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Hot Mix Asphalt Production

Hot Mix Asphalt Production. Chris Lange PMP, Pr.Tech.(Eng) Director (Technical) Much Asphalt (Pty) Ltd. Road Pavement Forum: 10 th April 2006. Hot Mix Asphalt Production. Plant types and basic components Plant calibration Dust extraction Filler handling and control Aggregate heating

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Hot Mix Asphalt Production

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  1. Hot Mix Asphalt Production Chris Lange PMP, Pr.Tech.(Eng) Director (Technical) Much Asphalt (Pty) Ltd Road Pavement Forum: 10th April 2006

  2. Hot Mix Asphalt Production • Plant types and basic components • Plant calibration • Dust extraction • Filler handling and control • Aggregate heating • Procurement / handling of raw materials • Finished product storage • Delivery

  3. Scalping screen to remove oversize aggregate Cold Feed Bins Drum Mix Plant - Conventional Hot Storage Bins Exhaust Fan Filter Baghouse Primary dust collector HMA made continuously and sent to storage silos Bitumen Tanks Drying and mixing drum Belt scale

  4. TWIN DRUM PLANT : COUNTER-FLOW

  5. Old Drum Mix Mix Plant:

  6. Plant filler storage and feed Twin Drum Plant RAP Feed Filter Baghouse Coating & mixing drum Aggregate feed Finished product storage Drying & heating Drum

  7. Parallel-Flow Drum-mixer Zones Combustion Air Heating Drying Mixing BIT. Hot Mix Asphalt

  8. Mixing Combustion Heating Drying Air Hot Mix Asphalt Bitumen Counter-Flow Drum-mixer Zones Aggregate

  9. Counter-Flow Batch Plant Dryer Zones Combustion Heating Drying Air Aggregate Hot Aggregate

  10. Batch/Mixing tower Primary collector Filter Baghouse Hot Storage silos Batch Plant Elements Bitumen storage tanks RAP Feed Dryer Drum Cold feed bins

  11. Aggregate to screens Aggregate weigh hopper Bitumen weigh pot Pugmill Hot mix asphalt dispensed into truck / hot-bin Aggregate from dryer Screens size aggregate Hot aggregate travels up bucket elevator

  12. Aggregate and bitumen weigh hoppers Bitumen Weigh-hopper

  13. Aggregate Hot Bins

  14. Warren Brothers Patent Application Drawing: Original Batch Plant

  15. Belt Scale Calibration Cold feed system Belt scale Reference scale

  16. Cold Feed Bins and RAP Bin

  17. “Graphing the Feeders”

  18. Tachometer Mounted on Tail Pulley of Cold Feed Bin Belt

  19. “No Flow” Paddle at Feeder Discharge

  20. Induced Air Burner

  21. Fuel Reticulation and Heating System HFO Tank In-line heater HFO Sampling pt

  22. Temperature Profile of Counter-Flow Dryer Heating Combustion Drying 800º C 760º C 120º C 400º C Gases Aggregates Aggregate 0º C 150º C 150º C 300º F 100º C 20º C

  23. Drum Flights / Lifters

  24. Primary and Secondary Emission Control Primary Dust Collector Filtered Air Secondary Dust Collector Fines collected and returned Drying Drum Exhaust Fan

  25. Primary Collector:Cyclone

  26. Multi-Tube Collector Outlet tube Gas inlet Spin vanes Inlet tube Collector element Valve

  27. Discharge Housing Functions as a Knockout Box Air Gas flow Optional knock down plate Bitumen Fines mix with hot mix asphalt

  28. Cutaway Section of a Typical Baghouse

  29. Pulse Jet Baghouse Exhaust fan Exhaust fan Manifold Manifold Dust screw Dust screw

  30. Automatic Damper Controls

  31. Hot Elevator Cyclone feeding fines directly back Batch tower Cyclone, Screw Collector, and Hot Elevator

  32. Filler Weigh-Pod After Surge Silo

  33. Emission Control Summary • Remove particulate matter • Primary • Secondary • Return fines to the mix • Affects void content • Affects mix stiffness • Difficult to control

  34. Batch plant filtration

  35. Aggregate storage

  36. Aggregate Storage

  37. Bitumen Storage BITUMEN TANKS – ELECTRICALLY HEATED/ 24 HR TEMPERATURE MONITOR AND CONTROL

  38. Old Style Operating Cabin

  39. Plant automation: Modern control cabin:

  40. Plant automation

  41. Roodepoort Op Screen Plant Automation – Operating System Graphics

  42. Batch Plant Schematic

  43. Batch Plant Op Screen

  44. Laboratory from the past

  45. Modern Asphalt Laboratory

  46. Quality Control Trends Monitored Binder Content Voids in Mix Filler Content

  47. Slat Conveyor Feeding Storage Silos

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