Asphalt Batch Mix Plant Operation - Atlas Industries

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ASPHALT BATCH PLANT OPERATION AND
COMPONENTS Read Our Blog - Atlas Industries /
Asphalt plants / Asphalt Batch Plant Operation
And Components
October 7, 2017 Atlas Industries Asphalt
Plants The main components and operation of
asphalt batch mix plant. It is to produce HMA
known as Asphalt Batching Plant and hot mix
plant. It blends together aggregates and bitumen
to produce the hot mix paving material. The
aggregates here can be a single sized material.
It can be a combination of different grades /
sizes of materials. Finer aggregates are also
added along with mineral filler material. The
binding material also known as asphalt cement
can be cutback asphalt, synthetic binders or
emulsion. There are two major types of
plants Batch mix plants Continuous mix
plant The purpose served by both the plants is
the same. The difference lies in the method by
which they produce asphalt.
Asphalt Batch Mix Plant Operation
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The operation of asphalt batch mix plant starts
from feeding the aggregates into the feeder bins.
The operation ends when hot mix asphalt is
discharged into the truck. The first step is to
feed unheated-raw aggregates into different bins
of the cold aggregate feeder. This feeding has to
be as per their sizes. There are cold feeder
gates on individual bins which will control the
aggregates flow. The aggregates are then
transferred to drying drum. A charging conveyor
will transfer the aggregates to the drum. The
drying drum comes fitted with a burner. Burner
heats-dries the aggregates effectively. Most of
the hot mix plants are equipped with a primary
dust collector. It is for settling heavy dust
particles. The primary dust collector works best
with secondary dust collector. This secondary
dust collector is a bag filter. Once the heating
of aggregates is done in the drum, they are
transferred to the tower unit. A bucket elevator
is used to transfer the aggregates. On top of
the tower unit we have the screening unit. It is
multiple layered. As the hot aggregates pass
through the screens they get treated to
screening effect. They will get separated and
stored into different bins based on their sizes.
Separate hot bins are there. These help to
separately store each type of aggregates. Aggrega
tes are then weighed. After weighing these
aggregates will be discharged in to the mixing
unit. In the mixer, aggregates will be mixed
with bitumen and filler material. Bitumen tanks
heats and stores bitumen. It is equipped with a
pumping station. Bitumen is pumped to the
weighing hopper prior to discharge. This bucket
weighs it before addition into the mixer. Filler
material is added in a separate container and it
is pumped to its weighing hopper. Only after
weighing the filler material it is discharged
into the mixing unit. After mixing for a fixed
time, the hot mix asphalt is ready to discharge
into waiting trucks. In some cases it is
transferred to storage silos for storing the
same temporarily. A control panel is for
using/controlling the plant. Asphalt Batch Mix
Plant Process The process of asphalt batch mix
plant is explained in details below. This
equipment makes hot mix asphalt in batches. Each
batch is of a specific proportion of each item
that we need to mix.
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Feeding cold aggregates
This is the very first step. Different sized
aggregates are fed into the different feeder
bins. This helps in getting proper proportion of
each size as per the need. Each bin will have
individual gear and variable speed drive motor.
It is possible to control the speed of each bin
to get proper proportion of each item.
Aggregate heating by drying drum
Drying drum is one of the important components of
an asphalt plant. It is equipped with a burner
unit on one side of the rotating drum. The drum
is inclined and allows the material to flow
freely from one end to the other. The aggregates
are transferred to the drying drum after
they pass through a primary screening unit. Once
inside the dryer, the high temperature inside the
dryer will help to get rid of the moisture
content in the aggregates. Here the burner unit
plays an important role. The lifting mechanism of
the drying drum flights allows aggregates to heat
up evenly.
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Bucket elevator transferring the aggregates
As soon as the aggregates leave the drying drum
they enter the bucket elevator. Bucket elevator
is a long and covered structure going up to the
top of the tower unit. On top of the tower unit
we have vibrating screen. The bucket elevator has
many buckets that are attached to a chain. This
elevator unit will transfer the heated aggregates
to the top of tower unit and help them enter the
top of the vibrating screen unit.
Hot Aggregates Screening
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On top of the tower unit we have the vibrating
screen unit. This screening unit is multi layered
and fully covered unit. Screens of different
sizes are laid out in succession one below the
other. As the aggregates fall on top of the first
layer of the screen they will be treated to a
vibrating effect. This vibrating effect will help
the material to pass from one screen to the
other. As they pass from one screen to the other
the oversize material will be removed as they
will not be able to pass through the top most
screen.
Hot bins
After the screening is over all the materials
will be separated and stored in different
compartments. These compartments are called as
hot bins. They will store the aggregates and
help in weighing the same before the aggregates
are discharged into the mixing unit.
Bitumen and filler weighing mechanism
Bitumen and mineral filler both are weighed
before being discharged into the mixing unit.
There is a circular and insulated bitumen weigh
hopper which will store some quantity of bitumen.
This hopper will weigh and discharge the required
quantity of bitumen into the mixing unit. The
filler hopper holds and also weighs filler
material before discharging into the mixer.
Mixing unit
Mixing unit receives aggregates from the weigh
hoppers transferred from the hot bins. It also
receives bitumen from the weigh
hopper transferred from the bitumen tanks. Filler
is also discharged from the filler weigh hopper.
If there is addition of RAP it is weighed prior
to discharging the same into the mixing unit.
Mixing unit will mix all the contents thoroughly
for a fixed time before discharging the contents
into the truck or into storage silos. There are
two horizontal shafts which have arms and tips
fitted on them. These arms and tips will be
rotating on the shaft for mixing of material
inside the mixer. Mixers are jacketed so that
contents inside stay hot.
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Bitumen storage and transfer tanks
Bitumen tanks act as storage point for bitumen
used in the asphalt plant. Bitumen tanks are
direct heating or indirect heating type. Direct
heating type bitumen tanks will come with a
burner fitted for heating of bitumen. The burner
flame is led into a tube which will transfer the
heat inside the tube for melting bitumen.
Indirect heating system has coils running inside
the bitumen tanks. These coils will continuously
circulate hot oil inside the coils which in turn
will heat the bitumen. Bitumen tank comes in
different sizes as per the customers requirement.
Filler storage
Mineral filler is an integrated component of
asphalt batch mix plant. It will store filler
material and then via a screw conveyor transfer
the same to the filler weigh hopper. Size of the
filler storage can vary as per the requirements
of the customer.
Bag filter unit for pollution control
Bag filter and pre separator are two important
units for trapping harmful gases and dust
particles. Pre separator will trap all the heavy
dust. Bag filter is with number of bags close to
each other in a closed chamber. As the gas sucked
from the drying drum is made to pass through
the bags they will be trapped. This action of the
bag filters will help clean most of the
pollutants and give out smoke with less
pollution. https//www.youtube.com/watch?vn-UkeX
y4qlY
Control panel
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Control panel is the controlling unit of the
asphalt batch mix plant. The operator can control
all the operations of the plant from the control
panel. Control panel supplied by Atlas. It is a
PLC type panel. It is highly advanced control
unit with all important parameters laid out
nicely. There is a touch screen HMI unit. It is
easy to use and displays all important parameters
in different screens nicely. Asphalt Batching
Plant Components The components of asphalt
batching plant ensure that the plant works
smoothly. It is necessary for all the parts to
work in perfect synchronization. All the types
of asphalt plants may have different components.
But their purpose is to produce hot mix asphalt
as per desired recipe. Below are the components
of asphalt plant Cold aggregate feed
bins Primary vibrating screen Charging
conveyor Drying drum with multi fuel burner Hot
aggregate bucket elevator Pre-separator with bag
filter Multi deck vibrating screens Hot
bins Mixing unit Bitumen storage and transfer
tanks Weighing hoppers for aggregate, bitumen and
filler material Filler storage silo /
hopper Control cabin and panel Asphalt storage
silo Cold or warm RAP hoppers What are the
common operation of an asphalt mixing
plant? Common operations of an asphalt mixing
plant include heating of the aggregates and
mixing them with bitumen and binder material.
These process can be carried out in a simple way
by a continuous plant or in a complex but more
accurate way by a batching plant. What is an
asphalt batching plant? Asphalt batching plant is
designed to produce hot mix asphalt in fixed
batches. It weighs each component individually
before adding them into the mixer to prepare a
batch. The accuracy offered by an asphalt
batching plant is more compared to a continuous
plant. What are common types of asphalt
mixers? The common types of asphalt mixers are
continuous type and discontinuous (batch) type
asphalt plants. Asphalt mixers are also available
as stationary type as well as portable
types. Asphalt Batch Mix plant Operation,
Asphalt Batch Mix Plant Process, asphalt batch
mixing plant, Asphalt Batching Plant Components,
asphalt plant manufacturer, mobile asphalt mixing
plant
Mini Batching Plant
Bitumen Decanter
Atlas Industries Atlas is manufacturer and
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from India. We expertise in custom grade
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exports to 38 countries (and growing) proves that
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different locations in the globe. https//www.atl
asindustries.in
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