Asphalt Plant Speco.

LTD
Model: BM 1500

CAPACITY

Max. 120 T/Hr. (Based on 4% moisture content)

MIXER

1500kg/batch

TYPE

Batch and Stationary type

OPERATION

Automatic / semi-automatic / manual / Fully computerized control system in English

Parts and Description

1. COLD BIN & BELT FEEDER - These feeders and belts are used to handle cold aggregates (such as
sand, gravel, and crushed stone) in asphalt mixing plants.

Features:
Proven Performance: They operate effectively even under harsh conditions.
Frequency-Controlled Dosing: Precise dosing of aggregates.
Trouble-Free Flow: Ensures smooth material flow.
Vibrator: Facilitates the flow of fine materials.
 Control from Cabin: The process can be monitored and controlled from the control cabin.
Grid: Prevents the passage of coarse material.
Total Proportional Control: Offers flexibility and accuracy

2. HORIZONTAL BELT CONVEYOR - Horizontal belt conveyor is a conveyor system that uses a
continuous belt to move materials horizontally. It is commonly used in industries such as
manufacturing, mining, agriculture, and logistics for efficient material handling and
transportation.

3. SLANT BELT CONVEYOR

4. DRYER - A dryer is an important component of an asphalt plant. It consists of a revolving cylinder,
a large burner, and a fan. The revolving cylinder is lined with long vanes called “flights,” which
spread the aggregate into a veil to ensure proper drying.

5. BURNER - The burner is located at the lower end of the dryer, so while the aggregate is moving
down, the hot gases are moving up. The dryer is used to dry and heat the cold aggregate and mix
the mixture in the asphalt drum plant, while in the asphalt batch plant, it is only used to dry and
heat the cold aggregate
6. HOT ELEVATOR - A hot elevator in an asphalt plant serves as a conveyor for carrying hot
aggregate (which exits the drying cylinder or dryer) to the hot screening sieve, where the
aggregate is separated based on size

7. BATCH TOWER (SCREEN, HOT BIN, SCALE, MIXER ETC.)

Vibrator Screen - machines used to separate aggregates by particle size by means of an exciting force
applied to the machine. The vibration lifts the material, causing it to stratify, allowing the smaller
material to move from the top of the depth of material to the bottom of the material, thus exposing
them to the screening surface.

Hot Bin - used for storing and maintaining the hot asphalt mixture produced by the mixer.

Mixer - Asphalt mixer, which is one of the most important units of the asphalt plant, turns the
aggregate, filler and bitumen discharged from the scales into a hot asphalt mixture.
 Aggregate Handling: Raw materials, such as crushed stone, gravel, and sand (aggregates), are
separated by a vibrating screen based on their size.

Hot Bins: These aggregates are temporarily stored in separate compartments called hot bins. Each
bin holds a specific type or size of aggregate.

Mixing Unit: When needed, the aggregates are released from the hot bins and fed into the mixing
unit, where they combine with asphalt binder (bitumen) to create the final asphalt product.

8. DUST SILO - These components are required between the drum and the baghouse. They are
used to control/meter the dust as a measured component of the asphalt mix design to achieve
densities, Voids in Mineral Aggregate (VMAs), etc. Additionally, we offer a wet auger system
when the fines need to be wasted or rejected.

Dust Storage and Disposal Systems:

Ancillary Equipment: These systems are designed for the transfer, collection, storage, and disposal of
dust and filler products used within the asphalt plant process1.

Types of Silos:

Low-Level Silos: Used in mobile asphalt plants.

Raised Silos: Found in conventional tower asphalt plants.

Twin Vertical Silos: Used in high-level asphalt plants with integral product storage.

Horizontal Mobile Silos: Complement ultra-mobile plants.

Dust Disposal Alternatives:

Wet Dust Conditioning Unit: Excess dust is fed into a continuous discharge mixer, where minimal water is
added. The twin contra-rotating shaft design creates a manageable dust-free cake for disposal.

Dry Dust Disposal: Directly delivers dry dust into tankers with minimal dispersion.

Mineral Filler Silos (Alternative Source):

These silos collect dust and add stored minerals to dried aggregate, ensuring precise baghouse dust
control in asphalt mixing.

Metering and Handling:

Systems accurately weigh fine dust collected from baghouse bags, transfer it to storage silos, and then
meter the required amount back to the drum mixer

9. DUST ELEVATOR
10. FILLER INPUT HOPPER
11. FILLER ELEVATOR - a vertical transport system designed to move materials like hot aggregate and
filler to different layers within the plant.
 The heated aggregate is carried over a sieve at the top of the plant using a bucket elevator. This
elevator can be either a chain-type bucket conveyor or a belt-type bucket conveyor.
 The material is then separated according to its size and poured into different bins.
 Additionally, the filler collected in the asphalt plant filter is transported to the filler weighing
area by the filler elevator
 12. OPERATION HOUSE

Baghouse Operations:

The baghouse is responsible for removing fines (dust) from the airstream before releasing it into the
atmosphere.

Visual Inspection: Regularly check the exhaust stack for visible dust. If you see any, schedule a visual leak
test to identify and address leaks promptly.

Pulse Jet Baghouse:

Maintain 80-90 psi of mainline air pressure.

Set pulse interval time to maintain a pressure drop (Delta ‘P’) of 3-5 inches.

Adjust pulse “on” duration for minimal “trail.”

Rotary Baghouse:

Set rotor speed to maintain a pressure drop of 3-5 inches.

Maintain draught through the drum between 0.1 and 0.2 inches.

Prevent excessive suction to avoid wear and gradation issues.

Shutdown Procedure:

End the blending process in the computer.

Kill pulsars/rotors.

Reverse the AC pump and open the AC valve to clean out the drum line.

Run the AC pump in reverse for about 2 minutes, then shut it down along with the pulsars/rotors.

Leave all augers running until the plant is cleaned out.

Shut down everything in reverse sequence of start-up.

Start-Up Procedure:

Proper start-up ensures efficient production:

Follow the correct sequence for turning on equipment.

Avoid running pulsars/rotors for too long to prevent excessive waste.

Maintain a positive suction in the drum to minimize puffing and wear.

Ensure bags have a layer of “cake” to protect them.

13. PRIMARY DUST COLLECTOR - used in controlling and collecting airborne dust emissions produced
during the drying and handling process.

 Skimmer Systems: These are better suited for static installations where space allows. Skimmer
systems remove coarse dust particles (between 75 and 200 µm) and reintroduce the collected
particulates into the asphalt mix. They minimize wear on exhaust ducting and secondary stage
filters.

 Multi-Cyclone Systems: Ideal for mobile equipment, multi-cyclone systems are mounted as
assemblies within the dryer section of the plant. They also remove coarse dust and contribute to
the asphalt product recipe

14. BAG FILTER - used for pollution control. It will help eliminate dust and harmful gases. Dust is
produced from aggregates and most of the time we don’t want additional dust to get into the
final product. It will spoil the final product. Harmful gases are emitted as a result of the burner
that fires the drum. These gases along with the dust is made to pass through the filter bags for
cleaning.
15. STACK
16. ASPHALT TANK – 40,000L
17. DIESEL TANK – 10,000L
18. HOT OIL HEATER - Hot oil heaters are used in asphalt factories to heat bitumen in the existing
bitumen heating systems. The machine transfers the heat towards the bitumen flask and two-
shell pipes located in the asphalt factory by circulating hot oil in the system. Hot oil heaters are
at the center of the network to process quality asphalt. They supply superheated oil throughout
the asphalt plant and are designed with efficient sections of coil. The oil is heated as it circulates
through the heating coil of the heater, which is heated by hot gases from a burner that is fired
either by natural gas or fuel oil.

19. SMA EQUIPMENT - SMA is produced in an asphalt plant in the same manner as dense graded
asphalt. However, SMA requires tighter quality control in both production and laying.
Conventional asphalt paving equipment is used and a light tack coat is normally applied.
Compaction is usually carried out by 4 to 6 passes of a steel drum roller.