A portable asphalt mixing plant is a compact, trailer-mounted or modular mechanical equipment, the core function of which is to mix aggregate, asphalt and filler to realize the on-site production of asphalt mixture. Compared with the traditional stationary asphalt mixing plant, it does not need complex fixed foundation, has the characteristics of rapid transfer, installation and dismantling convenience, especially for short-term projects, construction in remote areas and urban road maintenance scenarios – whether it is a mountainous road repair, or urban street renovation, the portable asphalt mixing plant can be flexibly adapted to effectively solve the inconvenience of transportation of stationary asphalt mixing plant equipment, pre-trailer or modular machinery and equipment. The portable asphalt mixing plant can be flexibly adapted to effectively solve the pain points of inconvenient transportation and long preparation period of fixed equipment.

The reason why portable asphalt mixing plant can stand out in the short-term, flexible projects, the core lies in its four outstanding features, each of which accurately meets the actual needs of industry users, taking into account the efficiency and cost control.

Easy to Move and Transport.

The main modules of the portable asphalt mixing plant are equipped with wheels and tires, adopting modular design, and the structure is simpler than that of the stationary asphalt mixing plant, which not only can be quickly transferred from one construction site to another, but also the installation and dismantling process is very convenient, significantly reducing the burden of the equipment’s preliminary preparatory work, and saving a lot of time and labor costs, which is a perfect match for the needs of projects that need to frequently change the construction site.

Easy to Operate and Maintain.

The overall structure of the portable asphalt mixing plant equipment is simple, with a high degree of automation, and operators can be trained to operate the equipment, which reduces labor costs and operation threshold. At the same time, unlike stationary asphalt mixing plant equipment, portable asphalt mixing plant does not need to be equipped with mixing towers and vibrating screens, reducing the number of wearing parts and maintenance links, the maintenance difficulty is greatly reduced, effectively reducing the time of equipment downtime for maintenance, to ensure the continuity of production.

The Construction Area is Small.

Portable asphalt mixing plant consists of independent modules, the overall structure is small and compact, with the trailer frame as the main support components, without occupying a large number of sites, even in the limited space of the urban construction areas or narrow construction sites, can be flexibly deployed, to solve the problem of stationary asphalt mixing plant equipment covers a large area, poor adaptability of the site.

Cost is Lower.

Compared with the stationary asphalt mixing plant, portable asphalt mixing plant without laying complex fixed foundations, can directly save a foundation construction of additional expenditure, the cost savings can be invested in raw material procurement to further enhance the cost-effective asphalt production, especially suitable for budgetary constraints, short-term construction of the user’s choice.

The stable operation of the portable asphalt mixing plant depends on the concerted efforts of the core components, which are connected in an orderly manner according to the production process, with each component assuming a key role, and all of them are in line with the user’s durability, customizability and environmental protection of the equipment’s core concerns. The following asphalt production process, detailed analysis of the functions and advantages of the core components.

Cold Aggregate Bins

Cold aggregate bins are the initial stage of asphalt production, usually in groups of 4, which can be customized according to the actual needs of users, budget plans and construction conditions. Each cold aggregate silo is equipped with a discharge gate, which can precisely control the flow of cold aggregate to ensure that the aggregate ratio meets the production standards, laying the foundation for the quality of the subsequent asphalt mixture.

Conveyor Belt

The core role of the conveyor belt is to carry out preliminary measurement of cold aggregate, and then the measured cold aggregate will be smoothly transported to the drying drum, as a key link between the cold aggregate silo and the drying drum, the stability of its operation has a direct impact on the production efficiency, to ensure that the cold aggregate can be continuous and uniform into the next production process.

Drying Drum

The drying drum is the core heating component of the portable asphalt mixing plant, and it is installed on the chassis, which is convenient for the whole equipment to be moved, and greatly saves the time of equipment transfer. The outer surface of the drum is covered with a thermal insulation layer, which can effectively reduce heat loss and enhance the efficiency of energy utilization; at the same time, the drum is made of stainless steel alloy, which has good abrasion resistance and corrosion resistance, and can significantly extend the service life of the portable asphalt mixing plant equipment.

Dust Collector

Dust collector is a key component to ensure the environmental protection operation of the portable asphalt mixing plant equipment, there are various options for the dust collection system of the portable  asphalt mixing plant, including water filter dust collector, bag dust collector and cyclone dust collector, etc., of which the bag dust collector is the most widely used type due to its excellent environmental performance. After being treated by the bag filter, the dust emission concentration can be controlled at a lower level, which is in line with the national environmental protection standards and reduces the pollution of the surrounding environment.

Bitumen Storage Tank

The bitumen storage tank is mainly used for storing and supplying bitumen, and at the same time, it can receive the heat transferred from the thermal oil storage tank to heat the bitumen to the specified temperature required for production, ensuring that the asphalt is in the liquid state, which facilitates the subsequent mixing with aggregates and guarantees the uniformity of the asphalt mixture.

Filler Bin

The function of the filler bin is to store and supply filler, filler as an important part of the asphalt mixture, can enhance the adhesion and stability of the asphalt, filler bin’s reasonable design ensures the continuity and stability of the filler supply, to further protect the quality of the asphalt mixture.

Mixer

The mixer adopts double shaft design, and the mixing blades and liners are made of wear-resistant materials with long service life, which can adapt to the long-term high-intensity production demand. The mixing cycle is fixed to ensure that each batch of asphalt mixture can be mixed evenly, to achieve a stable production process, to protect the consistency of asphalt product quality.

The core working logic of the portable asphalt mixing plant is to integrate the whole process of asphalt production – cold aggregate feeding, drying, screening, weighing, mixing, dust removal, etc., into a compact and movable chassis, realizing rapid on-site production of asphalt, eliminating the need for raw materials to be transported to a fixed site for processing, and significantly improving construction efficiency. According to the different production methods, portable asphalt mixing plant is mainly divided into two kinds of batch type and drum type, the two workflow has its own characteristics, suitable for different construction needs.

Batch Type Portable Asphalt Mixing Plant

Batch type portable asphalt mixing plant is currently the most widely used type, high precision, suitable for asphalt quality requirements of the project, its workflow is mainly divided into seven steps.

Step 1, Cold Aggregate Feeding and Initial Measurement: The graded cold aggregate (crushed stone, sand, gravel, etc.) is poured into different cold aggregate bins by a loader. The variable speed conveyor belt under each cold aggregate bin measures the cold aggregate by volume or by weight, and then transports it to the main conveyor belt for final delivery to the drying drum.

Step 2, Drying and heating: The cold and wet aggregate enters the rotating drying drum, which is heated by a burner (diesel, natural gas or fuel oil can be used). The hot air flow is counter-current with the aggregate, evaporating the moisture in the aggregate and heating it to the specified temperature. The dust and exhaust gases generated in the process of heating are sucked into the cloth bag dust collector for filtration and treatment, so that it can meet the requirements of environmental protection and emission.

Step 3, Hot aggregate lifting and screening: the heated aggregate is transported to the vibrating screen through the bucket elevator, the vibrating screen classifies the aggregate according to the size, and the screened aggregates of different specifications are deposited into the corresponding hot aggregate silo for storage, which facilitates the subsequent accurate proportioning.

Step 4, Accurate weighing: according to the requirements of the production formula, the aggregate in the hot aggregate bin is discharged into the weighing hopper for electronic accurate weighing; at the same time, the filler is transported from the filler bin to the weighing device, and enters into the mixing process together with the aggregate after completing the weighing process; the heated liquid asphalt is pumped from the heat preservation tank, and then stands by after weighing.

Step 5, Mixing: the weighed aggregate, filler and bitumen are discharged into the twin-shaft mixer together, and after sufficient mixing, the output is uniform and the bonding degree of qualified hot mix asphalt mixture.

Step 6, Discharge and Storage: The finished asphalt mixture can be directly discharged into the insulated silo for storage, or directly transferred to dump trucks for delivery to the paving site to ensure that the asphalt temperature meets the paving requirements.

Step 7, Move and Deploy: The whole portable asphalt mixing plant adopts trailer design, which can be towed to different construction sites without fixed foundation, and can be installed and deployed in a few hours to put into production quickly.

Drum Type Portable Asphalt Mixing Plant (Continuous Mixing)

The drum type portable asphalt mixing plant is a simplified version of the design, with high production efficiency, suitable for large-scale, fast-paced construction projects. Its core feature is that the drying and mixing are done in the same drum, which makes the process more concise. Cold aggregate is fed into the long tilted drum, and as the drum rotates, the aggregate moves toward the burner end and is heated and dried in the process; near the discharge end of the drum, heated asphalt is injected and mixed with the hot aggregate in the drum, and the finished asphalt mixture is continuously discharged without the need for a batch weighing process, which realizes continuous production and greatly improves the production efficiency, and it is suitable for short-term and large-scale projects with high requirements for output. It is suitable for short-term and large-scale projects with high output requirements.

There are various types of portable asphalt mixing plant in the market, for example, ZOOMLINE brand, mainly divided into four types, each type of capacity, features are different, accurately adapted to different scales, different scenarios of the construction needs, the user can choose the right type of equipment according to their own project.

T-type Mobile Batch Mix Asphalt Plant

T-type mobile batch asphalt mixing plant (ZAP-MT series), with a capacity range of 60-200 tons per hour, adopts German mixing technology, stable performance and excellent mixing quality. The plant adopts modular structural design, which is compact, easy to install, dismantle and transport, and each unit is independent and can realize seamless connection, with fast moving speed, which can effectively save the cost of pre-construction preparation. It can be used in a wide range of scenarios, such as airport runways, ports, roads and bridges and other large-scale construction projects, and is also an ideal equipment for emergency road repair, which can quickly respond to the construction needs.

Mobile Asphalt Mixing Plant

The mobile batch asphalt mixing plant (ZAP-M series), with a capacity range of 60-320 tons/hour, also belongs to the batch production equipment, with the core advantage of high mobility and convenience. The core modules of screening, hot storage, weighing and mixing of this plant are integrated on a folding frame, which enables the mixing tower to be towed as a whole without the need for dismantling and transportation, significantly reducing the time and cost of dismantling, transporting and re-installing the plant. It is mainly applicable to small and medium-sized road construction projects, especially suitable for the scenario of frequent change of construction sites, and can be quickly adapted to the production needs of different sites.

Super Mobile Batch Mix Asphalt Plant

The super mobile batch asphalt mixing plant (ZAP-ME series), with a capacity range of 40-90 tons/hour, adopts a semi-trailer design for greater mobility, meets the driving safety requirements of ordinary roads and highways, and is equipped with active and passive safety measures, such as brakes and the entire electrical system, so that it can be driven directly on the highway and transferred to the construction site quickly. The machine does not require any foundation to be laid, which further reduces installation and operation costs, and is especially suitable for short-term projects that require frequent relocation, dramatically increasing construction flexibility.

Super Mobile Drum Mix Asphalt Plant

The super mobile drum asphalt mixing plant (ZAP-CM series), with a capacity range of 20-200 t/h, is a continuous production plant, which is optimized and redesigned on the basis of the stationary drum asphalt mixing plant and the semi-mobile drum asphalt mixing plant, and combines mobility with the stability of stationary production. The plant can flexibly switch between mobile and fixed production modes, with a wide range of application scenarios, and can be used in all kinds of road construction projects, and has been exported to Europe, Africa, North America and other regions, and has gained the recognition of users around the world.

In the actual project, users often hesitate between portable asphalt mixing plant and stationary asphalt mixing plant, both have their own advantages, the core difference is focused on mobility, site requirements, cost and capacity, etc., clear the differences between the two, in order to make a precise choice according to the project needs.

The Advantages of Stationary Asphalt Mixing Plant

The core advantage of stationary asphalt mixing plant is production efficiency and stability, its capacity is higher, usually suitable for long-term large-scale asphalt production in a single site; at the same time, the stationary asphalt mixing plant equipment is usually close to the fuel supply, the fuel supply is more stable and lower cost, the equipment structure is more durable, can adapt to the long-term high-intensity production needs, suitable for large-scale production, long construction period, fixed site projects, such as large-scale highway construction, large industrial park road paving, etc..

The Advantages of a Portable Asphalt Mixing Plant

Compared with the stationary asphalt mixing plant, the advantages of portable asphalt mixing plant is more prominent, especially suitable for short-term, flexible projects.

Mobility

First, strong mobility, small equipment size, streamlined components, the use of the overall road axle design, transportation is convenient, can be quickly transferred to different construction sites, without the need to be fixed in a position for a long period of time;

Use Less Space

The second is space-saving, compact equipment modules, small footprint, without occupying a large number of construction sites, suitable for urban construction sites or remote mountainous areas with limited space site;

Less Installation Time

The third is the installation of a fast, no need to lay complex fixed foundations, equipment, pre-installed lines, installation time is short, the installation of the plant is fast, hours to days to complete the deployment, and quickly put into production; Lower Costs

Fourth, the cost is more advantageous, the portable asphalt mixing plant equipment components are smaller, the site requirements are low, the installation time is shorter, the overall setup and operating costs are lower, and it is suitable for temporary projects, short-term projects, or projects that need to frequently change the site.

How to Choose?
In summary, the selection proposal is very clear: if the project needs to be quickly installed, frequently transfer site, and the production scale is moderate, the construction cycle is shorter, give priority to portable asphalt mixing plant; if the project has a large scale of production, construction cycle is long, and the site is fixed, do not need to transfer frequently, the stationary asphalt mixing plant is a more appropriate choice.

The choice of site for portable asphalt mixing plant directly affects the operational efficiency of the equipment, production safety and environmental compliance, but also affects the construction cost, so when choosing the site, we need to follow the core principle of “taking into account the operational efficiency, cost, environmental protection and safety”, focusing on the following four aspects.

First, consider the distance from the construction site. Asphalt mixture transportation distance directly affects the asphalt quality and transportation costs, asphalt paving temperature has strict requirements, the transportation distance is too long will lead to asphalt temperature drop, affecting the quality of paving; at the same time, too long a transportation distance will also increase fuel consumption and transportation time, increasing construction costs. Therefore, it is recommended that the transportation distance between the portable asphalt mixing plant and the construction site be controlled within 80 kilometers, with a maximum of 100 kilometers, to ensure the quality of asphalt while maximizing the construction profitability.

Second, consider the convenience of raw material supply. Portable asphalt mixing plant production process, need to consume a lot of sand, asphalt, fuel (fuel or natural gas) and other raw materials, site selection should be given priority to consider the convenient supply of raw materials in the region, reduce the transportation distance and cost of transportation of raw materials to ensure that raw materials can be supplied in a timely manner, to avoid shortages of raw materials to avoid affecting the production schedule.

Third, pay attention to the geological conditions. The geological conditions of the site directly affect the deployment of equipment and operational safety, should avoid the existence of cracks, landslides, waterlogging and other geological hazards in the region, to prevent safety accidents during the operation of the equipment; at the same time, the nature of the soil also needs to be considered as a priority, try to avoid sandy soil areas, sandy soil bearing capacity is insufficient, may require additional reinforcement of foundations, increasing construction costs, select the soil bearing capacity, geological stability of the region, can reduce the cost of foundation construction, to protect the production progress due to the shortage of raw materials. Can reduce the cost of foundation construction, to ensure the stable operation of equipment.

Finally, pay attention to the surrounding environment. Portable asphalt mixing plant is a highly mechanized equipment, the production process will inevitably produce dust and noise pollution, so the site selection should be as far away as possible from schools, residential areas and other densely populated areas, to reduce the impact on the lives of the surrounding residents and the environment, while also avoiding complaints arising from environmental issues, to ensure that the equipment is operated in a compliant manner.

Portable asphalt mixing plant installation process is relatively simple, without the need for complex foundation construction, according to the process step-by-step operation, you can quickly complete the deployment, put into production, the specific installation steps are divided into four phases, close to the actual operational needs, reduce the user installation difficulties.

Initial Setup and Positioning

After the site preparation is completed, the core components of the portable asphalt mixing plant, including the drying drum, silo, mixing unit, etc., placed in the preset designated location, to ensure that the components are placed on a level, reasonable location, to facilitate subsequent connection and operation. Depending on the size and complexity of the equipment, this stage usually takes from a few hours to a few days, with smaller equipment completing the positioning quickly and larger equipment taking more time to adjust their positions.

Electrical and Mechanical Connections

Once the portable asphalt mixing plant equipment is positioned, the electrical and mechanical connections are made, including connecting the equipment’s control system, installing the motor, linking the conveyor belt to the mixing drum, and connecting the fuel lines, asphalt delivery lines, and so on. This stage is the key to ensure the normal operation of the portable asphalt mixing equipment, and requires specialized personnel to ensure that all connection parts are firm and the lines are smooth. Compared with the batch type portable asphalt mixing plant equipment, the structure of the drum type portable asphalt mixing plant is simpler, and this stage takes less time, but no matter which type, it needs to be carefully checked to avoid equipment failure due to improper connection.

Calibration and Testing

Once the electrical and mechanical connections are complete, the portable asphalt mixing plant equipment needs to be calibrated and tested to ensure that it is produced to standard. Calibration work mainly includes debugging temperature settings, material flow, mixing speed and other parameters to ensure that all aspects of the operation of the precise; test work is to simulate the production process, check the overall operating status of the equipment, to confirm that the portable asphalt mixing plant equipment is trouble-free, the production of asphalt mixture quality in line with the requirements. Roller equipment due to process simplification, the test cycle is relatively short, batch-type portable asphalt mixing plant equipment due to high precision requirements, the test cycle is slightly longer, the specific time consumed according to the complexity of the portable asphalt mixing plant equipment.

Formal Operation

After calibration and testing, the portable asphalt mixing plant can enter the formal operation stage, start asphalt production. During the operation process, it is necessary to arrange professional personnel to continuously monitor the operating status of the portable asphalt mixing plant equipment, timely detection and treatment of abnormalities in the operation of the equipment, to ensure stable operation of the portable asphalt mixing plant equipment, and at the same time to ensure that the output and quality of the asphalt mixture to meet the construction needs.

Operation of portable asphalt mixing plant safety measures are critical, directly related to the personal safety of the operator and the stable operation of the equipment, the specific need to strictly implement the following points:

First, wear appropriate personal protective equipment. Due to the asphalt production process will produce high temperature, dust and other potential risks, the operator must be required to wear helmets, high-temperature protective gloves, protective eyewear, non-slip shoes and dust masks and other equipment, all-around avoidance of high-temperature burns, dust inhalation, mechanical scuffing and other safety hazards.

The second is to strictly follow the standardized operating procedures. The need to check the portable asphalt mixing plant equipment before the operation of the switch, piping, wiring is normal, the start of the equipment needs to be in accordance with the established steps to operate in an orderly manner, it is strictly prohibited to operate in violation of the law, unauthorized changes in the operating procedures, the process of production, if you find abnormalities of the portable asphalt mixing plant equipment, you need to immediately shut down and disconnect the power to check for hidden dangers before resuming operation.

Third, regular comprehensive inspection of portable asphalt mixing plant equipment. Daily before starting, during operation and after shutdown, the transmission components of the equipment, electrical systems, fuel lines, safety guards, etc. to carry out a detailed inspection, timely detection of loose parts, wear and tear, leakage and other problems, to avoid minor hazards leading to major accidents.

Fourth, provide sufficient professional training for portable asphalt mixing plant equipment operators. To ensure that operators are proficient in equipment operation skills, safety precautions and emergency response methods, and those who are not qualified are strictly prohibited to operate without training.

At the same time, strict compliance with all relevant safety regulations and guidelines is also critical, the enterprise needs to establish a sound safety management system, regularly carry out safety alert education, to ensure that every operator can establish a sense of safety, standardized operation, strictly abide by the bottom line.

Portable asphalt mixing plant maintenance is to protect the long-term stable operation of the asphalt mixing plant equipment, to extend the service life, reduce the cost of downtime, the core maintenance points need to be fully implemented, detailed implementation, including the following aspects:

First, regular inspection of all components, covering the cold aggregate silo, conveyor belt, drying drum, dust collector, asphalt tanks, mixers and other core components, the inspection includes parts of the fastening, wear and tear, sealing performance and operating conditions, focusing on the investigation of pipeline leakage, loose parts, wiring aging and other potential problems, so as to achieve early discovery, early treatment, to avoid the expansion of small faults for equipment overhaul, to protect the continuity of production (b) The second is to carry out regular inspections on the moving parts of the equipment;

Secondly, lubricate the moving parts of the portable asphalt mixing plant equipment on a regular basis, including conveyor belt bearings, mixer shafts, drum support shafts and all other moving parts, choose the appropriate lubricating grease and apply or refill it according to the specified cycle, so as to effectively reduce the friction loss between the parts and prevent the parts from being damaged due to dry abrasion, and at the same time, enhance the smoothness of the operation of the equipment;

Third, regular cleaning portable asphalt mixing plant equipment, timely removal of equipment surface and internal dust, asphalt residue, debris, etc., focusing on cleaning the drying drum wall, mixer liner, dust collector bags and silo walls, to avoid the accumulation of residual substances affecting the operating efficiency of the equipment, to prevent the asphalt residue coagulation damage to the components, and also reduce equipment corrosion, prolonging the service life of the portable asphalt mixing plant equipment;

Fourth, timely replacement of worn parts, for mixing blades, liners, conveyor belts, filter bags and other vulnerable parts, need to check their wear and tear on a regular basis, once the wear and tear limit, we must promptly replace the appropriate original parts, to avoid wear and tear of parts leading to the decline in the quality of the asphalt mixture, or cause portable asphalt mixing plant equipment failure.

At the same time, be sure to strictly follow the equipment manufacturer’s maintenance plan and related recommendations, according to the frequency of use of portable asphalt mixing plant equipment, production load and operating environment, to develop a personalized maintenance program, complete the maintenance work on time, do not change the maintenance cycle or simplify the maintenance process, to ensure that the maintenance work of professionalism and effectiveness, to maximize the use of the value of the portable asphalt plant equipment.

Portable asphalt mixing plant operation of environmental considerations, is the core requirement of the equipment to comply with the operation, reduce the impact of the surrounding environment, but also an important prerequisite for the sustainable development of the industry, the need to combine the operating characteristics of the equipment, the full implementation of various environmental measures, including the following aspects:

Strict Control of Dust Emissions

Portable asphalt mixing plant in the aggregate conveying, drying, mixing and other aspects of dust, need to prioritize the use of bag filter and other efficient and environmentally friendly dust removal equipment, regular cleaning of the filter bag, check the sealing of dust removal system, to ensure that the concentration of dust emissions in line with national and local environmental protection standards; at the same time, set up in the area of the aggregate stockpiling of dust enclosure, sprinkler dust reduction facilities, to avoid dust diffusion in the wind to reduce the impact on the air environment and neighboring residents, to reduce the impact on the air environment and neighboring residents. Reduce the impact on the air environment and neighboring residents.

Scientific Control of Noise Level

Portable asphalt mixing plant operation, mechanical operation, material transportation and other processes will produce a certain amount of noise, the need for reasonable planning of equipment operation time, to avoid the residents to rest time (such as 22:00 at night to 6:00 the next morning); at the same time, the noise source of the equipment (such as motors, rollers, conveyor belts) for noise reduction, can be added sound insulation cover, shock absorbing pads and other facilities, to reduce the propagation of noise to ensure that noise emissions in line with environmental norms, reduce the impact on the air environment and the surrounding residents. noise emissions comply with environmental norms and reduce interference with the lives of neighboring residents.

Fully Implement All Pollution Control Measure

In addition to dust and noise control, it is also necessary to properly deal with asphalt leakage from bitumen storage tanks, regularly check the pipeline sealing, set up anti-leakage pallets to avoid asphalt contamination of the soil and groundwater; classified collection and standardized disposal of wastes generated in the production process (such as discarded filter bags and worn parts), and it is strictly prohibited to throw them away, so as to realize the all-round control of pollutants.

Strictly Comply with Relevant National and Local Environmental Regulations

Take the initiative to dock with the environmental protection department, cooperate with environmental protection testing, adjust environmental protection measures in a timely manner according to the test results, and take effective means to minimize the impact of portable asphalt mixing plant equipment operation on the surrounding soil, water, air and ecological environment, so as to achieve green, compliant and sustainable production.