Asphalt Plants and Bitumen Emulsion Equipment
What is an Asphalt Plant? What are Bitumen Emulsion Equipment?
Polygonmach, with its leading name in the construction industry, offers a wide range of asphalt and bitumen processing equipment. Its premium machinery also includes Stationary Batch Type Hot Mix Asphalt Plants, Mobile Hot Mix Batch Type Asphalt Plants, Continuous Type Mobile Asphalt Drum Mix Plants, Bitumen Emulsion Plants, Mechanical Stabilization Plants, Bitumen Barrel-Drum Heaters Decanters, Polymer Modified Bitumen Plants.
Stationary Batch Type Hot Mix Asphalt HMA
Stationary batch type hot mix asphalt HMA plants are the great elements to road construction or construction in general. It finds its importance in carrying out the task of road construction or repair. This category of plant is basically meant for the production of hot mix asphalt in batches, hence giving ample control over the composition and quality of the mix. Every lot can be made to suit the need based on aggregate size or type of bitumen or additives that might be employed. Each lot may be tailor-made to suit a particular requirement. This facility of operation makes the stationary batch-type plant very versatile and suitable for projects needing several asphalt mixes. Major components of the concrete plant include the aggregate supply system, drying drum, batching tower that houses the mixing unit, and finished product storage silos. These types of plants, operating from a fixed location, are normally preferred for long-term projects or when repeated use of the same mix formula is required over some period of time.
Unlike continuous mixing plants, batch processing in a stationary batch type HMA plant provides assurance that each batch can be accurately produced with a high level of quality control. This is very important for projects with tight specifications such as airport runways, major highways, or key urban roads. Aggregate first is metered into the dryer drum, where it is heated and dried. The heated aggregate is subsequently taken to the mixing tower, where it is mixed with bitumen and other additives. These are put together properly to come up with the final asphalt mix, which is then stored in silos until use. It is easier to make adjustments between batches using this methodical approach to asphalt production. It enables the stationary batch type hot mix asphalt plant to deliver high-quality, customized asphalt mix, thus becoming an asset for any road construction project with high demands on quality and consistency.
Mobile Hot Mix Type Asphalt Plants
Polygonmach's Mobile hot mix type asphalt plants are modern facilities that are frequently preferred in road construction projects requiring high efficiency and flexibility. In general, these plants manufacture hot asphalt mix by compacting raw materials in specific proportions, such as sand, gravel, and bitumen. The main characteristic of the mobile hot mix plants is that they are easily relocated and not constrained to a specific site. This way, they can be installed and put into operation in various projects and construction sites according to the needs of the job. In fact, the portability feature allows changing the optimal place of the facility at different stages of the project by reducing the logistics cost and saving time.
Different capacities and features mobile hot mix type asphalt plants are produced, which provide solutions that are suitable for the needs of projects of different scales. Equipped with modern control systems, the facilities are constantly monitoring and adjusting the quality of the mixture in order to make sure that the final product will comply with the standards. Other solutions can be more friendly to the environment because of improved filtration and emission control systems that minimize environmental impacts. Along with the short times of installation and ease of use, high efficiency promotes mobile hot mix asphalt plants to an important instrument in modern road construction projects.
Continuous Type Asphalt Drum Mix Plants
The Continuous type asphalt drum mix plants are those types of asphalt mixing plants that are specially designed to produce the asphalt mix in a continuous and efficient manner. Continuous type asphalt drum mix plants are especially suitable for those projects where a huge volume of asphalt is required and without major variation in the mix design. Unlike the batch type plant, the continuous drum mix plant produces the asphalt mixture continuously and is done by continuously mixing the aggregate, bitumen, and additives in a rotary drum. This process starts the cold feeding of the aggregates into the drum where they are heated and mixed with bitumen, and possibly RAP materials in one pass. The simplicity in design minimizes disruptions in production and allows for a constant, uninterrupted supply of HMA. This, in turn, results in a continuous flow of process, which again brings more uniformity in the product, as the materials keep on moving, which reduces the possibility of segregation and maintains the quality of the asphalt mix consistently.
One of the key benefits related to continuous type asphalt drum mix plants is that they are much more efficient to operate and require much less maintenance compared to batch type plants. Since the mixing of the components happens in one continuous process, fewer moving parts mean less wear and tear, which eventually translates to less cost of operation. Besides that, these plants often are more compact and take less space; hence, they are easier to establish and move, if needed. This continuous process of mixing allows for a great deal of flexibility with materials and mix designs that can often be changed on the fly to meet specific project requirements. Other modern environmental concerns are taken into account in modern drum mix plants, which boast advanced dust collection systems and emissions controls to meet regulatory standards. In addition, this factor, coupled with the reduced cost of operation and ecological compliance, makes continuous type asphalt drum mix plants the first choice for large-scale road construction and maintenance projects.
Bitumen Emulsion Plants
Polygonmach Bitumen emulsion plants are professional plants designed for the production of bitumen emulsion-a mixture of bitumen and water with the addition of an emulsifying agent. These plants mix these components under controlled conditions to a homogeneous emulsified product that is used in road construction and maintenance, as well as other civil engineering applications. The most characteristic advantage of bitumen emulsions is the opportunity for their application at lower temperatures compared to hot bitumen; thus, they are much friendlier to the environment and safer. This characteristic reduces not only energy consumption but also the risk of burns to workers who are involved in its application.
In general, the process in a bitumen emulsion plant involves dosing and mixing appropriate quantities of bitumen, water, and an emulsifier. This is a process very dependent on sophisticated control systems if one aims to get a really stable and regular final product. In that respect, Bitumen emulsion could be classified into several categories depending on the nature of the emulsifier applied, such as cationic, anionic, and non-ionic. Each class has its particular characteristics and fields of application; among them, the cationic one is by far the most commonly used in road applications, given the fact that it presents better adhesion characteristics. Modern bitumen emulsion plants can produce a wide array of emulsions, meeting various specifications for applications that range from 'simple' surface dressing to sophisticated cold in-place recycling in the execution of jobs in road construction and maintenance.
Mechanical Stabilization Plants
Mechanical stabilization plants represent industrial installations crucial in the process of enhancing the physical properties of soil or aggregate mixtures, primarily used in the production of foundations, road bases, and embankments. The principle of mechanical stabilization consists in the treatment-mixing and compacting-soils with or without the addition of aggregates, to improve their bearing capacity, density, and stability in general. Plants dealing with these kinds of elements have at their disposal highly complex machinery-such as mixers, crushers, and pugmills-allowing the treated material to be very well mixed and homogeneously treated. In mechanical stabilization techniques, the method alters the physical properties of soil, which includes gradation, texture, and compaction, in such a way that the necessary strength and durability of the mixture can be achieved for certain construction projects.
Mechanical stabilization plants serve an important role in the construction industry due to their use of locally sourced materials and the processing of those materials into a much more stable and reliable construction material. It not only optimizes the strength and durability of the foundation in construction but at the same time reduces environmental impacts, which would derive from transportation of goods over long distances. Besides this, these plants are designed to work with a wide range of soils, which can be adjusted according to the project's needs, thus offering flexibility and lower costs compared with ground improvement processes. In fact, the final product of such a mechanical stabilization plant is a material that is uniformly mixed and compacted. It plays an important role in infrastructure projects, as this material will help infrastructure projects be built on sound and stable bases, hence safer and more durable.
Bitumen Barrel-Drum Heaters Decanters
Also, Polygonmach Bitumen barrel-drum heaters and decanters are special devices in the construction industry-road construction, maintenance, and the like-where it needs to melt the bitumen efficiently kept in barrels or drums. In such high melting points, this machine is vital to get the bitumen to a workable temperature by heating it. The general process of heating involves a gradual increase in the temperature of the bitumen barrels or drums by either direct or indirect methods. In the case of direct heating, the flame could touch the container, while for indirect heating, thermal oil or some related heat transfer fluid would be used that would heat the bitumen without allowing any flame to touch and thus preventing overheating or damage to quality.
These systems were designed in such a way that they can ensure uniform heating of bitumen without degradation of its properties. In this regard, bitumen decanters just happen to be some of the most efficient equipment so far, which facilitate easy transfers of melted bitumen from barrels or drums into hot mix plant tanks or directly into trucks and sprayers for application. Equipment like this significantly enhances operational efficiency by reducing the time and labor involved in handling and preparing bulk bitumen. The use of a barrel-drum heaters and decanters reduces waste to a minimum, including enhancing on-site safety since the bitumen remains enclosed in a controlled environment, reducing exposure to hot materials and fumes. These systems have become irreplaceable in the ways of road construction and maintenance for the growing demand for efficient solutions to ensure continuous availability of ready-to-use bitumen in safe and efficient conditions.
Polymer Modified Bitumen Plants
The third is the PMB, or Polymer modified bitumen plants by Polygonmach, Flowcharts of production of improved quality bitumen mixed with other polymers. Its main objective would be to mix bitumen with SBS, EVA, among other polymers, for the production of bitumen with excellent performance characteristics. These include improved elasticity, resistance to deformation, durability when exposed to weather conditions, and resistance to extreme temperature conditions. PMB finds very wide applications in road surfacing, especially in those areas that record extreme weather conditions or with heavy traffic flow, because it enables the duration of the roadways by preventing common occurrences such as rutting and cracking.
The first critical stage in a production process within a PMB plant involves heating base bitumen to an appropriate temperature, at which mixing with the polymer can occur satisfactorily. This mixture is then appropriately agitated in a high-shear mill in such a way that the polymer becomes uniformly and fully dispersed inside the bitumen to give a homogenous blend. Before going to the construction site, after the interaction, the polymer-modified bitumen is obliged to be stored at a certain specified temperature in front of the enhanced properties. The latest plants installed for PMB have modern control systems. They offer an accurate control of parameters in production and quality homogeneity of the final product. These also include safety and environmental protection measures, such as fume recovery systems, which minimize the impact of the production process on the environment and health of workers. Due to an increasing demand for more durable and long-lasting road surfaces, the field of application of polymer-modified bitumen plants in the construction industry keeps on widening.
In a nutshell, Polygonmach's range of asphalt and bitumen processing equipment offers efficiency, flexibility, and high quality in road construction projects. If what you are looking for in your next project is reliability, high performance, and cost-effectiveness, then you should look no further than Polygonmach's portfolio of equipment.