How an Asphalt Plant Works - Batch Asphalt Plant

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HOW AN ASPHALT PLANT WORKSAtlas Industries
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• How an asphalt plant works this question is
  asked many times. In this blog post I will try
  and explain the working of asphalt mixing plant
  in a simple manner. We also have an
  easy-to-understand video explaining the working
  (operation) of asphalt batch mix plant see the
  video
• The aim of an asphalt mixing plant is to produce
  hot mix asphalt. It can do so in a batch type
  process or a continuous process. The plant for
  producing hot mix in batch process or continuous
  process are different.
• Asphalt plant uses aggregates, sand, bitumen and
  filler material to produce hot mix asphalt. This
  is also called as asphalt concrete or blacktop.
  It is then paved and rolled so that it can be
  made ready for use. The main purpose of the
  asphalt mixing plant is to heat up the aggregates
  and mix them with bitumen and other materials.
  Heating is done at specific temperature and
  mixing is for a specific time. This process helps
  to generate hot mix asphalt. Aggregates used can
  be one, two or more different sizes depending on
  the requirement of the job.

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Types of asphalt plants batch and continuous
(drum) type

• There are primarily two different types of
  asphalt mixing plants
• Batch type
• Drum type
• There are key differences in the operation
  (working) method of each of the type of asphalt
  plant. The process of a drum type plant is much
  simpler than a batch type of asphalt plant. Batch
  type employs a more complex process to produce
  hot mix asphalt. The continuous type plant (drum
  mix) produces hot mix asphalt in a continuous
  process. These plants are called as continuous
  asphalt mixing plant or drum mix asphalt plants.
  Then we have batch type asphalt plants also known
  as tower asphalt plants. These plants produce hot
  mix asphalt in specific batch sizes.
• The method of producing the end product in both
  the type of asphalt machines are different. Even
  though the end product is the same, the quality
  of the end product produced from both the plants
  is different. Batch plant produce a better
  quality of hot mix asphalt compared to a drum
  type plant.

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How an asphalt plant works Batch asphalt plant

• The working of an asphalt mixing plant depends on
  its type. The batch type will produce hot mix
  asphalt in batches. Below is explanation of how
  an asphalt batch plant works
• Aggregate is the first component that we start
  our process with. Different sized aggregates are
  fed into the different feeder bins. This helps in
  getting proper proportion of each size as per the
  need. Each bin will have individual gear and
  variable speed drive motor. It is possible to
  control the speed of each bin to get proper
  proportion of each item.
• Drying drum will receive the aggregates once
  they pass through the primary screening unit.
  Rotating drum is inclined to allow smooth passage
  of the aggregates.
• Burner unit will heat up the aggregates so
  that they are ready for coating with bitumen and
  filler. As the air along with dust particles
  enter, heavy dust particles are trapped by the
  pre-separator. Air is made to pass through series
  of bags inside bag filter. Lighter particles will
  get accumulated on the bags and clean air will
  pass through the dust collection system. Filter
  bags are cleaned thoroughly and all the dust
  collected is carried through screw conveyor.
• Filler is stored in filler silos or filler
  bins and available for mixing. Filler is
  transferred via a screw or bucket elevator to its
  weighing unit.

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• Hot aggregate elevator will take up the heated
  aggregates to the top of the tower unit.
  There are many buckets driven by a chain
  system to carry the aggregates.
• Multi deck vibrating screens will receive the
  aggregates from the hot elevator. It will
  separate the aggregates as per the different
  sizes.
• They are then stored in the hot bins in
  separate compartments. Hot bin compartment is
  below the screening unit. Each compartment has
  radial gates to feed aggregates into the weighing
  hopper.
• Aggregates will be discharged from the hot
  bins as per the pre-defined recipe.
• Bitumen is stored in tanks. Here they will be
  heated to make it flow easily. There can be more
  than one bitumen tank to allow sufficient storage
  and uninterrupted flow of bitumen. It is
  transferred via pipeline to the bitumen scale.
  Bitumen and filler are received by its respective
  weighing units. Here they are accurately measured
  prior to discharge into the mixing unit.
• All components are added into the mixer for
  mixing. The powerful mixing force ensures that
  aggregates are rapidly and evenly encased with
  layer of bitumen. They are discharged via the
  door below the mixer.

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Hot mix asphalt can also be stored into the
silo from where it will be ready to be discharged
into the truck. After the mixing cycle
the homogeneous mixture of hot mix asphalt is
ready for laying. Working of
the asphalt mixing plant is controlled by the
system. It has all the features and controls for
each part. Adding and editing recipes is possible
from the control panel.
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How an asphalt plant works Drum asphalt plant

• The continuous type will produce hot mix asphalt
  in a continuous process. Continuous asphalt
  plants are also known as drum type or drum mix
  asphalt plants. Below is the explanation of how
  an asphalt drum plant works
• Different size of aggregates are fed into the
  different feeder bins. Each bin will have
  individual gear and variable speed drive motor to
  allow proper grading.
• Drying and mixing drum will receive the
  aggregates once they pass through the primary
  screening unit. Drum is rotating and is inclined
  to allow smooth passage of the aggregates. This
  drum unit is equipped with a burner unit. Drum
  will heat aggregates as well as mix the
  aggregates with bitumen and filler material.
• Burner unit will heat up the aggregates in the
  first half of the drum. They are now ready for
  coating with bitumen and filler. This coating
  with bitumen and filler material is done in the
  second half of the drum.

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• As the air along with dust particles enter, dust
  particles are trapped by the wet dust collector.
  The heavy and light dust particles are trapped by
  the jet flow of water and then treated to a
  cyclonic effect. Once this is done, they will be
  discharged out in form of a sludge.
• Filler is stored in filler silos or filler
  hoppers. Filler is pushed into the drum via a
  compressor.
• Bitumen stored in tanks are heated to make
  bitumen flow easily. There can be more than one
  bitumen tank to allow sufficient storage and
  uninterrupted flow of bitumen. It is transferred
  via pipeline through a bitumen pump.
• Once bitumen and filler are received into the
  other half of the drum, they will thoroughly coat
  the heated aggregates.
• Control panel will control the flow of all the
  materials. All the important mix material data
  can be printed out.
• We produce and export asphalt batch plants of
  60-80 tph, 80-100 tph, 100-120 tph, 160 tons, 180
  tph, 200 tph and 260 tph per hour. Our hot
  asphalt batch mixers come with a host of
  components and features. The machines are with
  top quality component and promise smooth
  operation.

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Contact Us
Atlas Industries Pvt. Ltd.
Address Plot No. 14, 1, GIDC-II, Dediyasan,
Mehsana, Gujarat 384002, India For export
inquiries 91-97238 10565 For domestic
inquiries 91-98240 40565 Website
https//www.atlasindustries.in/ Email
contact_at_atlasindustries.in