Asphalt Plant Production for Sale

What is Asphalt Plant?

Asphalt Plant is a complex machine that produces asphalt. As POLYGONMACH, our company can manufacture Asphalt Plants according to the demands of our customers in the desired capacity and design according to the needs of our customers.

Asphalt Plants that are generally used in areas of road construction, highways, and various parking lots can be manufactured as mobile or fixed for easy and fast installation. As a rule, fixed asphalt plants are installed in places far from the town. At the same time, mobile plants are installed in places near a city for an immediate requirement of road repair or repair of damages in asphalt areas by providing a quick and effective response. Simultaneously, this situation can sometimes be the subject of protests due to air and environmental pollution concerns. However, the asphalt plants produced by POLYGONMACH are environmentally friendly and planned to emit the least harming gas to the environment.

Thanks to this machine, which is composed of different equipment, the inputs used in asphalt production-aggregate, bitumen-are combined in a mixer at the optimal amount and temperature, and after adding and mixing bitumen, finally asphalt product is obtained.

Advantages of Asphalt Produced in Asphalt Plant for Sale

Asphalt is a material produced in asphalt plants-which we also manufacture as POLYGONMACH-by mixing bitumen with aggregate at certain heat rates. The low cost due to its operation has made it attractive for insulation and the construction of roads. According to studies conducted, asphalt reduces noise to around 5 dB(A). Compared to other materials that could be used on this place, asphalt production has a lower energy consumption. Also, asphalt roads reduce friction between the wheels and the road; therefore, fuel consumption is reduced.

The most outstanding distinctive feature of asphalt is that upon heating, it softens and turns into a fluid, while upon cooling, it will harden again. On its normal air temperature, asphalt behaves as if it were a solid, for at the highest temperatures in summer, it practically doesn't soften. However, it is possible to make it fluid by heating, which makes road construction easier. Thanks to its elasticity, it absorbs pressure; instead of breaking, it moves in a flexible form and therefore can self-repair.
Keep in mind that asphalt pavement is economical, durable requires less maintenance and at the same time friendly to the environment.

Paver asphalt can be laid in half of the time and at a much lesser cost compared to concrete. In addition, it has the following advantages over the concrete. These are as under:

Whenever cracks develop in the asphalt they can be repaired at a much lesser cost.

As compared to the concrete snow and ice melt in much lesser time due to the heat absorbed and trapped on the surface of the asphalt.

Although the use of salt deforms the concrete, it does not spoil the asphalt.

Compared to concrete, asphalt is an environmentally friendly material. Because while it is possible to recycle asphalt, this is not the case with concrete.

While it exfoliates like concrete, this is not the case with asphalt material and asphalt is much less likely to crack.

Quality Asphalt Material Production Stages

What is important in the asphalt plant is to ensure that all necessary procedures are carried out to obtain a product of desired quality. Many plants have electronic gadgets and devices, so, above all, attention has to be given to the calibration of the devices for the realization of quality asphalt products.

The high-quality equipment is used in the Asphalt Plants manufactured by POLYGONMACH, and the necessary theoretical and practical trainings are given to our customers on using and calibrating these equipment.

In particular, whether or not asphalt weighing scales measure correctly, continuous calibration settings, routine maintenance and control should be performed to ensure that the heaters can provide the required quantity of heat.

Similarly, it should be checked whether the mixer which performs the mixing task functions in the required time. Aggregate and bitumen, the main building materials of asphalt, should constantly be checked whether they are transferred to the mixer in the right amount or not and aggregate dried at the required temperature.

The most important points to be taken into consideration in obtaining the material to be used in asphalt construction:

1-Making the mixture with the right amount of ingredients

2-Determining the temperature setting in the most optimum way

3- Taking the materials to be mixed in the mixer in the right order and amount and making the dehumidification process without errors are the most important issues affecting the quality of the asphalt.

Asphalt Plant consists of the following parts:

Cold Aggregate Feed Unit

The cold aggregate feed unit is an integral unit of an asphalt plant, which is engaged in the job of storing and proportioning various sizes of aggregates that are to be mixed with bitumen in due course. It normally consists of a number of chambers meant for different sizes of aggregate that facilitate the accurate and controlled feeding into successive stages of the asphalt production process. The cold aggregate feed unit ensures a continuous supply of the aggregates into the dryer drum, where they get dried and heated up to a set temperature before being mixed with bitumen to come up with asphalt mix.

Dust Separator Auxiliary Filter

The dust separator is essentially an auxiliary filter in the dust control system of the asphalt plant. It is intended to intercept and separate the particulate matter emanating from the dust and fines that one can expect from the exhaust fumes coming out of production activities. This filter has immense importance in maintaining air quality through prevention of dust emission to keep up with environmental stipulations. It helps dust separator auxiliary filter reduce the load in the air due to pollution while lessening the impact of the plant activity on the surrounding atmosphere, as it cleans contaminants from the exhaust fumes.

Conveyor Belts

In an asphalt plant, conveyor belts are deemed an indispensable component that is used for transporting aggregate, filler materials, RAP, among other materials, from one stage to another within the production process. These belts are heavy-duty and designed to bear massive loads in order to keep the flow continuous in the plant. The conveyor belts come in many configurations, such as incline or horizontal, and may contain different belt surfaces depending on the material handling requirement. Either way, effective maintenance and monitoring of conveyor belts is necessary for smooth operation and productivity at the asphalt plant.

Mixer

In the asphalt plant, mixers are the points where the main hot aggregates and bitumen are mixed to achieve the final asphalt mix. There are different mixer models used depending on the needs of production, be it batch mixers or continuous mixers. A mixer should ensure that proper mixing is achieved for hot uniformity and a consistent asphalt mix that will meet quality and performance standards. It plays a very important role regarding the final characteristics of the asphalt mixture, temperature, gradation, and quality.

Aggregate and Filler Elevator

The elevator for aggregate and filler in an asphalt plant is meant for lifting and conveying aggregates, filler materials, and other granular substances from the cold feed unit of the aggregate to the dryer drum or mixer for further processing. This elevator ensures a continuous feeding of materials into the subsequent stages of the asphalt production process at all times, thereby the ability of the operation to run seamlessly and the mix to be optimal. The elevator will handle different types of material in a coherent manner so that the flow is maintained to realize a proportionate asphalt mix.

Weighing Scales

Every weighing scale at the asphalt plant is a precision instrument that must be utilized specifically to accurately measure and proportion the various constituents of an asphalt mix, which includes aggregates, filler materials, bitumen, and additives. These scales must be interfaced with the control system for correct and accurate batching of materials according to the mix design requirements. The all weighing scales are critical to the quality control of the asphalt mix in that it provides the right proportions of each component added towards the production of a uniform, high-class end product.

Vibrating Screen

In an asphalt plant, the vibrating screen forms part of the screening system that separates and classifies aggregates into different sizes. It consists of successive decks or layers with different opening sizes that allow efficient segregation at various fractions. This screen will help eliminate oversized particles, regulate the gradation of the aggregates, and ensure that the asphalt mix is uniform. Thus, proper screening of the aggregates by the vibrating screen ensures that the final asphalt mixture attains intended quality and consistency, hence ensuring superior performance and durability of the paved surfaces.

Storage Silo

A silo is basically a storage structure or any other form of storage commonly used in an asphalt plant for the purpose of storing raw materials, such as aggregates, filler materials, or RAP that are to be used in the production process. This is normally done in a multi-compartment silo in order to allow for storage of various types and sizes of these materials independently. Storage silos are used to maintain a constant and controlled feed of materials to the plant; it provides for efficient and systematic storage of bulk materials. Capacity and design of the storage silos may very well depend upon the production requirement of asphalt plant. The storage silos should be maintained and monitored on a routine basis to avoid segregation of material and material quality for optimization of the plant operations.

Dryer

Basically, drying drum or dryer drum is the essential component of an asphalt plant where the aggregates are kept dried and heated for producing asphalt mixtures. Aggregates enter the dryer drum and are exposed to heat and air flow in order to take out moisture to attain proper temperature in order to mix with bitumen. These dry aggregates are critical in terms of quality and performance of the asphalt mix, enabling adequate adhesion among aggregates and binder. In general, productivity and quality of the asphalt plant depend on the design and efficiency of the dryer; it is thus regarded as one of the major components in the process of asphalt production.

In fact, asphalt material passes through some production stages until it is produced. These steps, which will be followed until the asphalt material is ready for paving, can only be achieved when taken according to a predetermined plan.

The heterogeneity of the input materials used in asphalt production and the systematicity of the stages in the processing of these materials are specific and necessary conditions for asphalt production. For this reason, continuous inspection and surveillance undertaken by engineers and qualified personnel who are experts and possessing the required qualifications prevent any irregularity in the whole production course. Due to this control and inspection, in other words, the mixing conditions of the input materials, quality of the aggregate or bitumen material to be used in production, and the quantity balance will determine the quality of the asphalt to be produced.

Cold silos are used for storing and protecting the aggregate to be used in asphalt production. In the next stage, a drier is used to dry the aggregate, which is further used in the mixer. It shall be ensured that the right amount of aggregate is sent to the dryer and later transferred to the mixer. The aggregate to be utilized is heated and dehumidified with the help of a drier. Inside the drier, there is a flaming zone in the form of a rotary boiler where the drying process is done. One of the points to be considered here is to make sure of a healthy accumulation of the powder material which emerges after the drying process. This accumulation is done with the help of a device called dust collector. The products, which have been passing through the elevator used as a transferring system and which is protective against temperature, have been classified into desired sizes by means of the vibrating sieves. The aggregate, transported from the dryer into the elevator and from there into the vibrating sieves, sieved and having the desired temperature, is kept in the section called a hot waiting bunker just before it is weighed and sent to the mixer.

The correct storage of bitumen is then transferred to the mixer where the mixing shall be done to produce quality asphalt. Hot bitumen tank is used in transferring the bitumen material that shall be used in the production of asphalt. The desired quantity of the bitumen is transferred to the mixer by the pumps in the bitumen scale, whereby in this mixer the aggregate and the hot bitumen will be blended together. The hot asphalt produced in the mixer is transported and stocked.