Major specification
Illustration: The plant is designed for a production of 120~160 t/h of road mix asphalt with a finished product temperature of 160ºC, under the following standard conditions:
· Maximum production: 160 t/h
· Rate output included aggregate, bitumen and filler
· Maximum mixing capacity: 2,300 kg / batch
· Aggregate bitumen ratio accuracy: ≤±0.3%
· Bitumen weighing accuracy: ≤±1% (Continuous real-time detect)
· Aggregate weighing accuracy: ≤±2% (Continuous real-time detect)
· Filler weighing accuracy: ≤±2% (Continuous real-time detect)
· Aggregate temperature accuracy: ≤±3ºC
· Fuel consumption (diesel): ≤6.5 kg/t
· Working environment noise level: ≤80 db(A)
· Noise level in control room: ≤70 db(A)
· Dust emission (Filter bag system): ≤90 mg/Nm3
· Standard layout area approx. 35 m x 35 m (Flexible to be adjusted to fit actual job site limitation)
· Working voltage: 380V/50HZ/60HZ; 3P
· Operation: Automatic / Manual / Fully computer controlled
· Operation voltage: 423 kW
· Desired environment temperature: 20 ~ 50ºC
· Working altitude level: <2,500 m
· Aggregate moisture content; ≤5%
· Aggregate density; ≥1,700 kg/m3
· Ph value: ≥7
· Fuel Calorific value ≥9500kcal/kg
· Material not porous and hygroscopic with normal shape
Any deviation of above-mentioned working condition may cause fluctuated production of plant.
1.0 Cold Feed System
· Imported Frequency Converter Controller for Belt Feeders, places typical magnetic speed controller.
· Speed adjustment of Frequency Converter in control room, easy operates, visible on screen, reliable operation, stable accuracy adjustment, and low malfunction performance.
· No flow switches for every hopper, signal to control room for run out of aggregate or blockage.
· Vibrators for sands hoppers, avoid material blockage; oversize meshes for hoppers, avoid large aggregate to system, provides reliable operation of system.
· Equipped with pre-vibrated screen device, located at inlet position of Inclined Conveyor, screen out large aggregate without enter Dryer Drum, effectively reduces foul material of system.
· Reduce foul material benefits save energy, increase heat efficiency, protect Dryer Drum, increase reliable operation of Hot Elevator and Screen Deck, and finally increase working life of equipment.
1.1 Cold Feed Hoppers
Quantity: 5 sets
Capacity: 8 m3
Loading width: 3.5 m
Loading height: 3.2 m
1.2 Belt Feeders
Quantity: 5 sets
Conveyor capacity: 60 t/h of each set (max.)
Belt width: 500 mm
Drive: 2.2 KW of each set
1.3 Vibrators
Quantity: 2 sets(for sand and fine aggregate hoppers)
Drive: 0.2 KW of each vibrator
1.4 No Flow Switch
Quantity: 5 sets
1.5 Collecting Conveyor
Quantity: 1 set
Belt width: 600 mm
Frame length: 21.2 m
Capacity: 180 t/h (max.)
Drive: 5.5 KW
1.6 Inclined Belt
Quantity: 1 set
Belt width: 600 mm
Frame length: 10.6 m
Capacity: 180 t/h (max.)
Drive: 5.5KW
2.0 Dryer Drum and Burner
2.1 Dryer Drum
· Inclined cylindrical construction Dryer Drum, inclined angle approx. 3.5º, low height installation, low centre of gravity, stable and reliable rotation.
· Friction roller driven type of Dryer Drum, 4 motors simultaneous driven. Advantages of friction type driven are smooth rotate, low noise; improve the impact force and high level of noise of typical chain and gear ring driven.
· Reasonable layout of Dryer Lifters, increase aggregate drying efficiency. Bolt and nut connection of Lifter bases and Drum body, deformation and loosen of Lifters by typical electric welding could be avoided.
· Mineral wool insulation covered Drum body, decrease heat loss, lower down fuel consumption, increase drying capacity; stainless steel plate cladding, shining outlook.
· Bottom scraper for aggregate discharge of Dryer Drum: low position outlet, constant and smooth output of aggregate.
· Dryer Drum air ducting equipped with negative pressure sensor, signal of Dryer negative pressure Drum to control for the instant adjustment of Exhaust Fan Damper, which angle could be shown on control panel. Therefore, the system being proper navigated, thus the Burner works under optimal condition.
Specification
Quantity: 1 set
Drying capacity: 160 t/h (max.)
Dimension: Dia. 2,250 mm x L 8,690 mm x thickness 12 mm
Drive: 60 KW
2.2 Burner
Adopt imported assemble special type of Burner, which is a high pressure, low noise and proportional adjust burner, diesel or heavy oil as fuel, double times ignition, stable, even and complete burning. According to the comparison of sensed temperature by sensor and set temperature, execute the PID adjustment of output capacity, perform fully automatic operation of Burner.
Specification
Quantity: 1 set
Type: middle pressure, low noise and proportional adjust
Fuel consumption: 291 ~ 1120 L/h (light diesel)
Turbo Charge Blower
Quantity: 1 unit
Type: Turbine fan
Capacity: 300 m3/min
Blower pressure: 350 mm Aq
Drive: 30 KW
Fuel pump
Quantity: 1 unit
Capacity: 2,600 L/h x 30 kg/cm2
Drive: 4 KW
3.0 Aggregate elevator
· Special shape elevator buckets, vertical elevated, gravity discharge type, avoid returning the aggregate without discharged.
· Twin strand chain elevator, smooth elevation, low noise transmission, long working life chain strand.
· Discharge hole of elevator equipped with blocking grille, decrease the impact force of falling aggregate to screen deck, thus the working life of screen meshes could be extended.
· Anti-reverse device, protect elevator effectively.
Specification:
Quantity: 1 set
Elevator capacity: 180 t/h (max.)
Drive: 15 KW
4.0 Aggregate Screening System
4.1 Vibrate Screen Deck
· Inclined 4 screen decks hot aggregate vibrate screening system, inclined angle approx. 15º, high strength manganese steel screen meshes, easy access for replacement of meshes. The shape of screen meshes are higher in the middle, dented at two sides, wavelike profile cross-section, increased surface of screen meshes for better production, capable to increase screen efficiency and accuracy of screening.
· Eccentric single shaft mechanism vibration device, strong impact-vibrate force, oil bath type lubrication for two end bearing of eccentric shaft, highly increase working life of system.
Specification:
Quantity: 1 set
Type: Inclined 4 x vibrate screen decks
Screen capacity: 180 t/h (max.)
Drive: 22 KW
Screen meshes specification (square holes in mm):
Ex-factory equipped: 6 x 6; 11 x 11; 19 x 19; 30 x 30
Spare parts equipped: 15 x 15; 22 x 22; 35 x 35
(Spec. could be ordered when contract)
4.2 Hot Bin
Type: 4 x individual compartments, with overflow and foul material discharge hole.
Total volume; 30 m3
Level indicator: Continuous type, real time oriented material level in bins
4.3 Weighing System
4 points load cell aggregate weighing system, bitumen and filler weighing system adopts 3 points load cell, signal to electronic weigher and computer system, weighing value digital indication, continuous automatic correction (continuous tare compensation).
4.4 Aggregate weighing
Capacity: 2,700 kg (max.); 1kg (min.)
Weigh hopper volume: 2.18 m3
4.5 Bitumen weighing
Capacity: 220 kg (max.); 0.1 kg (min.)
Weigh cylinder volume: 0.24 m3
Heating: Coiled pipe and thermal oil heated
4.6 Filler weighing
Capacity: 300 kg (max.); 0.1 kg (min.)
Weigh hopper volume: 0.30 m3
Delivery: Feed hopper and screw conveyor
5.0 Mixing Tower and Mixer
5.1 Mixer
· The mixer is the most critical part of asphalt plant. The design of the length and width ratio parameter of the mixer, the volume parameter and the layout of mixer arms, and the angle of mixer paddles will influence the production and mixing quality. Kudat have applied reliable improvement after we have investigated the advance experience and special features of imported equipment, and continuously searching the best solution of the mixer arm distance and mixer paddle angle.
· The tiles and paddles of mixer are wear-resistance Chrome Alloy casting products.
· Bitumen being injected by pump into mixer, evenly spread through the aggregate surface in mixer, performs homogenous mixing of asphalt.
· Thermal oil heating with thermostat for surface of mixer, capable for SMA production.
· Fill up ratio less than 60%, good for evenly mixing of aggregate and bitumen, mixing cycle should be shortened.
Specification:
Quantity: 1 set
Type: Horizontal Twin Shaft compulsory batch mixing
Mixing capacity; 2,000 kg/batch (max.)
Drive: 74 KW
Bitumen injection device
Type: Screw pump deliver, thermal oil heated
Injection capacity: 420 L/min, 0.6 Mpa (max.)
Drive; 7.5 KW
5.2 Mixing tower
· The tower is constructed in 4 modular sections, easy for installation and dismantles.
· The size of modular sections fulfils legal transportation condition.
· Easy maintenance and safety operation of platforms, handrails and staircases.
6.0 Reclaimed Filler System
6.1 Reclaimed Filler Elevator
Quantity: 1 set
Capacity: 20 t/h (max.)
Drive: 4 KW
6.2 Reclaimed Filler Storage
Quantity: 1 set
Type: Vertical silo
Volume: 25 m3
Accessories: Ventilation door, level indicator, handrail.
6.3 Screw Conveyor
Quantity: 2 sets
Capacity: 20 t/h per set
Drive: 3 KW per set
7.0 Imported Filler System
7.1 Filler elevator
Quantity: 1 set
Capacity: 20 t/h (max.)
Drive: 4 KW
7.2 Imported Filler Storage
Quantity: 1 set
Type: Vertical silo
Volume: 25 m3
Accessories: Ventilation door, level indicator, handrail.
7.3 Screw Conveyor
Quantity: 2 set
Capacity: 20 t/h per set
Drive: 3 KW per set
8.0 Pneumatic System
8.1 Air Compressor
Quantity: 2 sets
Type: Piston type compressor, air cooled
Capacity: 1.5 m3/min (per set)
Pressure: 7 kg/cm2
Drive: 11KW per set
9.0 Dust Collection System
9.1 Spiral Case Dust Collection (Primary collection)
The capacity of device could achieve up to 60% of dust collection, which are 0.075 mm or up in size of dust. The collected content being delivered to hot aggregate elevator for re-use.
Type: Spiral Case Dust Collector (delivered to hot bin)
Dimension: 3500 x 1925 x 2760 (mm)
Efficiency: >80%
Screw Conveyor
Capacity: 20 t/h (max.)
Drive: 3KW
9.2 Filter Bag Dust Collection (Secondary Collection)
· The type of Secondary Collection is Partition-shelf High Pressure Pulse Filter Bag Dust Collector. Equipped with high temperature resist imported USA filter bags, guaranty for long working hour under rate high temperature, long working life and good through put performance. The system collects 0 to 0.075 mm dust, which pass through Primary Collection device. The dust collecting efficiency of filter bags could achieve 99.5% or up, which is over the nation environment regulation.
· In order to handle the case when the dust content is too high, we put the bags in different partitioned compartments. During the operation, one of the compartments closed from the air ducting. Thus the suction force from exhaust fan is smallest, then the bags being cleaned by compressed air blowing. The optimal dust collection effect could be achieved.
· Horizontal constructed Dust Collection System; insulated for upper portion of bag house, avoid condensation of dust during operation. Angular steel plate for cladding.
Specification:
Type: Partition-shelf High Pressure Pulse blowing type
Dimension: 10,460 mm X 2,600 mm X 5,900 mm
Filter Area: 600 m2 (adopt US Dupont raw material)
Filter Throughput: ≥60,000 m3/h
Dust Collection Capacity: 30 g/Nm3 (led in); 0.15 g/Nm3 (exhaust)
Efficiency: 99.5%
9.3 Air Compressor
Quantity: 2 sets
Type: Piston type compressor, air cooled
Capacity: 1.5 m3/min (per set)
Pressure: 7 kg/cm2
Drive: 11KW per set
9.4 Exhaust Fan
Quantity: 1 set
Type: Low noise Fan type
Air Flow X Air pressure: 1,010 m3 X 3,450 Pa
Drive: 90 KW
9.5 Air Damper regulator
Quantity: 1 unit
Drive: 0.55 KW
10.0 Control System
· System equipped with Siemens electrical elements, provide stability for long time usage. Start-sequence Protective Circuit for the motor drive control circuit, thus guarantee the safety and reliable of motion of the working processes. Frequency Converter for the Feed Hopper Motor drive increases the accuracy of speed adjustment.
· Centralized install Air Valves, avoid dust and rain invaded, guarantee long working life.
· Micro-drive Control System: Computer control system equipped with famous brand industrial computer control system (or named Data Processor). This system obtains high performance of Anti-invade and reliable operation. The Micro-drive Control System receives the data from Operation Processor, which handle the deviated figures during asphalt production. Then the Data Processor performs the mode of operation management, such as automatically process the amendment of Free Fall value and also the over weigh value by gravity. So the production process could be controlled reliably thus the fully automatic operation could be obtained.
· The system equipped TOLEDO weighing controller, which is capable to accurately control the weighing tolerance. Furthermore, the system can take over the job to a semi-automatic mode when the computer has broken down.
· All the procedure of production could be effectively controlled in Central Control Room, capable to interchange the mode of fully automatic, semi-automatic and manual production. The Data Processor can store 1,000 recipes, production data of one year and also capable to show and check the production data and curve of each day.
· The system monitoring the temperature of 6 places: (i) aggregate discharged from Dryer Drum; (ii) ready mixed material discharged from mixer; (iii) aggregate in Hot Bin; (iv) bitumen temperature; (v) ready mixed material silo and (vi) cold air door control temperature. The aggregate discharge temperature of Dryer Drum controls the output of Burner. The ready mixed material discharge temperature is sensed by non-contact infrared sensor, signal to control system and data being shown by special temperature indicator. Data could be stored and print out.
· Autotransformer for the high power consumption devices such as Mixer and Exhaust Fan, effectively avoid electric over loaded when start up.
10.1 Fully Automatic Computer Control Panel
Working temperature: 5ºC ~ 35ºC
Working humidity: 20% ~ 70%
Control System Capacity: Manual, semi-automatic and fully automatic interchangeable
Major input and output function:
· Input all kinds of mixing recipes
· Automatically adjust and accurately weighing of recipes according input requirement.
· Collecting all the data from sensors, instantly control and adjust the motion of components.
· Indicate all kinds of mixing process, such as weighing figures, discharge of mixed material and temperature indication.
· Data storage for long period (all the production data and input recipes for one year)
· Self-diagnose of malfunction. Indication on screen when malfunction occurred.
· Monitors: one set of colour monitors with visual processing analogical diagrams indication. Operation and production process could be clearly observed.
10.2 Electric Circuit
· Power supply wires is EV wire, the major wires is VCT wire.
· Coverage: The connection from Control Room to all components of plant.
· Socket type connection between Control Room and motors, which is fast and convenience to operate.
10.3 Printer function
· Print out the date of mixing, time, mixed material temperature and actual mixing content.
· Capable to indicate, inspect and print the production data and curve diagram of everyday. Provide convenience and direct observation of inspecting the production information of everyday.
· Working temperature: 5ºC ~ 35ºC
· Working humidity: 20% ~ 70%
10.4 Monitoring System
· 1 colour monitor with 4 separations to monitor major locations
· Equipped with 4 cameras (interchangeable monitoring screen, angle adjustable camera)
10.5 Control Room
Dimension: 9,000 mm X 2,200 mm X 2,500 mm
Air conditioner: 1.5 hp x 2 sets
11.0 Mixed Material Storage System (OPTIONAL)
11.1 Silo
Quantity: 1 unit
Type: Rectangle, easy to dismantle.
Volume: 100 tons
Insulation:
· Upper portion of rectangle silo body with mineral wool insulation, outside with angular steel plate cladding.
· Lower portion of cone type silo body with thermal oil heating, outside with angular steel plate cladding.
· Discharge door with electrical heating.
Equipped with Full / Empty level indicator
11.2 Skip Bucket
Type: wire guided with soft-start driven
Volume: >2,000 kg
Drive: 55 KW
11.3 Twin track rail with Secured Anti-drop device
12.0 Bitumen System
12.1 Bitumen Tank
Type: Horizontal type with thermal oil heating pipes, outside with insulation layer.
Volume: 30 m3
Quantity: 3 units
12.2 Bitumen Deliver Pump
Type: Screw pump with heating device
Capacity: 420 L/min, 7 kg/cm2
Drive: 7.5 KW
12.3 Bitumen Loading System
Bitumen transfer tank: 2.5 m3 X 1 unit
Deliver pump: 1 unit
· Capacity: 420 L/min X 0.6 Mpa
· Drive: 7.5 KW
12.4 Bitumen Pipe
3",4"pipe with thermal heated and all necessary valves
12.5 Thermal Oil Heater
Type: Horizontal cylindrical compact unit
Capacity: 500,000 kcal/h
Automatic 24-hour thermostatic temperature control
Burner
· Type: Fully automatic high pressure burner
· Output: 200-850kw
· Fuel consumption: 30 ~ 71.6 kg/h
· Drive: 1.1 KW
12.6 Thermal Oil Circulate Pump
Oil flow: 100 m3/h
Potential energy: up to 55 m high
Drive: 22 KW
12.7 Diesel Storage Tank
Quantity: 1 unit
Type: Horizontal tank
Volume: 30 m3
12.8 Heavy Oil Storage Tank (optional)
Quantity: 1 unit
Type: Horizontal tank, with thermal oil pipe and heated, outside with insulation layer.
Volume: 30 m3
12.9 Heavy Oil Loading System (optional)
Heavy oil transfer tank: 2.5 m3 X I unit
Deliver pump: 1 unit
· Capacity: 420 L/min X 0.6 Mpa
· Drive: 7.5 kW
13.0 Painting
13.1 Standard Colour: BLUE AND WHITE
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