Immediate Delivery Batch Type Asphalt Plant

Immediate Delivery Batch Type Asphalt Plant

What is a Batch Type Asphalt Plant?

A batch type asphalt plant is a facility used in the manufacture of asphalt by mixing hot bitumen, aggregate, and filler in specific batches. Unlike continuous plants that operate non-stop and mix asphalt in a continuous flow, batch plants produce asphalt in individual batches. Each batch can be customized to meet different specifications, making this type of plant suitable for varying paving assignments and enables meticulous control over the composition and quality of the asphalt. The plant operates in cycles that include drying and heating the aggregates, mixing them with bitumen and filler, and then discharging the finished asphalt mix ready for road construction.

The process in a batch type asphalt plant begins with the feeding of cold aggregates into individual bins that subsequently release controlled amounts into a rotary drum dryer where they are heated and dried. The hot aggregates are then screened into different sizes and stored in hot bins, awaiting the mixing phase. Following this, the hot aggregates are weighed and mixed with the precisely measured amount of hot bitumen and mineral filler. This mix is then churned in a mixer to ensure even distribution of bitumen. Finally, the asphalt is dispatched from the mixer and stored or directly sent to the construction site. This plant's batch-by-batch operation allows for flexibility in production and high quality control, making it a preferred choice for specialized and high-grade road laying works.

What are the advantages of Batch type Asphalt Plant?

Batch type asphalt plants offer distinct advantages over other types of asphalt plants, particularly when it comes to quality control and mix versatility. One of the primary advantages is their ability to produce asphalt in batches, allowing for meticulous control over the mixture and the timing of production. This batch-by-batch production method ensures that each batch can be customized to meet specific requirements, making it ideal for projects that require multiple types of asphalt mixes or where high-quality is paramount. Moreover, the end product is consistently high in quality because the production settings for each batch can be finely adjusted to accommodate changes in materials or project specifications.

Another significant advantage of batch type asphalt plants is their adaptability to changes in production specs without substantial waste. Unlike continuous asphalt plants which produce asphalt at a constant rate, batch plants can switch between different mix designs with minimal downtime and material wastage. This flexibility is especially valuable in projects requiring different types of asphalt applications alongside each other. Additionally, since each batch can be individually tested for quality before use, the risk of integrating subpar asphalt into major projects is significantly minimized, enhancing overall project quality and durability. Batch type asphalt plants, with their precise mixing and flexibility, cater especially well to specialized high-performance paving projects like highways, airports, and high-volume urban roads.

How does Batch type Asphalt Plant work?

A batch type asphalt plant operates through a meticulously controlled and sequenced process to produce asphalt mixture batch by batch, allowing for high customization and precise mixing of the components. The process starts with the cold feed bins where different types and sizes of aggregates are stored. These aggregates are then metered out from their respective bins onto a conveyor belt, based on the specific requirements of the asphalt mix being produced. They are conveyed into the rotary dryer drum where they are heated and dried to remove any moisture present, ensuring they are prepared for effective mixing with bitumen.

Once the aggregates are heated and dried, they are elevated to a screening deck which sorts them into different size groups; these groups are then stored in separate hot bins. From these bins, aggregates are measured and sent to the mixing unit where they are combined with the precise amount of heated bitumen and fillers. This mixing occurs in the mixer and is controlled carefully to ensure even distribution of all materials. Once the mixing is complete, the asphalt is discharged into trucks for transportation to the construction site or into silos for temporary storage. This batch processing allows for adjustments and flexibility in the asphalt production, adapting to varying project specifications efficiently. This process repeats for each batch, maintaining a consistent output of high-quality asphalt.

What parts does the Batch Type Asphalt Plant consist of?

1. Cold Feed Bins

Cold feed bins are integral components of a batch type asphalt plant, used for storing and dispensing various aggregates such as sand, gravel, and asphalt material types. Each bin holds a different size or type of aggregate and releases it on demand. This separation of aggregates into individual bins allows for precise mixing and batching, essential for achieving the intended asphalt composition.

The operation of cold feed bins involves adjustable gates that control the flow of aggregates to the conveyor belts. These belts feed the aggregates into the drying drum. The feed rate is carefully controlled by variable speed drives, ensuring the correct proportion of each aggregate type enters the drum. This precision is vital in maintaining the quality and consistency of the asphalt mix.

2. Rotary Drying Drum

The rotary drying drum is where the initial heating of aggregates takes place. In this large rotating cylinder, aggregates are heated to the proper temperature necessary for mixing with bitumen. The drum features internal flights designed to lift and cascade the material through the hot air stream, maximizing heat transfer and efficiency.

This component not only heats the aggregates but also removes moisture that could potentially affect the final quality of the asphalt mix. Effective operation of the drying drum is critical for the overall efficiency and output of the asphalt production process, ensuring that materials meet the required specifications for further processing and mixing.

3. Hot Aggregate Elevator

The hot aggregate elevator is used to transport the heated materials from the drying drum to a screening deck located on a higher level. This component is vital for maintaining the flow of materials through the plant, preventing bottlenecks and ensuring continuous production.

The elevator must handle high temperatures and severe mechanical stresses. It is typically designed with buckets attached to a rotating belt or chain to efficiently lift the hot aggregates. Proper maintenance and operation of the hot aggregate elevator ensure prolonged service life and reliability of the asphalt plant.

4. Screening Deck

A screening deck in a batch type asphalt plant is crucial for classifying and separating the heated aggregates into specified sizes. The deck consists of several screens that vibrate to sort the aggregates, ensuring that each size is routed to its respective storage bin. This separation is essential for the accurate formulation of asphalt mixtures.

Proper functioning of the screening deck ensures that only correctly sized aggregates are used in the mix, contributing to the overall quality of the asphalt. It also helps in reducing waste and optimizing the use of materials, thereby enhancing efficiency and reducing operating costs.

5. Mixing Tower

The mixing tower is the heart of the batch type asphalt plant, where the screened aggregates, bitumen, and sometimes fillers and additives are combined to produce the final asphalt mix. This component typically includes a pugmill or a mechanical mixer that thoroughly mixes the components under controlled conditions.

The accuracy and efficiency of the mixing tower determine the homogeneity and quality of the final product. The tower also houses control systems that regulate the timing, temperature, and mixing operations, ensuring that the produced asphalt meets the required standards and specifications. Proper monitoring and maintenance of the mixing tower play a crucial role in the performance and output of the asphalt plant.

In which areas is Batch type Asphalt Plant used?

1. Highway Construction

Batch type asphalt plants are extensively utilized in highway construction due to their ability to produce various asphalt mixes required for different layers of highway pavements such as base, binder, and surface layers. Each of these layers may require different types and grades of asphalt, depending on the traffic loads and environmental conditions. The capability of a batch plant to switch between different recipes quickly is invaluable in projects where multiple types of asphalt mixes are needed intermittently.

The precision and control offered by batch type plants allow for the production of high-quality asphalt that meets strict specifications, which is crucial for the longevity and durability of highways. By custom mixing asphalt batch by batch, engineers can adjust the composition based on the feedback from ongoing quality tests, ensuring that the pavement will perform well under the stress of heavy traffic and adverse weather conditions.

2. Urban Road Construction

In urban areas, roads often require specific types of asphalt mixes to cope with a variety of traffic conditions and to reduce noise pollution. Batch type asphalt plants are ideal for urban road projects because they can produce small batches of different asphalt mixes as needed throughout the construction process. This flexibility is particularly useful in cities where roads may need to cater to both heavy vehicles and passenger cars, requiring different types of asphalt surfaces.

Moreover, urban road construction often occurs in stages or phases to minimize disruption to local traffic. Batch type plants can efficiently handle such phased schedules by providing specific mixes in precise amounts at scheduled times. The ability to customize each batch allows for better resource allocation and waste reduction, which is especially important in constrained urban settings.

3. Airport Runway Construction

Airport runways demand high-quality asphalt that can withstand the intense loads from aircraft landings and takeoffs. The unique specifications required for such asphalt can be achieved reliably with batch type asphalt plants. These plants can produce high-strength, durable asphalt mixtures that are crucial for the safety and serviceability of airport runways.

Batch mixing also ensures that each batch can be tailored to include additives that improve the performance characteristics of the asphalt, such as its resistance to fuel spillages and the stresses of varied temperature ranges. The stringent quality control possible with batch type plants is essential in airport constructions to ensure that all sections of a runway meet international safety standards.

4. Specialized Industrial Paving

Industrial sites such as container depots, warehouses, and factories often require specialized paving solutions that can withstand heavy machinery and constant traffic. Batch type asphalt plants are well-suited for creating custom mixes that include reinforcements or modified bitumen to enhance load-bearing capacity and resist deformation.

These plants' ability to batch mix makes it possible to develop specialized mixtures with precise material specifications and additives aimed at increasing the lifespan and functionality of industrial pavements. This capability ensures that the pavement will be up to the task of supporting heavy-duty operations without frequent repairs or overhauls.

Pioneer in Innovative Technology: Polygonmach

POLYGONMACH is a leading global manufacturer of concrete batchingplants, crushing screening plants, and asphalt plants. With TSE and ISO 9001 quality assurance certifications ans a commitment to innovation, quality, and customer
satisfaction, we have established ourselves as a trusted name in the construction industry. Our extensive range of high-performance plants caters to the diverse needs of construction projects, ensuring efficiency, reliability, and durability.

 

Contact us

Quick Links

Quick Links

Quick Links