Operation procedures of an Asphalt Mixing Plant

Atlas is an operation procedures of an asphalt mix plants. We are asphalt mixing plant consists of several mechanical and electrical components working in sync. In many cases reclaimed asphalt is added to virgin asphalt. These items are heated and blended in fixed quantity. We can produce asphalt as per our requirement. This machine can be stationary or mobile type.

There are many types of asphalt plants. We can safely name a few types like asphalt batch plant, parallel-flow drum mix plant, double drum plant, counter-flow drum mixers, etc. But in general and broadly these plants can be typed into two categories:

• Batch type asphalt mixing plant
• Continuous type asphalt plant

In both the batch type as well as continuous plants there are stationary as well as portable versions. Stationary versions are for producing material at a single place. Mobile versions are preferred by those who will want to move from one site to another to produce hot mix material. In batch type asphalt mixing plant. We are produce of hot mix asphalt in batches. The aggregates are heated and mixed with bitumen and filler material in fixed proportions in a mixer. This is called one batch. As the batch is ready after mixing it is discharged. In drum-type mixing unit aggregates are dried and heated, bitumen is heated to convert to liquid. They are then mixed properly in a continuous process. Although the process of both the plants are different, the end result is the same. Obviously, there is difference in the quality of the materials produced by batch type and drum type asphalt plants.

Components of standard asphalt mixing plant are

Many components of asphalt mixing plant both drum type or batch type are common. The major change is in the drying, mixing and weighing process. Due to this the batch plant is bigger and more advanced compared to the drum mix plant. In batch type machine the components are more and it requires more space and power to run. Drum mixers are simple and easy to use.

Components of Batch Mix Asphalt Plants:

Some most important components of Batch Mix Plant. We are manufacturer of asphalt batching mixing plants in Samoa, Botswana, Oman and Turkey.

• Cold aggregate feeder bins to receive and transfer cold aggregates to the drying drum.
• Primary vibrating screen for removal of oversized material.
• Charging conveyor to transfer the aggregates from the bottom of screen to the drying drum.
• Drying drum equipped with a burner for heating the aggregates.
• Bucket elevator is covered. It will transfer the aggregates to the top of the tower unit.
• Tower unit has 3 components top most is vibrating screen. It will screen out and separate the aggregates into different components.
• Hot bins are below the vibrating screen. It will store the aggregates into separate components after the screening process is complete. Each of the hot bin will release the aggregates into the mixing unit as per the set weight.
• Mixing unit is a twin shaft jacketed mixer. It consists of two shafts fitted with arms and tips for homogeneous mixing in short time. After the mixing is done the mixer will discharge the contents into waiting truck or into a storage silo.
• The asphalt plant is also equipped with a bag filter unit for pollution control.
• Bitumen tanks will heat and transfer bitumen to its weigh hopper.
• Filler silo or filler hopper will transfer the filler material to its weigh hopper.
• There are two weighing hoppers one for bitumen and one for filler material.
• There is control room with control panel for controlling the entire plant.

Continuous Drum Mix Plant Components:

Below describe of components of continuous drum mix plant. We are supplier of double drum asphalt plants in Tanzania, Morocco, Egypt and Israel.

• Cold aggregate feeder bins to receive aggregates in different bins.
• Primary vibrating screen for removal of oversized material.
• Slinger conveyor belt to transfer the aggregates from the feeder to the drying and mixing drum.
• Drying and mixing drum fitted with a burner will heat the aggregates in the first half.
• In the second half aggregates will be mixed with bitumen and filler material.
• Pollution control unit can be a wet dust collector or a bag filter unit.
• Bitumen tanks will heat and transfer bitumen to the drum.
• Filler hopper will transfer the filler material into the drum.
• There is a control panel to control the full plant.

Asphalt Mixing Plants functions or operations:

The two types of asphalt mixing plants functions or operations in common. The basic principle of any type of asphalt plant is the same i.e. to produce hot mix asphalt. The different lies in the method by which the end product is prepared. Some of the common functions of both the types of asphalt plants are:

• Different sizes of aggregates stockpiling and feeding into bins.
• Screening of aggregates. In continuous type the aggregates are screened to remove over size. While in batch type the aggregates are screened to separate them into different compartments.
• Drying and heating of aggregates.
• Melting storage and transfer of bitumen
• Storage and transfer of filler material.
• Bitumen, aggregates and filler material are weighed in batch type plants. Where in continuous type plants they are added and controlled by a variable frequency drive.
• Discharge of hot mix asphalt into truck or a storage silo.
• Control panel is common for both the types. It controls the activities of the plant and gives us report of the important parameters.

Four Basics Factor of Asphalt Mixing Plant Working :

There are some basics that are common to all the asphalt mixing plants. They are as below:

• Drying and heating of aggregates.
• Weighing of aggregates, bitumen and filler material.
• Mixing aggregates with bitumen and filler material.
• Release of hot mix asphalt.

In any type of asphalt plant the accuracy of the weighing is the key factor. There should be consistent and accurate weighing of the aggregates, bitumen as well as minerals. When the weighing is consistent, we get the desired end product which is as per the expectations and norms. Its helps in building better roads as per the set norms. The asphalt plant has ability to store different recipes. We can change use different recipes for different applications as when required. Even it is important to note that the storage and usage of multiple recipes is important when you are dealing with multiple customers. When you have recipes of different customers stored with you it becomes easy to select any specific required recipe. Once the desired recipe is selected with few clicks it is possible to make the AMP produce the required quality of hot mix asphalt.

The success of any asphalt mixing plant requires adequate balance and co-ordination of all the components. Since the asphalt plant is a combination of mechanical and electrical components. It is important that all the components work in tandem to give desired results. It is possible to get consistency and balance by observing caution and management. It is important to check all the plant components before starting. It is important to do daily, weekly, monthly maintenance as described by the manufacturer from time to time. All the material like aggregates, fuel, bitumen should be inspected for quality before being used. When caution is observed it is easy to make quality mix material from hot mix plant of any good company.

Atlas is India based manufacturer and exporter of asphalt mixing plant.