Tuesday, 22 October 2019
Tuesday, 16 July 2019
Capious Roadtech Pvt. Ltd. Manufacturer & Exporter of Asphalt drum mix plant, asphalt Double drum type plant, counterflow type asphalt plant, parallel flow type asphalt plant
Asphalt drum mix plant is divided in two types of technologies.
Capious asphalt drum mix plants are the two types of plants that are categorized as continuous type asphalt drum mixing plants. Both these types of plants produce hot mix asphalt in a continuous process. Batch mix plants are also there which make hot mix asphalt in batch wise. The end product is to get hot mix material which lay on road but the process of asphalt batching plants and asphalt drum mix plant continuous type plants is totally different from each other. The difference in the process is what makes the quality of hot mix material is totally different in all the types of plants.
Capious make asphalt drum mix plant – counterflow type with capacity 40 to 120 TPH
Do you want to know how does an asphalt drum mix plant operation work? Then see the image below..
Capious make Asphalt drum mix plant (Parallel Flow type) operation diagram
Capious make Asphalt drum mix plant (Double Drum Type) diagram
Asphalt drum mix plant process starts with the feeding of cold aggregates into feed bins. The equipment is usually equipped with three or four bin feeders (or more) and aggregates are loaded into different bins as per their sizes. This is done so that different sized aggregates can be graded as per the requirement. Each bin is provided with separate adjustable gates for controlling the flow of material. There is a conveyor belt below the bins which takes the aggregates to the over size removal screen.
Related: Click here to get information on asphalt drum mix plant from our website.
The next part is the screening process. Here is a single deck vibrating screen which removes the oversized aggregates thus preventing them from entering the drum.
Charging conveyor plays an important role in the asphalt plant process because it not only transfers the cold aggregates from below the screen to the drum but also does the weighing of the aggregates. This conveyor is equipped with a load cell which continuously weighs the aggregates and sends signal to the control panel.
Counterflow type drying cum mixing drum
Parallel flow type drying cum mixing drum
Drying and mixing drum is responsible for two operations first drying and then mixing. This drum is continuously rotating and in the course of the rotation, aggregates are transferred from one end to the other. The aggregates are treated to heat by the burner flame to reduce the moisture content in the aggregates. When we talk about the process in a parallel flow plant, the aggregates move away from the burner flame and in the counter flow plant, the aggregates move towards the burner flame. On the other end of the drum, the heated aggregates are mixed with bitumen and minerals. The drum plays an important role in the drum mix plant process.
Fuel tank for drying drum burner stores and provides fuel to the drum burner. Apart from that, the critical component includes asphalt storage tanks which store, heat and also pump required asphalt to the drying drum for mixing with the hot aggregates. Filler silos are for addition for optional filler / binder material into the mixer.
Pollution control devices play an important part in the process. They help to eliminate the harmful gases that may have escaped the environment. Primary dust collector is a dry dust collector and it works in sync with secondary dust collector which can be a bag filter or a wet dust scrubber.
Load out conveyor collects the ready hot mix asphalt from below the drum and takes it to the waiting truck or into the storage silo. Optional storage silo stores the HMA till the truck arrives.
Control panel with today’s machines comes with modern and sophisticated controls. They allow storage of different mix recipes as per customer’s demand. Plant can be controlled from a single place from the control panel.
Drum mixers India
There are two types of continuous mixing plants: parallel flow and counter flow. The above images represents and compares both the parallel-flow and counter-flow asphalt plant. In parallel flow plant the flow of aggregates is parallel to the burner flame. This also means that the aggregates are moving away from the burner flame during their journey. In the counter flow plant, the flow of aggregates is opposite (counter) to that of burner flame and hence the aggregates are moving towards the burner flame before getting mixed with bitumen and other minerals. This seems simple but it makes a huge difference to the process of both these types of asphalt mixers and even affects the quality of the HMA. It is believed that counter flow mixer is better for fuel saving and also offers better HMA compared to the other.
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www.capious.com
Ahmedabad, Gujarat - India
Thursday, 11 July 2019
Capious Manufacturer & Exporter of Asphalt Batch Mix Plant, Asphalt Drum Mix Plant, Hot mix plant, Bitumen Sprayer, Wet Mix Macadam Plant, Concrete plant
Capious Asphalt Batch Mix Plant
The Capious Asphalt Batch Mix Plant is mainly used to produce hot mix asphalt known as Asphalt Batching Plant ( Discontinue Type ) and hot mix plant. It blends together aggregates and asphalt to produce the hot mix paving material. The aggregates here can be a different sized material. It can be a combination of different grades / sizes of materials. Finer aggregates are also added along with mineral filler material.
There are two major types of plants:
The purpose served by both the plants is the same but mix material quality is different. The difference lies in the method by which they produce asphalt.
Asphalt batch mix plant operation:
The operation of asphalt batch mix plant starts from feeding the aggregates into the feeder bins. The operation ends when bitumen mix material is discharge into the storage silo or in 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 transferred through gathering conveyor to vibratory screen which remove dust and over size material to prevent fuel consumption and environmental damage then transfer this material to drying drum. A charging conveyor will transfer the aggregates to the drum. The drying drum comes fitted with a modulating 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 four deck vibratory screen and it is called 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.
Layout of CAPIOUS make asphalt mixing plant
Separate hot bins are there. These help to separately store each type of aggregates. Aggregates 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.
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.
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.
Vibrating screen and hot bins Hot Aggregates Screening:
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 required quantity of bitumen into the mixing unit. The filler hopper holds and also weighs filler material before discharging into the mixer.
Twin shaft mixing unit 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.
Bitumen storage tanks / 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 asphalt batching plant / 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.
Control panel:
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 Capious. 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.
The functioning of asphalt batching plant is dependent on many components. It is necessary for all the parts to work in perfect synchronization.
Below are the components of asphalt plant
Cold feed bins (Four bin Feeder)
Primary vibrating screen (For dust and over size removal)
Charging conveyor
Drying drum with modulating burner
Hot aggregate bucket elevator
Pre-separator with bag filter
Multi deck vibrating screens
Hot bins
Mixing unit
Bitumen storage tanks
Weighing hoppers
Filler storage silo / hopper
Control cabin and panel
four further query feel free to contact us
CAPIOUS ROADTECH PVT. LTD.
An ISO 9001 : 2015 Company
Government Recognised ONE STAR Export House
Address :Plot# 4008, Phase IV, G.I.D.C., Vatva,
An ISO 9001 : 2015 Company
Government Recognised ONE STAR Export House
Address :Plot# 4008, Phase IV, G.I.D.C., Vatva,
Ahmedabad - 382 445, Gujarat, India.
Phone : +91-79-40083274, 25833436
Phone : +91-79-40083274, 25833436
Fax : +91-79-25833597
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