Asphalt Batch Mix Plant

ASPHALT BATCHING PLANT

Comix Asphalt Batch Mix Plants are designed keeping in mind asphalt contractor expectations on investment. These plants comply with international environmental regulations. The batch plant is ideal when a large number of different mixes have to be made with accurate proportioning and homogenous blending. Easy to calibrate and rugged multipoint load cell weighing arrangement for all the constituents, heavy-duty large pug-mill mixer and carefully designed PLC/SCADA control system takes care of the cumulative error corrections and deliver world-class mix with total accuracy and consistency with huge power savings. The counter flows dryer drum with multi-direction mixing technology & modulating burner gives the highest fuel efficiency.

Silent features:

  • Optimum fuel efficiency
  • Energy Efficient
  • AC Motors
  • Mixing Tower is equipped with sturdy skid which saves costly RCC work. Tower is rest on PCC work only.
  • Bigger Hot Bin New design of hot bin increase 10% storage capacity and extra wide gate ensure free fall of aggregates which will reduce batch time. Gate Cylinder are in open atmosphere. No possibility of damaging pneumatic cylinder seal kit.
  • Batch Tower is with Screen Bypass Duct. Screen is bottleneck of batch mix plan. You can run plant without screening material. All material collected in first bin. Material proportion set by AC drive of Aggregate bin feeder.
  • Recycle Asphalt Adding Provision. With Screen bypass your plant also handle RAP up to 20%. RAP is add to hot elevator where it is heated by superheated virgin aggregates by conduction.
  • Fully insulated Counter flow Dryer Drum fitted with automatic multi fuel burner.
  • Hot bucket elevator system.
  • Four / Five deck vibratory screen.
  • Four / Five hoppers for storage of hot aggregates.
  • Aggregates, bitumen, filler and hot mix weighing unit.
  • Bitumen storage and heating system with thermic heater.
  • Fully computerized control panel with option to store various types of hot mix recipes with possibility to change the recipes frequently.
  • Bag type air pollution control system with bag filters complete with exhaust fan and chimney.
  • Filler elevator for recovered dust from bag filters.
  • Hot mix silo with 2 compartments, discharge doors, intermediate hopper and level indicator.
  • All major bought out items are imported from Germany, Italy, France, Japan, Korea.
  • Asphalt batching mix plant is containerized for easy transportation & fast installation.

Components of the asphalt plant are:

Cold Aggregate Bin Feeders

The bins are all-welded and modular in construction, Steep bin walls and the valley angles allow free flow of aggregates from the feeders minimizing the hold up of materials in the corners and bridging with sticky aggregates, adjustable skirts are provided to prevent leakage between bin bottom and belt surface. The bins have adjustable calibrated gate openings, bins are provided with feeding units comprising of head and tail pulleys, single roll idlers, endless rubber conveyor, screw-type belt tensioners, replaceable rubber skirting no flow indicators in the control panel for operator acknowledgments, and variable speed feeder drives together offer total proportional control, greater flexibility, and accuracy of operations. long belt feeders with an adjustable radial discharge gate.

Gathering Conveyor & Slinger Conveyor

with rated feeding capacity with squirrel cage electric motor and speed reduction unit & is Supplied with trough idlers, roller guides, return rollers, and screw-type belt tensioners.

Counter Flow Dryer Drum

Fully insulated Counter flow, Cylindrical inclined type Dryer Drum unit with field-proven internal flights designed to give bonus drying capacity with change in moisture content. Internal dryer flights are specifically designed and arranged in the dryer drum to obtain higher heating efficiency and homogeneous heating of different grain size aggregates. Hot aggregates temperature measuring thermocouple type probe for measurement of hot aggregates at the dryer outlet is given. Dryer drum supports comprising of four heavy-duty trunnion rollers and two thrust rollers on a rigid frame and equipped with two trunion rings. The four-wheel-drive (4WD) system with steel drum rollers comprising the friction drive system ensures a smooth and silent drive and reduces maintenance cost, high thermal efficiency reduces heat losses, aid power saving & reduces the thermal stresses on the drying drum and noise emissions from the burner.

Burner

Fully Automatic, Proportioning, High Pressure, Fuel atomizing type low noise burner suitable for Light diesel fuel oil or ASTM D396 No.4 fuel oil with a wide turndown ratio with fully integrated low noise turbo blower powered by an 18.5 kW, 4 pole motor. Remotely operated from the control station, high-pressure fuel oil pump together with flame monitoring system, with an electric igniter, interconnections, controls, safety devices, and interlocks are given fuel line piping with necessary control valves, filters, structural base, supports, and complete internal wiring and connections into the control cabin are provided. Gas Burner can be provided as per customer requirements.

Hot Bucket Elevator

A totally enclosed, vertically mounted, centrifugal discharge type bucket elevator having a heavy-duty K type chain and toothed sprocket at drive ensures smooth operations of the entire elevator system. Eliminating unbalancing of buckets during heavy loads when the plant is operated at full capacity. Toothed sprocket chain drives with a fully covered box for easy installation on tower container frame. The hot aggregate bucket elevator is a totally enclosed chain-driven system. Bucket tips are double reinforced for maximum durability. The elevator unit is electrically driven directly by a gear motor eliminating the chain drive mechanism having higher maintenance. Comix bucket elevators are designed for long service life and easy maintenance access. Super-tough wear materials and a special entry chute design make bucket elevators superior performers.

Vibrating Screen

A totally enclosed, vertically mounted, centrifugal discharge type bucket elevator having a heavy-duty K type chain and toothed sprocket at drive ensures smooth operations of the entire elevator system. Eliminating unbalancing of buckets during heavy loads when the plant is operated at full capacity. Toothed sprocket chain drives with a fully covered box for easy installation on the tower container frame. The hot aggregate bucket elevator is a totally enclosed chain-driven system. Bucket tips are double reinforced for maximum durability. The elevator unit is electrically driven directly by a gear motor eliminating the chain drive mechanism having higher maintenance. Comix bucket elevators are designed for long service life and easy maintenance access. Super-tough wear materials and a special entry chute design make bucket elevators superior performers.

Hot Bin

Four compartment hot aggregates bin with storage capacity, overflow and oversize rejection chute, bin level indicators, pneumatically controlled cut-off gates, and a sampling device on each compartment is given. A temperature measuring probe on bin no.1 is provided. The hot bin unit is also equipped with highly efficient low maintenance pneumatic controls with High and Low-level indicators in Control Cabin system integration allowing for automatic controls of the aggregate input from cold feeder bins thus minimizing material loss by wastage. Highly reliable weighing systems with low maintenance load cells and an easy calibration system make it highly popular.

Weighing System

Automatic accumulating, weighing type Aggregate weigh hopper, with four-point suspension hopper and load cell transducer. Automatic individual weighing type Asphalt and Filler weigh hopper with four points suspension hopper and load cell transducer. All weighing hoppers are fitted with proper shock isolation devices. Aggregate weigh hopper, Filler weigh hopper& Asphalt weigh hopper are there.

Pug Mill Unit

The mixer unit is hot oil jacketed and supplied with a low-maintenance oil-bath type. The Twin shaft paddles, arms, and tips are made of wear-resistant High Nickel Hardened cast alloy steel. The design of the mixer internals is replaceable & wear-resistant ensuring a lower operational cost. Provided with a wide-opening radial gate for quick discharge of hot mix. Specially designed arms and tips ensure a very homogeneous mix in a short mixing time. pole motor Mixer drive, with V- Belt arrangement is standard fitment. Hot Mix Storage Silo Hot mix storage silos can be supplied in different capacities as per customer requirements.

Fines/Filler feeding system

Completely enclosed Vertically mounted Filler elevator with induction discharge type bucket elevator for feeding filler into a filler storage bin on the mixing tower is there. The filler and dust storage bin is provided with a level indicator to control the filler supply from the filler elevator automatically. A Rotary type filler feeder with pneumatically operated seal gate feeds filler from filler storage bin into filler weigh hopper. Dust Filler Filling & Storage Filler receiving from ground level (with suitable storage capacity) to silo by pneumatically or through bucket elevator control with level sensor. Silo with vibratory motor, filler receives dust from filter baghouse through an auto control screw conveyor into receiving hopper of bucket elevator. The filler from silos can optionally be supplied with a filler feeding bucket elevator to suit bagged filler feeding. As a standard, the filler silo is supplied with level indicators and process interlocks.

Primary Pollution Control System

Primary pollution control is a dry dust collection type. The dust is collected by the dry dust collectors from three points: the drying drum, vibrating screen, and the hot bins ensuring that proper dust-free aggregates enter the mixing drum. A primary dust collection system in form of a Double Cyclone is provided to entrap larger dust particles from the dryer drum exhaust and for scavenging for the batching tower. Reclaimed dust recycling conveying system comprising of a material seal damper at the bottom of the cyclones, feeding the reclaimed dust at the foot of the hot elevator. High capacity Exhaust fan powered by a heavy-duty motor with automatic damper controls is provided.

Bag House Filter

The two-stage dry dust collection system has a baghouse filter with around 380 m2 of filtering area. The 288 nos. of bags in Meta Aramid filtering media, operating on the latest low maintenance, high-efficiency Reverse Air Flow type de-dusting mechanism. Safety Interlocks (eg high exhaust temperature etc. ) and controls to ensure the safe functioning of the unit. Fully automatic De-dusting system incorporating three nos. of de-dusting devices, ensuring freedom from frequent maintenance of air compressors, solenoid valves, pneumatic controls, etc. Fine recycling system comprising of a screw conveyor for conveying the entrapped fines in the baghouse to the filler elevator, which in turn feeds the filler weigh hopper atop the mixing tower.

We also provide pulsing system & rotor system as per your requirements.

Asphalt Transfer Pump

A Jacketed, gear-type Asphalt transfer pump is provided for feeding asphalt from the storage tank to the asphalt weigh hopper. A Bitumen weighing hopper is at the bottom which is hot oil heated and mounted onto three electronic load cells. By heated, & well-dimensioned feeding pipe, Bitumen gets distributed via gravity into mixer within seconds. Which guarantees Homogeneous distribution in a mixer.

Bitumen Heating & Storage System

Customers can opt for direct heating type bitumen storage tanks or indirect heating type hot oil heated bitumen storage tanks. Storage capacity ranges up to 50 tons. The indirect heating tanks are supplied with a superior design thermic oil heater. The direct heating tanks are supplied with automatically imported pressure jet burners. As a standard, all our tanks are supplied with auto thermostatic controls and level & gauge indicators. Bitumen jacketed piping with process valves and fittings for manual tank selection and a single bitumen delivery pipeline are given.

Thermic heater

Thermic heaters are supplied with hot oil jacketing on bitumen pipeline, asphalt pump, bitumen weigh hopper section, and pug mill body. Opting for hot oil heating reduces asphalt pump binding, asphalt pipeline blocking, smoother bitumen weigh batcher, and smooth pug mill operations.

The thermic oil heaters are supplied with auto temperature control to maintain precise bitumen temperature, independent automatic control including oil temperature indicator controller, low-level switch, low circulation pressure switch, over-temperature cut-off thermostat burner operating circuits.

Control Panel

Fully Automatic computerized air-conditioned control cabin, with on-board electrical power control console, distribution switchboard, fully automatic process, interlocks and sequence controls with User-friendly software on the computer with a parallel PLC man-machine interface gives control panel with unlimited job mix parameter, display in hi-resolution screen and 19″ LCD color graphic monitor with CPU for live operation on-screen with safety signal indicators, which indicates the perfect time required for service & maintenance of the plant.

Dust Filing & Storage

Filler receiving from ground level (with suitable storage capacity) to silo by pneumatically or through bucket elevator control with level sensor. Silo with vibratory motor, filler receives dust from filter baghouse through an auto control screw conveyor into receiving hopper of bucket elevator. The filler from silos can optionally be supplied with a filler feeding bucket elevator to suit bagged filler feeding. As a standard, the filler silo is supplied with level indicators and process interlocks.

Compact Modular Design

Comix Batch Mix Plant Tower & Hot elevator (Hot elevator is Integrated into the tower itself) both can be erected together by heavy crane in a couple of hours only. the whole tower can be transported in one Trailer of 40’ or Container & can be easily transported domestically & world wide result in big saving for the customer.