What You Need to Know About an Asphalt Mixing Plant
An Asphalt Mixing Plant is a mechanical device used for mixing asphalt. Generally, the equipment includes the following parts: aggregate screener, stone measuring bin, asphalt supply system, baghouse fines collection system, and mobile plant. Hot aggregates are then split into several particle sizes, and flow into corresponding hot material storage bins. Stone measuring bins load aggregates in batches. The aggregates are then mixed with asphalt in a forced-mixing pot. The finished products are then directly loaded onto dump trucks.
Mobile asphalt plant
If you’re considering purchasing a mobile asphalt mixing plant, you have a number of choices. Mobile asphalt plants come in various sizes and configurations, and you’ll want to make sure the unit you choose can handle the job that you need to get done. You can choose from semi-mobile, mobile, or super-mobile units, each with their own advantages and disadvantages. To help you find the right plant for your project, consider the following factors:
Feeding Unit: The feeding unit of the mobile asphalt mixing plant is mounted on a sturdy chassis with a single axle. There are wide bins that allow for easy loading of aggregates. The feeder bins are equipped with a manual gate to set the aggregates, but no flow indicator switch is provided. The plant also includes variable speed drive gear and a motor. The sand bin features a vibrating motor. The unit is flexible enough to be moved from job site to job site, and the vibrating motor can be replaced with another one.
Drive System: The mobile asphalt mixing plant uses a new-type of combustor, so that it has a high working efficiency and reliable safety. The plant’s hydraulic system can be set to use oil or coal as fuel, whichever you choose. Mixing Drum: Mobile asphalt mixing plant features a mixing drum to produce the mixture. Cold aggregates and mineral powder are mixed together in the drum using a mixing device.
Capability: Mobile asphalt mixing plants can produce a wide range of materials and are highly versatile. They are easy to transport and install. They are also suited for remote sites and are highly versatile for short-term contracts. They can produce from 80 to 200 tonnes of asphalt per hour, depending on the model and configuration. Some of these units can also be converted to recycle. The plant can also be fitted with an optional insulation system to enhance the efficiency of the drying process.
Features: Modern mobile asphalt plants are manufactured with the latest technology and are suitable for small to medium-sized road construction. Their modular design makes it easy to move, assemble, and disassemble. They feature an accurate fabricated dryer, idlers, and guide rollers. Their steel rollers provide support and are equipped with segmented driving sprockets. This feature makes mobile asphalt plants more versatile than other types of plant.
Drum mix plant
A drum mix plant for asphalt consists of a series of separate components. A rotary drum heats and coats the aggregate, while a charging conveyor transports the finished product to a truck or silo. Many modern asphalt plants include sophisticated controls and a capacity for multiple mix recipes. All of these components can be operated from a single control panel. Below are some of the most important components of a drum mix plant.
Aggregates are mixed together in a drum to form an asphalt mixture. The drum continuously rotates, transferring the aggregates from one end to the other. As the drum rotates, the aggregates are heated by the flame and move towards the burner, where they mix with the bitumen and minerals. The drum plays a vital role in the production process, and is a critical part of a drum mix plant.
The UF Series of Asphalt Plants provides producers with a versatile solution for their mixing needs. With an array of auxiliary equipment, this line is perfect for smaller and medium-sized producers. UF Series models are available in both skid-mounted and portable configurations. Their versatility allows users to match their needs and budget. Furthermore, they are easy to maintain and require little maintenance. They are also efficient and energy-efficient, enabling you to save on fuel costs.
Many manufacturers of drum mix plants employ computerized controls to ensure proper mixing results. Some systems even feature automatic process controls to control belt speeds and liquid asphalt flow. Once the proper parameters are established, a drum mix plant for asphalt can meet the demands of any job. There is a practical limit for the production of asphalt, and most manufacturers allow as much as 30% of it. That’s an excellent result for most production companies. The RAP is recycled up to 50 percent and the mix design is completely automated, so there is little need for manual labor.
An asphalt drum mix plant’s main component is the Thermodrum unit. This unit utilizes advanced heat transfer technology and internal flight design to produce the best possible asphalt mix. Additionally, the Thermodrum is mounted on a sturdy structure made of heavy-duty structural steel. The drum is supported by a series of thrust wheels and surface-hardened trunnon rollers. Moreover, these wheels trap heavy-duty particles from the exhaust stream.
Counter flow technology continuous drum mix plant
Counter flow technology is an innovative way to process asphalt, enabling producers to create high-quality asphalt mixes quickly and efficiently. The counter flow process utilises high percentages of recycled asphalt and recycled concrete in its production, reducing the environmental footprint of the process while producing an excellent quality of product. This process is easy to install and is quick and efficient to maintain. There are various models of counter flow plants available. Some are single-chassis plants, while others are equipped with chassis dosers and ready-mix silos of up to 25 tons.
A counter flow asphalt plant is designed for recycled asphalt pavement and has the benefits of mixing and drying in one single drum. As the drum rotates, aggregates are fed into the raised portion and move to the lower end. The burner flame begins in the center and moves out the opposite end, which helps treat the aggregates inside the drum in a counter flow manner. This minimizes energy loss and reduces the overall size of the drum plant.
A counter flow asphalt plant comprises a substantially horizontal single cylindrical drum 50, a ground-engaging support frame 52, and two pairs of large motor-driven rollers 54. The drive rollers rotate the drum 50. This prevents excessive blue smoke and reduces fuel usage. The counter flow plant also helps to meet strict emission reduction regulations. The counter flow plant is the preferred choice for many asphalt producers. In addition to reducing the environmental impact of the plant, it offers many other advantages.
A counter flow drum mix plant uses a dual-barreled design with a large mixing space than a traditional drum mixer. The outer shell of the drum doubles as a coater. In the inner drum, virgin aggregate material is heated between three and four hundred degrees and then dropped in the annular space where it meets the RAP. The entire mixing process takes about one and a half minutes. When the mixing process is complete, the outer shell of the drum contains the RAP and the aggregate.
Baghouse fines collection system
In an asphalt mixing plant, baghouse fines are dust particles produced during the process of a hot mix asphalt batch. These materials are secondary collection equipment, and they collect very fine sized materials. The fines are generally routed to another part of the plant to be used in the mix or may be stored in silos and used as a mineral filler additive. Approximately 80 to 90 percent of baghouse fines from an asphalt mixing plant are recycled into hot mix asphalt.
A baghouse collects fines from the mix as it passes through the drum, and the air is then pulsated. This pulsation allows the baghouse to collect a certain amount of fines at any given time. The remaining fines, however, are sometimes put back into the mix. While the process of asphalt mixing does not end in the baghouse, it still contributes to air pollution and can affect the quality of the hot mix.
A baghouse fines collection system can include an intertial primary collector installed at the inlet side of the drum. The primary collector requires a dramatic change in air velocity to catch larger dust particles. As the air passes over the bars of the inertial collector, heavy dust particles collide with them and fall into the hopper below. They are knocked out before entering the baghouse bags. Once collected, the material is gravity-fed to a return dust screw.
Baghouse fines collection systems can be static or mobile. Mobile systems have more options than static models. Mobile systems are ideal for blending within the dryer section of a plant. They have a wide range of applications and can handle a variety of granules. The system can handle a variety of materials, including minus 75 um reclaimed dust for reuse in asphalt plants. Storage and transfer of the finished product are also options.