Atlas is a manufacturer of hot asphalt batching plants. We have successfully exported many machines of different capacities. This blog is about our recent installation of a 260 tph asphalt mixer and about its components and features. Atlas manufactures top quality asphalt batch plants with focus on quality and service. The equipment is designed to be working for long time without breakdown. The use of quality brought out items in the manufacturing enables us to offer the best quality.
Stringent quality norms are followed at each manufacturing stage. In the end, the equipment is sand blasted prior to application of paint. This process allows us to get a plant that is more finished and better looking. When higher quality components are used, the machine tends to perform better. Each component is designed with care, and it works in tandem with other units for a trouble free performance. Better- and high-quality raw materials = better quality and performance.
Components Of Hot Asphalt Batching Plant 260 tph
All the components of the hot asphalt batching plant are important and crafted with precision. Since this is a tower type batch asphalt plant of 260 tph the components are bigger compared to the other smaller plants of 60 tph, 100 tph, 120 tph or even the 160 tph plants. The components are modular means the plant is easily broken down into different small components for easy installation. This also facilitates easy transportation of the full plant. The key components of this machine are listed as below:
- 5 bin cold aggregate feeder.
- Primary vibrating screen and slinger conveyor.
- Drying drum
- Fuel efficient air atomization burner.
- Bag filter with pre-separator
- Filler silo with elevator
- Hot aggregate elevator
- 5 deck vibrating screen
- 5 deck hot bins
- Mixing unit
- Weighing scales for filler, aggregates and bitumen on tower of hot asphalt plant.
- Bitumen storage tanks with thermic heating unit.
- Fuel tank for drum burner.
- Control panel system
Features of Hot Asphalt Batching Plant (asphalt mixer) of 260 tph capacity
There are many strong advantages of atlas hot asphalt batching plant. The asphalt mixer of 260 tph is designed to perform with precision. It is manufactured to produce quality hot mix asphalt as per the desired mix recipe. Some of them are under:
- The 5-bin feeding unit is with adjustable push up roller for easy alignment.
- The corrugated auxiliary belt avoids material wastage at the site.
- Drum unit is supported by EN 350 forged rings.
- Bigger trunnion rollers for better drum support.
- Low noise air atomization burner
- Proven and fuel efficient burner compliments the drum
- Hot elevator with dual chain design for prolonged life.
- 5 or 6 screening decks – upon request of customer
- Larger screening area for uninterrupted production.
- Bigger hot bins for storing sufficient quantity of aggregates into separate compartments.
- Hot bins are thermally insulated for heat retention.
- Mixer is supplied by BHS. It is of 3500 kgs. Capacity.
- Stringent and proven design of mixer that works smooth.
- Aggregate scale size is 4500 kgs.
- Filler scale size is 450 kgs.
- Bitumen scale size is 300 kgs.
- Bag filter with larger filtration area.
- Bag filter has high cleaning efficiency.
- Bag house is thermally insulated to keep the bags away from moisture.
- Exhauster is heavy and bigger.
- It is equipped with a variable frequency drive for efficient operation.
- Foreign filler silo provided is of 60 m3 capacity.
- Four bitumen tanks of 50 tons each provided with the plant.
- Bitumen tanks are heated by a 700,000 thermic heater.
- Control cabin is double storey with 2 PC’s on the top floor and all the control boards on the bottom floor.
- Both the floors are air conditioned.
- High technology cabin with user friendly software.
- PLC with SCADA and with Siemens HMI.
- Fuel tanks provided are 2 in number for using 2 different fuels. Each tank is of 24,000 liters.
- Platform railings and ladders are of high quality with diamond shaped grating and anti-slip design.
- Duct line comes with an improved design which is now maintenance free. It also allows free flow of gases.
Some advantages of Atlas hot asphalt batching plant, 260 tph
Atlas asphalt mixing plants have proven their advantages and worth with more than 140 installations in 5 years. Below are some of the advantages of the Atlas hot asphalt batching plant of 260 tph. The higher level of acceptance with customers is a proof of our quality product. The higher number of units is also a testimony of low maintenance, better after sales support, low fuel consumption, more savings and superior overall performance.
Few of the core benefits of asphalt mixers by Atlas are as below:
● Structure: Overall structure is heavy with the plant tower unit girders being wider compared to the competition.
It’s advantage: It aids in getting more stability to the machine. The equipment can withstand harsh weather. The machine life will not be affected even after several re-installations.
● Drying drum: This is one of the most important component. If the machine is a stationary plant or in a mobile asphalt batch plant, the importance of a well done drum cannot be under estimated. The drying drum that we manufacture is thoroughly cladded with cera wool. It is then coated with stainless steel sheet to give it an aesthetic look.
It’s advantage: The glass wool coating helps retain heat. Which means we can apply less heat on the aggregates. This translates to better fuel efficiency. Since the drum is thermally insulated, less heat will escape. The intelligent flight design helps heat the aggregates efficiently.
● Burner unit: Burner is fixed on the drum unit. It is an important component. The finer the burner’s amalgam with the drum, the better its performance and its fuel efficiency.
It’s advantage: The burner is air atomization type. It works with less air pressure generating less smoke. Highly reduces the gases. It can regulate the burner temperature quickly and in a smart manner. Its performance is unmatched with higher thermal efficiency and low fuel consumption. Better safety features, safety interlocks to ensure zero accidents. Unmatched performance years after year.
● Thermic hot oil heater: This is one of the key components responsible for heating of bitumen. Fuel consumption and heating efficiency matters as the oil is heated first. This hot oil will indirectly heat the bitumen once it is circulating from the pipelines. We use a “3 pass heater” for fast heating and with consumption of less fuel.
It’s advantage: The thermic oil heater supplied with our machine is 3 pass. It allows for superior heating efficiency and low fuel consumption. The coils used are of reputed make resulting in better life of all components. Faster heating time leading for better fuel efficiency numbers. Furnace oil can also be used which is a special option not given by many manufacturers of asphalt plants.
● Sand blasting: All components that we manufacture are sand blasted prior to the application of paint. Most of the manufacturers from India do not offer plant with this. It increases the manufacturing time and machine cost but it has distinct advantages.
It’s advantage: It helps to remove corrosion from the raw material prior to paint. The surface to be painted is very smooth. Paint applied after this process will stick better. Paint will also last longer and will not peel off easily. We use PU paint for better and durable paint quality.
● Bag filter: Elliptical shaped bags and capsule type cages are used. Due to the shape. They provide highest filtration area here. We use 550 gsm virgin material for optimum cleaning efficiency.
It’s advantage: Maximum filtration area possible due to oval shaped bags. Best material used in the bags to achieve maximum cleaning efficiency. It is possible to adhere to stringent environment norms. Longer bags ensure more savings to customers as bags don’t need to be changed often.
● Skid foundation: Skid mounted design is one of the key highlights. It is a standard arrangement provided by Atlas.
It’s advantage: It helps lower down the civil work costs. Less civil work is required. Installation and re-installation gets is easy as we don’t have to cut the foundation bolts and use new. It saves a lot of time during re-commissioning. Frequent shifting of the plant is possible.
● Pug mill mixer mixer: it is sourced from BHS – world leading in mixing technology. Other manufacturers use their own mixers which are not tested and prone to give trouble after some years.
It’s advantage: It performs sturdily even after years. Maintenance free operation is possible. Mixer is designed to produce tons after tons of production. Long life of pugmill components, low cost of operation and easy maintenance.
● Drying drum gear: Drying drum gear box is sourced from PBL. We use F series gear box where are other local manufacturers are using M series of gear box. The performance factor for F series is much superior compared to M series.
It’s advantage: F series gear box provide seamless and trouble free performance. This is counted after several tons of production. Maintenance is lowest with F series gear box.
Atlas 260 tph asphalt batch plant is designed to be rugged and perform with less maintenance. The simple to use control panel and easy maintenance points make it very easy for the plant operator to work with the plant. Contact us here to learn more.
