Types of Plants

There are two basic types of plants used

to manufacture hot-mix asphalt
Hot mix asphalt batch plants
and Drum mix asphalt plants.
Both plants are capable of producing
quality Hot Mix Asphalts

The difference between the two plants is

that the batch plants dry and heat the
aggregate and then in a separate mixer
blend the aggregate and asphalt one
batch at a time

Drum mix plants dry the aggregate and

blend it with asphalt in a continuous
process in the same piece of equipment
Common Components of Different
Plants

There are many components common

to batch and drum plants as can be seen
at left.

These include:
Cold feed bins
Asphalt binder storage
Dryer
Emission controls
Storage silos
Hot Mix Asphalt Plants

The capacity of a hot mix asphalt mixing plant is indicated by two

indicators.

For example 60/90TPH means that the plant has a minimum capacity of 60
tons per hour and a maximum capacity of 90 tones per hour.

The capacity is generally based on the mass (with a mass not less than 2160
kgs per cubic meter) and the moisture content (6% to 2%) of the material.

In order to maintain optimum operation and output, the feed to the plant
should be in the proportion of the required end product.
Functions

(i) Heating and drying the aggregates.

(ii) Screening the aggregates into required sizes and measuring the
required quantity of the aggregate, the filler and bitumen.

(iii) Mixing the aggregate, the filler and the bitumen in required proportion
and to produce homogeneous mix.
Asphalt Batch hot mix Plant

The hot mix plants consists of the following

1). The cold aggregate feeding bins to feed the aggregate to the drier drum

2). The drier a revolving cylindrical drum where the aggregates are heated.

The drum is also provided with a burner and a dust collector

3). The screens which are provided in deck form separates the aggregates into
the required sizes whilst deselecting the oversized aggregates.
.
4). The aggregate weighing system weighs the various sizes of aggregates and
allow them for mixing in a desired proportion.

5). Bitumen storage tanks, have heating system with a thermostat to keep the
bitumen at a constant temperature.

These tanks are provided with the heat insulators.

6). The mixing unit, which consists of a box with 2 horizontal shafts rotating in
opposite directions.

These shafts are fitted with removable mixing paddles.

These mixing boxes have an opening gate at the bottom at a sufficient height to
discharge into the waiting dump trucks
1. Bin Feeder
Generally 4 hoppers are provided which feed the coarse as well as fine
aggregates.

The capacity of these hoppers depend upon the capacity of the hot-mix plant.

The hoppers used for fine aggregates and sand are fitted with intermittent
vibrators, so that flow remains continuous and uniform.

The feed hoppers are loaded through wheel loader or directly by the Dump
trucks.

Each hopper has a gate, the opening of which is graduated, so that the gate
opening can be set according to proportion required of the particular size of
the aggregate
2. Drier
Drier consists of a long hollow steel cylinder with firebricks lining and
containing projecting radial fins.

The inlet end is kept slightly higher than the outlet, at the time of the
installation of the plant.

Heat is supplied by a jet of flame, fed by air vapourized oil provided at the
lower end.

The burner flame can be adjusted from the control cabin as per heat
requirement to get a proper temperature.
As the cylinder rotates, the aggregate is carried to the top by the fins, from
where it falls downward and a little towards the outlet due to inclination.

This way the aggregate proceeds further.

By the time the aggregates have traveled the length of the drier, they are free
from moisture and heated to the required temperature.

If the aggregates being fed to the drier are wet, the heating capacity of the drier
is greatly reduced and heating cost increases.

The rotation of dryers is obtained by means of an electric motor

The hot aggregates are then delivered to the hot elevator,

whose function is to carry hot aggregate from the dryer to the vibrating
screen in the gradation control unit.

The hot elevator is similar to a cold elevator, except that hot elevator is
totally enclosed to prevent the heat loss.
3. Dust Collector
To get a proper combustion and heating effect, a draft is created by
providing an exhaust fan and a chimney.

But this draft carries with it much of the fine dust introduced with the
aggregate, which not only is wasted but also creates a public nuisance in
settled areas.

These lost fines are generally replaced by expensive mineral filler.

The dust collectors are therefore provided to trap the fine particles and
return them to the heated aggregates below the drier.

The dust collectors may be of either

(i) cyclone type dry dust collectors, which returns the fines to the
aggregates, or

(ii) wet dust collectors, which collects the dust by means of atomised
water, or

(iii) dust bag filters.

4. Filler Storage Bins

Hot recovered fines are stored in these storage bins and additional filler
materials are also stored in these filler storage bins.

These are also provided with metering systems so as to feed the filler
material in required proportion.
5. Screening, Weighing, and Mixing Units

The vibrating screen of 4 sizes separates the aggregate into the required sizes
throwing out the oversized stones.

The 4 sizes of aggregates are collected in four aggregate storage bins.

Each size of the aggregates are weighed accurately in a weighing hopper.

The weights are indicated on a dial provided in the operator's cabin.

The hot aggregate is then fed directly to the mixing unit also known as a
pugmill.
The filler bucket elevator, brings the filler material to the filler storage
hopper.

This hopper is connected to a separate weight-dial.

The weighing hopper of the filler has a discharge door of width equal to that
of mixer, so that the filler distribution is immediate and uniform.

Predetermined percentage of bitumen, as analysed by the quality control

laboratory is fed through a bitumen metering device.

This weighed bitumen is sprayed over the whole mixer area for uniform and
quick coating.
6. Bitumen Heating System

(a) Bitumen storage and heating tanks.

These are used where the bitumen is transported in bulk from refinery to hot-
mix plant in bitumen carriers.

These consist of thermic boilers where the oil is heated by means of a burner
operated with diesel as fuel.

These are also provided with a thermostat arrangement to automatically start

and stop the burners so as to keep a constant temperature in the tank.

The heated bitumen at a prescribed temperature is fed through a pump to the

mixing unit. The excess bitumen returns back to the main bitumen tank.
(b) Melting Furnace for Bitumen in Drums.

The hot chamber for drum decantation holds number of drums.

The lifting and positioning of the drum is effected by an hoist and

hydraulic pusher for positioning and causing the exit of the empty drum.

The melting tank is insulated and has a burner which uses diesel as fuel.

It also has a thermometer.

It also feeds the bitumen into the mixing unit through a pump.
7). Control Cabin
Control cabins are located at a place where the operator can observe the
complete hot mix plant. The cabin is dust proof and air conditioned. These
control cabins have a number of indicators and controls. The important ones
are

1). Material storage control

2). Burner rate control
3). Burner ignition control
4). Emergency siren
5). Bitumen pump control
6). extractor belt control
7). Feeder belt control
8). Switches for various motors
Good Quality Mixing
To ensure Asphalt hot mix of good quality following precautions should be
adopted:

1. Aggregate Feeding
1). Feed hoppers should be fed with correct sizes of aggregate and should
always be kept sufficiently full so as to get an even flow of the material.

2). Feeder gate opening should be carefully calibrated in volumetric

proportions depending on the job mix formula.
3). Fine aggregate should be fed first on the belt conveyor, therefore fine
aggregates should always be loaded in the first of the 4 hoppers.

4). Mineral filler should be dry.

5). Arching of fine aggregate should be prevented by providing a vibrator

on the outside of the hopper.
2. Drying
1). Burner should be adjusted for correct operation so as to get a trouble
free flame which will facilitate a constant temperature.

2). The drier should not be overloaded by allowing more aggregates than
it can handle.

3). The dried aggregate temperature has to be carefully monitored.

3. Screening and Hot Aggregate Storage

Screens should be checked periodically for clogging and wear. Since

clogged screens will reject the correct size aggregates, whereas worn screen
will allow oversize aggregates.

4. Bitumen
1). Bitumen should be maintained at the correct temperature.

2). Add bitumen from the bitumen carrier into the tank at the correct
temperature, specially when the plant is in operation.
5. Material Proportioning
1). The aggregate, filler and bitumen weighing scale should be correctly
calibrated and checked from time to time.

2). The temperature of the aggregate should always be correct.

6. Mixing
1). The clearance between the paddle tips and the inside lining of the
mixing box should be checked periodically.
Normally this clearance should not be more than 2 cm.

2). To get a homogeneous mix each batch should have correct quantity of
material.
DRUM-MIX ASPHALT PLANTS
Drum-mix Asphalt plants are becoming more and more popular because,
initial capital investment cost of these plants is less than that that of
conventional batch, type asphalt mix plants.

Running costs are also greatly reduced due to fewer moving and wearing
parts.

These plants consist of following main components :

(a) Cold aggregate feeder with mineral filler supply system
(b) Drier and mixing unit with Dust collection system.
(c) Bitumen storage, heating and delivery system.
(d) Mix storage unit.
(e) Operator cabin and controls.
a). Cold Aggregate Feed System.
It is essential to feed these mixers with accurate proportions of aggregate sizes.

Multi compartment bin feeder system ensures this accuracy.

The number of bin hoppers could vary based on the requirement of asphalt mix
specifications. However 3 to 5 bin systems are common.

Each bin hopper is loaded with a specific size of aggregate which is discharged on
the collecting conveyor.

These bin hoppers are mounted on a rigid frame.

Cold Feed Bins

Aggregates are typically moved from

the stockpiles to the cold feed bin using
a front-end loader.

Cold feed bins are used to accurately

meter the different aggregates used in
the mix to the drying drum.

The amount of each aggregate is

controlled by a combination of the gate
opening at the bottom of the bin and
conveyor belt speed.
Aggregate Feed System

A conveyor below the cold feed bins

transfers the aggregate to the dryer where
the aggregate is dried and heated.

Because drum plants produce mix

continuously, a weigh scale is used to
weigh the aggregate before it enters the
dryer so the amount of asphalt binder can
be accurately added.
Each bin has independent belt feeder under it driven by independent and
mutually synchronised variable speed electric motors.

Each bin hopper is fitted with precision adjustable quadrant gates.

With the variable speed electric motors the belt speed can be accurately varied
to regulate the rate of aggregate flow from the bin.

When the discharge rate of each aggregate is required to be controlled by

weight, weighing system is provided on each belt conveyor to indicate the
weight in T.P.H. (tons per hour) on gauges in the operator's cabin is provided.
Synchronised variable speed motor is provided to increase or decrease the
aggregate flow in same proportion from each bin in order to increase or
decrease the production of mix.

Smallest size aggregate hopper is fitted with anti-clogging electro

mechanical vibrator on one of the side plates to maintain continuous flow of
material.
Filler is accurately proportioned by screw conveyor with a variable speed
motor, from a bulk storage silo or bag filled arrangements.

Filler may be mineral dust, lime or cement.

Sometimes these are directly fed into the mixing zone of the dryer drum.

The weight of the aggregate in T.P.H. is indicated in the cabin.

A signal from the belt weighing mechanism is transmitted to the plant

control system so that adjustments can be automatically effected.
Dryer and Mixing Unit.
A drum mixer is basically a long rotating cylinder fitted with a burner in
which aggregate is mixed, dried and coated with binder.

Inside the drum, aggregates are first thoroughly mixed in cold state and
then dried and heated.

In the latter half of the drum, binder is added and final mixing takes place.

The drum is fitted internally with renewable curved and angle flights.

The drum rotates in machined rings generally two, supported from barrels
on brackets. Drum is driven by steel chain sprocket ring bolted to drum.

Drive is by a sufficiently strong electrical motor.

At first sight a drum-mixer could be mistaken for a conventional aggregate
dryer (as in Batch type plants), but these have following important differences:

1). Longer Length. Since these have three processing zones i.e. cold mixing,
heating, and bitumen coating, against only heating in conventional dryers, and
hence are longer in length for the same diameter.
(ii) Material Flow: Drum mixers employ parallel flow principle of operation
which means that material enters the drum at the burner end, so that aggregate,
flame exhaust gases and steam move in the same direction.

Conventional dryers operate in counter-flow with the burner situated at the

discharge end firing against the flow of aggregates.
(iiii) Burner Flame.
In drum mixers, the burner flame stops short of the bitumen mixing zone
and is wide and flat, whilst in conventional dryers, the flame reaches the full
length of the cylinder and is long and penetrating.

(iv) Internal Construction.

Drum mixer internal flights are designed and arranged to perform specific
duties in their respective zones during operation.

Specific functions performed in each zone in the cylinder are :

In Zone 1, cold wet aggregate with filler, water or additive are mixed
together before being subjected to the heat from the burner flame.
In Zone 2, the moisture is evaporated and the aggregates heated in an area
where the radiated heat from the burner and the conducted heat from the drum
is at its maximum.

In zone 3, the binder is added to the partially dried and heated aggregate,
mixing in this zone produces a homogeneously mixed material.

Number and functions of zones vary free manufactured to manufacturer.

Some has 2 zone : Heating and mixing, some has 3 zones for heating, bitumen
spray and mixing respectively.
Burner

Multi Nozzle single flame burner is fitted in the dryer drum.

In advanced dryer drums burners are 'Turbo Jet' type fully automatic.

Fuel oil is pumped at the required pressure to the burner nozzles and
combustion air is supplied by an axial blower.

The burner is infinitely variable between maximum and minimum settings.

Emission Control System (Dust
Collection)

As hot air passes through the

aggregate it picks up some fine sand
and dust particles.

These particles are removed by the

emissions control system before the
air goes into the atmosphere.
Most plants have primary and
secondary collectors to remove these
particles.

The fine sand and some dust is

collected in the primary collector and
returned to the mix.

The secondary collector removes the

remaining fine dust.

In most cases this dust can also be

returned to the mix.
(c) Bitumen Storage, Heating, and Delivery System.

Bitumen is heated in bitumen storage and heating tanks by any of the means,
like, hot oil circulation, direct oil fired or electrically heated.

Hot oil heaters are more common.

In these, oil is heated up by means of fully automatic burner to a pre-set

temperature (normally 120° to 210°C).

The heated oil is circulated by the hot oil circulating pump to keep the asphalt
tank and pipe lines at a pre-set temperature.
These tanks are insulated having a level indicator, thermostat, temperature
indicator, pumps for sucking bitumen from bitumen carriers, feeding to the
bitumen distributors or carriers, and transferring the bitumen from one tank
to another.

All pipe lines and fittings are either steam or oil jacketed and properly
insulated to prevent loss of heat.
Heated binder is delivered to the plant by a positive displacement pump
via the gauged flow control valves operated by an electric actuator, rotary
piston type meter, and pneumatically operated ring main valve.

The binder percentage required is preset at the control console and

signals received by the ratio controller from the belt weighing mechanism
will automatically adjust the binder feed rate to meet the mix
specifications.

Delivery rate of bitumen is also indicated in T.P.H. (Tons Per Hour) on the
control console.
(d) Mix Storage Unit:

Since the process of mixing is continuous, a mixed material storage system

is essential.

A storage silo can be fed either by a conveyor carrying the mix from dryer
drum to the silo or by a bucket elevator.

To eliminate segregation of mixed material when falling into the silo,

intermediate hoppers are incorporated in the design.
An unloading system is provided to facilitate
placing it into the waiting trucks.

The discharge height of the silo is decided

accordingly at the time of erection.

Discharge of the mix is controlled through a

suitable hydraulically operated gate.
(e) Operator's Cabin and Control.

A fully automatic centralized control panel with off-on push buttons,

indicator lights, gauges etc. is provided inside a cabin, like that for a batch
type asphalt plant.

From this cabin an operator can monitor and control all motors, burners,
blower, belts etc. and control the temperature and flow of aggregate,
bitumen, arid filler etc. and also control the mix storage gates etc.
Advantages of Drum-Mix Plant Over Conventional Plant

Like conventional plant, these do not have the hot aggregate elevator
screen, hot aggregate bins, weigh hoppers for gradation control, and pedal
mixers and their associated wearing parts.

This feature results in following main advantages :

(a) Expenditure on spare parts reduces considerably.
(6) Expenditure on men-hour for maintenance is also reduced.
(c) This reduces the requirement of power.
(d) Initial cost of the plant is less than that of a similar capacity
conventional plant.
These plants are simple and easy to operate.

Easy to transport from one site to another.

Most important advantage of this type of plant is that, the chimney of this
type of plant emits less dust than a traditional plant.

This is because the heating and mixing process is carried out in the same
drum which renders this type of plant self-dust collecting.

Thus these plants are economical, saves energy, highly mobile, protects
environment, high quality coated material production besides having lower
capital investment and maintenance costs.
MIX-DEFECTS
Following defects are generally noticed in asphalt mixes :

1). Mix too Cold.

Such mixes are stiff and difficult to handle, larger particles are not properly
coated. Spreading of mix is difficult.

2). Overheated mix.

These results brown, dull burnt surfaces in appearance. Overheating is
indicated by excess blue smoke from the mix.

3). Excess Bitumen.

This indicated by a sloppy mix which slumps too readily even in the dump
trucks.
4). Lack of Bitumen. Such mixes give a dry lean appearance lacking the
shiny black lustre of a well coated mix. this is difficult to spread, and
transverse cracks may appear under the roller which do not readily heal up.

5). Poor Mixing. Such mixes will show in some areas as lean and brown
surface (where bitumen is less), and other areas as shiny and black (bitumen
is excess).

6). Poor Grading. If coarse aggregates is more, the mix appear to be rich,
though workability will be poor, and the appearance when laid will be rough
and open textured.

On the other hand when fine aggregates are more the mix appears lean and
too finely graded when laid.

On compacting the excessive fines will show persistent heaving.

Ideal conditions for maximum production

Asphalt mixing plant gives maximum production when overall conditions are
good, with respect to the quality of aggregate, climatic and weather
conditions, state of the mixing plant and the following additional factors.

1). Moisture content of the aggregate material fed to the plant is less that 3%.

2). Feeding aggregate material, passing through 200 ASTM (75 μm) sieve, is
less than 1% in weight.

3). Feeding aggregate contain a minimum quantity of chips and flakes.

4). Temperature of the of bitumen is not less than 180-200°C according to
the degree of penetration of the bitumen used.

5). Required temperature of the mix is not more than 110°C.

6). Fuel oil used for the burner has a heat value not less than 10,500
calories per kilogram.