What are the main components of the asphalt mixing plant?

There are many components that work in unison to make this plant complete. The feeder bins, dryer drums, filters for environment protection, tower unit, control panel, etc. Each component is discussed in detail below.

Cold aggregate feeders: Cold aggregate feeders are the starting point for any batch process of the plant. They will hold the cold and virgin aggregates in separate bins according to their sizes. Different aggregate sizes have to be in separate bins because they will be controlled by the frequency-controlled drives.

Charging conveyor and vibrating screen: Vibrating screen here is a single deck primary scalping screen designed for the removal of oversized aggregates. As the aggregates pass through the screen it helps in separating the bigger particles from the rest. From below the screen, a conveyor runs straight to the drying drum. This conveyor takes the aggregates from below the vibrating screen and transfers the same to the drying drum.

Burner and drying drum: This drum uses a counter flow technique to heat the aggregates and helps remove moisture content. Atlas is one of the quality asphalt plant manufacturers who take immense care in the manufacturing of this critical part. The drum is insulated from all sides to prevent heat loss and maintain a healthy temperature inside the drum. This also ensures that the burner fuel consumption is low. A burner is a mono-block unit that is a very compact yet efficient unit. The design of the drying drum flights coupled with the efficient burner makes this drying and mixing drum very efficient. The burner is a low noise system designed for optimum performance even in harsh conditions.

Pollution control devices: As responsible asphalt mixing plant manufacturers from India we supply this equipment with primary and secondary pollution control devices as a part of the standard package. Pollution control devices include dry dust collectors and wet dust collectors. Dry dust collectors will trap the heavy dust particles sucked straight from the drying drum and treat them to cyclonic effect to settle them. Behind the dry dust collectors, we have the bag filter system or wet dust collectors. The bag filters will take care of the lighter dust particles and treat them so that the environment is safe. Bag filters allow passing of the sucked air from the bags just to ensure that the dust particles get trapped in the bags. On the other hand, the wet dust collectors use water to trap the dust particles and prevent them from escaping.

Bitumen tanks: Leading asphalt plant manufacturers will always put emphasis on supplying sufficient storage for bitumen for the equipment. The bitumen tanks are insulated and have a heating system. The heating of the bitumen can be done directly or indirectly. In the case of direct heating, the tanks are equipped with burners. In the case of indirect heating, the heating is done with the help of hot oil circulating through the pipes that pass from inside the bitumen tanks. The heat from the hot oil is transferred to the bitumen which helps in melting bitumen.

Tower unit: The tower unit consists of three main components like the vibrating screen, hot bins, and the mixing unit.

Vibrating screen: This unit stands on top of the tower unit. Vibrating screen receives the aggregates from the drying drum by means of a fully covered bucket elevator. The vibrating screen helps the removal of oversized material by effectively and fast screening of the aggregates.

Hot bins: Hot bins will store the separated aggregates into separate compartments after the screening process takes place. Apart from the storage factor, the hot bins will allow separate weighing of aggregates as per the requirement form the set recipe. Aggregate discharge is pneumatically operated which is a maintenance factor. Just near the hot bins, there is a mineral weighing hopper. This hopper weighs the required minerals and transfers the same to the mixing unit.

Mixing unit: Any serious asphalt mixing plant manufacturers will consider making this unit a very maintenance-free device. The Asphalt mixing unit is with replaceable liners, arms, and tips. Uniform mixing in a short time is possible with the advanced and maintenance-free mixer. Weigh scale of asphalt is located just adjacent to the mixing unit. Bitumen from the tanks below is pumped into this weighing unit. After weighing, the bitumen is pumped into the mixing unit for addition to the mixing unit.

Control panel: The control panel is PLC based and is modern and sophisticated yet user-friendly. The Control panel is the heart of the equipment. Atlas is one such asphalt plant manufacturers who have developed a simple and user-friendly software which is very easy to understand and a pleasure to operate by the operator. There are several important commands like the setting of each and every critical parameter, setting the batch timings, sizing the batch, taking printouts, etc as a standard package. Optional SCADA type control panel is also available with Atlas.

Complete asphalt Plant comprises all these units that work in synchronization to make great equipment. Any maintenance-free equipment gets its name and fame only after years of consistent performance.