innovations in burner technology, dust collection, recycling optimization, and low-temperature mixing, Benninghoven—alongside its partner Ciber—demonstrated a comprehensive commitment to the future of sustainable road construction. The bauma 2025 exhibition in Germany offered a fitting stage for these developments, underscoring the industry’s steady shift toward greener, more efficient practices.

By Bitumenmag

Asphalt, Bitumen, Innovation