CAPIUS Asphalt Drum Mix Plants are available in different Models with output capacities ranging from
40 TPH to 120 TPH. (Higher capacity plants can be offered on request.)
Output Capacity of the Asphalt Drum Mix Plant is subject to the Moisture content in the aggregates, output hot mix temperature, dust content in aggregates and job mix, normal ambient temperature and plant site altitude.
Asphalt Drum Mix Plant Generally consists of :
A. Cold Aggregate Four Bin Feeder
B. Single Deck Vibratory Screen for oversized material removal
C. Slinger (Cold) Conveyor
D. Dryer Auto Burner
E. Drying Cum Mixing Thermodrum with Dust Collector
F. Load out conveyor with Gob hopper
G. Asphalt Tank
H. Mineral Filler Unit
I. Centralized Control Panel with insulated Cabin
J. Fuel Storage Tank
K. Pollution Control Unit
General layout of asphalt drum mix plant
A. FOUR BIN FEEDER: The Cold Aggregate Feeder consists of Four Bins. Self relieving bin walls with proper slope ensure constant discharge of aggregate without bridge forming. Self relieving bottom openings of the bins with optimum area avoid interlocking. One bin meant for fines or dust is fitted with vibratory motor to ensure the free flow of material. Each bin is equipped with an adjustable opening door that determines the discharge quantity for the materials capacity in outlet, as a function of specific weight of materials. Width of each bin is compatible with the width of the loader bucket.
The material from each bin is drawn out by means of extracting conveyor driven by adjustable variable speed motor, coupled with worm reduction gear boxes, that enables to increase or decrease the material output as per the job mix formula requirements. It is also possible to increase or decrease the total capacity without varying the preset settings by means of master control.
The material from the each bin is discharged into gathering belt driven by constant speed A.C. motor. Electronic load cell is fitted which continuously weighs the total output from the four bin feeder unit.
B. single deck vibratory screen: single deck vibratory screen 40 mm is fitted at the end of gathering conveyor for removal of oversized material.
C. SLINGER (COLD) CONVEYOR: Separate detachable Slinger Conveyor is provided to transfer the aggregates received from the vibratory screen to feed into the Thermo-drum.
Slinger Conveyor is driven by constant speed A.C. Motor coupled with Worm Reduction Gear Box.
The rigid frame of Conveyor is fabricated from appropriate size of Channel and the Conveyor belt is supported by uniformly spaced Idler Roller stands. Any sagging on the return travel of the belt is also taken care-of by Idler Roller.
D. DRYER BURNER: Thermo-drum Burner is the heart of the entire system and hence its efficiency, ease of serviceability etc. are most important factors. The Burner is fully automatic and two stages (High & Low) pressure jet type system is capable to reduce the moisture up to 0.5 % and achieve 180 deg. Celsius for aggregate.
This burner is suitable to use LDO / Diesel as fuel and is fitted with remote control system to detect flame failure and have electric spark ignition system.
The temperature is controlled through thermostatic control device to operate the plant in desired temperature range. The nozzle system is so designed that the nozzle can be cleaned during running condition hence nil downtime for nozzle cleaning.
E. dryer cum mixing thermodrum with dust collector: the thermo-drum or drier cum mixture unit is long rotating cylindrical drum. it is mounted on sturdy and robust steel structure fabricated from girders and channels. the drum is supported by heavy duty offset type drive chain and 4 nos. of trunnion rollers running on heavy duty bearings. three nos. rollers mounted on thrust bearing supports the guide ring taking care-of the down hill thrust produced due to the degree provided to the thermo-drum.
Flame Guard is provided in the Thermo-drum to restrict the Burner flame to reach up to the mixing zone. This Flame Guard divides the Thermo-drum into two zones viz.
1) Heating + Drying zone 2) Mixing zone
The specially designed thick `J’ type + `W’ type comb lifting flights have been bolted in both the zones in the zigzag / straight pattern which creates a dense veils of aggregate in front of burner flame, uniformly heats the aggregates and gives best mixing.
The rotational drive to Drum is through Heavy Duty Offset type chain and Worm Reduction Gear Box coupled with Motor through suitable Coupling.
The Thermo-drum is insulated with Ceramic Glass Wool and covered with Stainless Steel sheet to prevent the heat loss and to save Fuel as well as the life of the Drum. The Drier cum Mixing Drum is finally provided with Rotor for efficient mixing and sweep discharge. The discharge chute is fitted with replaceable type chute liners and it will discharge the material directly on the Load out Conveyor. The Multi Cone Dust Collecting system mounted on the same chassis allows optimum efficiency in accordance with the present ecological regulations.
F. load out conveyor with hopper: hot mix material discharged from the drier drum is carried by inclined hot conveyor belt and discharged into the tipper / truck through controlled hydraulic surge storage hopper.
The Hot Conveyor belt is heat resistance of reputed make like MRF / Nirlon/ Equiv. This belt is supported by adequate no. of Idlers and frame fabricated from appropriate size of channel and angles.
A separate AC Motor with Worm Gear Box is provided to run the Conveyor belt.
Belt Scraper is provided to avoid any sticking of the mix material to the belt.
Hydraulically operated storage hopper is provided at the discharge end of the conveyor which stores the Hot Mix and allows it to fall as mass in batches and thus avoids any segregation problem.
G. ASPHALT TANK : The Bitumen section of CAPIUS Drum Mix plant mainly consists of Bitumen Tank, Bitumen heating burner, Bitumen Pumping & Metering unit and Hot Oil system.
The Tank is insulated to minimize heat losses. The bitumen inside the tank is heated by U-shaped beating tube fitted with automatic burner of adequate capacity. A jacketed Bitumen Pump driven by Variable Speed Motor through Reduction Gear Box is provided to pump the bitumen to the Drum. The bitumen flow rate is controlled by varying the RPM of Motor. Bitumen Pump, all bitumen lines to and from the tank except pipe fittings and valves are hot oil jacketed. An independent electric motor driven pump is used for pumping the hot oil from hot oil tank to the jacketing lines. The single stage burner of bitumen tank is fitted with remote control system to detect flame failure and have electric spark ignition system. The temperature is controlled through thermostatic control device to heat bitumen in desired temperature range. The main bitumen tank, hot oil tank, blower, hot oil pump, bitumen pump with speed reduction gear box and motors are all mounted on standby chassis and are provided with heavy legs to facilitate of the unit.
H. MINERAL FILLER UNIT : The Filler Hopper is provided to add Filler / Mineral from a separate Hopper in the mix to the extent pre-selectable in percentage by weight of the maximum plant output.
The system is powered by a Variable Speed Motor coupled with Gear Box to Rotary Valve and also synchronized with aggregate & Bitumen output.
The Filler material from this unit is conveyed pneumatically up to coating zone in the Thermo-drum.
I. control panel with cabin: the control panel is provided with centralized control for operating the plant. the operations like percentage of aggregate, bitumen percentage, filler percentage, temperature control etc. have auto control as per the data fed by the operator. it has lamp indicators and meters for operation control, monitoring and fault finding. it is equipped with protections like single phasing, overload, fuses, sequence interlock etc. load wise data can be printed on the printer provided in the panel. the body of the panel is fabricated from crc sheet duly powder coated to protect against weather effect and has necessary ventilation.
The Control Panel is housed inside a insulated cabin. The cabin is fabricated from M.S. sheet and is insulated. The cabin has glass windows all around, so that the operator has full view on all sides from the cabin for ease of operation and control.
Drum mixing process
The Asphalt Drum Mix Plant operation begins with Four Bin Feeder. The cold aggregates are fed in to Four Bin Feeder (as per job mix formula) and are drawn out from each bin by means of Extraction Conveyor driven by presetable, adjustable, variable drive motor and carried on Gathering Belt to Slinger Conveyor, by removing oversized material through Vibratory Screen.
The Slinger Conveyor introduces the aggregates in the Thermodrum unit. The Thermodrum is divided into two zones i.e. 1) Heating and Drying zone & 2) Mixing zone. The Multi Cyclone Dust Collector unit is integral part of the Thermodrum.
The aggregates are introduces first in Drying zone and are mixed and dried by automatic High Pressure Jet Burner designed for easy serviceability and the nozzles can be cleaned even when the plant is in operation.
The aggregates then run into Asphalt / Mineral mixing zone where Asphalt is introduces from insulated Asphalt Tank equipped with separate High Pressure Auto Burner for heating the Asphalt. All the asphalt carrying pipelines are hot oil jacketed and thoroughly insulated to ensure easy flow of Asphalt into Thermodrum.
The aggregates also mixes with Mineral (lime/cement) which is introduced from Mineral Filler unit pneumatically from a separate pipeline in the mixing zone.
The aggregates now moves to Sweep Discharge unit and the polluted air is segregated and blow out through the Multi Dust Collecting unit while the aggregates pass through Sweep Discharge to Load Out Conveyor and to Hydraulically Operated Gob Hopper at the end, for phase wise transportation to the road construction site.
Contact Name: Jay Thakar
Company Name: Capious Roadtech Pvt Ltd
Street Address: Plot No: 4008, Gidc
Phase Iv, Vatva, Ahmedabad-382445,
Member name: capious1
Member Since: 06 April 2009
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Business focus: OEM Road Construction Equipment
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Product Category: Asphalt