Bitumen Melting Machine

Bitumen Melting Machine, also known as Bitumen Decanter, is a kind of special equipment used to heat, melt the solid asphalt stored in drums or bags, so as to reach 140 ℃ -160 ℃ fluid state for subsequent processing or application in various projects. 140 ° C -160 ° C fluid state, in order to subsequent processing or application in various types of engineering specialized equipment. The reason why the need for bitumen melting machine, the core reason for asphalt storage and transportation characteristics - in order to facilitate long-distance transportation and long-term storage, asphalt is usually made of solid blocks or loaded into barrels, and in the road paving, roof waterproofing and other practical applications, it must be melted into a fluid state, in order to achieve uniform application and mixing. The traditional artificial melting method is not only inefficient, time-consuming and laborious, but also has great safety hazards, and at the same time, it is easy to cause overheating degradation of asphalt due to uneven heating, loss of its core bonding properties.

The softening and melting temperature of asphalt is usually between 100℃-120℃, and the complete melting into a usable fluid state needs to reach 140℃-160℃, the specific temperature needs to be adjusted according to the grade and composition of asphalt. Many people will confuse asphalt and asphalt mixture melting temperature, in fact, asphalt mixture is a mixture of asphalt and aggregate, its melting temperature and asphalt is basically the same as asphalt, because asphalt is the core binder component in the mixture. In practice, precise control of the melting temperature is crucial to ensure the fluidity of the asphalt, but also to avoid the quality degradation caused by overheating, which is one of the core design focuses of the bitumen melting machine.

All common commercial grades of bitumen on the market can be melted in an asphalt melter. The adaptability of the equipment is key, and this is one of the core advantages of the ZOOMLINE asphalt melter. Specific melting asphalt grades can be divided into three main categories: penetrating asphalt, viscosity asphalt and performance asphalt. Among them, penetrating asphalt, 60/70, 80/100, 120/150 grades are most commonly used in melting processing type, widely used in general road construction and maintenance; viscosity type asphalt, VG-10, VG-20, VG-30, VG-40 grades can be based on different engineering needs and construction environment, through the bitumen melting machine to achieve precise melting, suitable for different mobility requirements; performance-based asphalt in the melting machine to achieve precise melting, suitable for different mobility requirements; performance-based asphalt. Requirements; performance-based asphalt, PG 58-28, PG 64-22, PG 70-22 grades, can be adapted to different climatic conditions and working conditions, through the bitumen melting machine to achieve accurate temperature control, to ensure that the performance of the asphalt after melting is stable. In general, all common commercial asphalt has the ability to melt, choose the right bitumen melting machine, can meet the needs of different grades of bitumen melting.

ZOOMLINE bitumen melting machine adopts humanized design, the overall operation is convenient, low maintenance costs, without professional training can be operated, and its core structure around the “efficient melting, safety and stability, easy to operate,” the design of the three major core requirements, mainly including the following four key components:

Melting Chamber: Adopting glass wool fully closed design, with good thermal insulation performance, can effectively reduce heat loss, to achieve energy-saving melting. The upper part of the melting chamber is used for placing barrels of asphalt, while the lower part is designed as a molten asphalt pool for collecting the melted fluid asphalt, ensuring a stable and orderly melting process and avoiding asphalt leakage.

Electric Hoist/Hydraulic Arm: as the core component of asphalt feeding, whether it is an electric hoist or a hydraulic arm, its core role is to push the barrels of asphalt into the melting chamber easily, without manual handling, greatly reducing the labor intensity, while avoiding the safety hazards brought about by manual operation, and improve the feeding efficiency.

Thermal Oil Heater: machine, through the heating of the thermal oil, and then the thermal oil circulating to the melting chamber, to achieve the indirect heating of asphalt. This heating method can effectively avoid direct contact between the flame and the asphalt, preventing the asphalt from overheating and degradation, and ensuring the stable quality of asphalt after melting.

Seamless Pipeline: mainly used for conveying thermal oil, the thermal oil from the heater to the melting chamber, and then the cooled thermal oil back to the heater, forming a complete heating cycle. The seamless pipeline adopts anti-leakage design with strong texture and durability, which eliminates the need for frequent maintenance and reduces the operating cost of the equipment.

The working process of ZOOMLINE bitumen melting machine is simple and easy to understand, even for non-professional operators can quickly master, the whole is divided into three core steps to efficiently realize the melting and conveying of solid asphalt:

Step 1: Feeding Operation. First of all, the barrel or bagged asphalt barrel lid drilling (to facilitate the flow of asphalt after melting), and then through the hydraulic arm or electric hoist and other feeding components, the asphalt will be transported to the flipping device, and then by the flipping device will be sent to the melting chamber. According to the different capacity of the equipment, 3 rows and more barrels of asphalt can be placed in the melting chamber at the same time to realize batch melting and improve production efficiency.

Step 2: Heating and Melting. The melting chamber is surrounded by pipelines for conveying thermal oil, when the thermal oil heater is activated, the heated thermal oil will circulate through the melting chamber through the seamless pipeline, and with the joint action of the hot air, the barrels or bags of asphalt are heated uniformly. As the temperature rises, the solid asphalt gradually melts into a fluid state, and the melted asphalt will drip down to the molten asphalt pool in the lower part of the melting chamber through the drilled holes in the bucket lid.

Step 3: Bitumen Transportation. When the asphalt in the molten asphalt pool reaches a certain amount, start the asphalt pump, the fluid state of the asphalt pumped to the transportation vehicle or special asphalt storage tanks for subsequent construction or further processing. The whole process is highly automated without manual intervention, which not only improves efficiency but also ensures operational safety.

In order to meet different users' asphalt packaging types and production needs, ZOOMLINE mainly provides three core types of bitumen melting machines, and also supports customized service, which can tailor-made exclusive solutions according to the users' production capacity, site conditions and other needs.

Drummed Bitumen Melting Machine

This equipment is specially used for melting asphalt in 200kg standard drums, completely replacing the traditional manual heating and handling of the cumbersome process, eliminating the safety hazards of manual operation and the problem of low efficiency. Its core advantage lies in the high efficiency of batch melting, suitable for large-scale asphalt production scenarios, can quickly provide a stable supply of molten asphalt for asphalt mixing plants, road construction sites, etc., is currently one of the most widely used bitumen melting equipment.

Ton Bag Bitumen Melting Machine

It mainly used for melting polymer lined ton bag (big bag) packaging asphalt, equipment equipped with high-performance heating chamber, can use thermal oil or electric heating in two ways, to achieve efficient melting of asphalt, and the whole process without asphalt burning, degradation phenomenon, to ensure that the quality of asphalt is not affected. The melted asphalt can be directly transported to the storage tank or asphalt mixing equipment, without the need for secondary transfer, further improving production efficiency.

Drum and Jumbo Bag Bitumen Melting Machine

This equipment combines the advantages of the first two types of equipment, can be adapted to both barrel asphalt and tonnage bag bitumen melting needs, great flexibility, suitable for both barrel asphalt, and tonnage bag asphalt production scenarios. Its working principle is: through the jib crane will be a ton of asphalt bags or barrels of asphalt lifted to the feeding platform, melting ton of asphalt bags, directly remove the bags and asphalt into the melting chamber; melting barrels of asphalt, barrels of asphalt through the flip device will be pushed into the melting chamber after the barrels of asphalt flip, asphalt after melting into the molten pool, after the pumping temperature is heated to the specified, transported to the external asphalt storage tanks. It should be noted that when melting the ton bag asphalt, the turning device of the equipment should be removed in advance to avoid affecting the feeding operation.

In addition to the three standard types mentioned above, ZOOMLINE also provides customized service, which can personalize the design of the equipment according to the user's production capacity, site size, heating method requirements, etc., to ensure that the equipment is fully adapted to the user's actual production scenarios, to improve production efficiency and reduce operating costs.

ZOOMLINE bitumen melting machine has become the preferred equipment in the asphalt processing industry by virtue of its humanized design and core technological advantages, and its core features are mainly reflected in the three major aspects of high efficiency, safety and convenience, which accurately solves the user's core pain points:

High-efficiency heating: the equipment is equipped with high-efficiency heating system, and its melting efficiency is up to 8-10 tons per hour, which can rapidly realize the batch bitumen melting and significantly reduce the production cycle. Efficient heating: the equipment is equipped with a heating system, melting efficiency of up to 8-10 tons per hour, can quickly realize the asphalt batch melting, significantly shorten the production cycle, improve production uptime, provide a stable supply of asphalt for the construction of the project, to help users save time and labor costs.

Safe and reliable: safety is the core requirements of the bitumen melting process, the equipment adopts thermal oil jacket design, to avoid direct contact between the flame and the asphalt, from the root to eliminate asphalt leakage, combustion and other safety hazards; at the same time, equipped with fire extinguishers and emergency shutdown system, once an abnormal situation occurs, can be quickly shut down to deal with the maximum protection of the operators and the production site safety, reduce the occurrence of safety accidents.

Convenient operation: the equipment adopts humanized design, equipped with digital temperature controller, can accurately set and monitor the bitumen melting temperature, to avoid excessive high or low temperature affecting the quality of asphalt; at the same time the equipment has a simple structure, low difficulty in cleaning and maintenance, no need for professional training, the ordinary operator can start operating, reduce manpower training costs, reduce the incidence of equipment failure.

For asphalt-related enterprises, the use of bitumen melting machine can not only solve the pain points of solid bitumen melting, but also bring a variety of core values to help enterprises to improve production efficiency, reduce operating costs, and protect the quality of the product:

Save time: compared with the traditional manual melting method, the bitumen melting machine to achieve automation of the batch melting, significantly shorten the time of the bitumen melting to reduce labor input, improve the overall production of It greatly reduces the time of bitumen melting, reduces the labor input, improves the overall production efficiency, and ensures that the construction progress is not affected by the supply of asphalt.

Safe operation: Through automated operation, the equipment reduces the direct contact between operators and hot asphalt, high temperature equipment, minimizes fire, scalding and other safety hazards, improves the operating environment, enhances workplace safety and reduces the cost of safety management of the enterprise.

Energy saving and consumption reduction: the equipment adopts advanced thermal insulation design and efficient heating system, thermal oil circulation heating can effectively reduce heat loss, reduce fuel consumption, compared with the traditional heating method, energy consumption is lower, long-term use can help enterprises significantly reduce operating costs.

Quality assurance: the equipment has a precise temperature control function, can strictly control the bitumen melting temperature, to avoid overheating degradation of asphalt, to ensure that the molten asphalt of the bonding properties and quality stability for the subsequent construction of the project to provide a strong guarantee of the quality of construction, to reduce the quality of asphalt due to problems caused by the rework of the project.

Wide range of uses: bitumen melting machine adaptability is very strong, can be widely used in asphalt mixing plant, emulsified asphalt production equipment, road maintenance sites, roof waterproofing projects, construction of seepage control projects and other scenarios to meet the needs of different industries, different projects of the bitumen melting to enhance the utilization rate of the equipment.

Bitumen melting machine as the core equipment for asphalt processing, its application scenarios throughout the asphalt related to various types of engineering and production processes, including the following three core areas, while covering a number of sub-scenarios:

Road construction field: this is the most important application scenarios of bitumen melting machine, whether it is a new road paving, or existing road repair and maintenance, need a large amount of molten asphalt. Bitumen melting machine can be barrels or bags of asphalt quickly melted into a fluid state, transported to the asphalt mixing plant, mixed with aggregates made of asphalt mixture for road grass-roots level, the surface layer of the pavement, but also can be directly used for road pothole repair, enhance the efficiency of road construction and maintenance.

Roof waterproofing field: asphalt is the core material for roof waterproofing project, which needs to be melted into fluid state and then evenly applied to the roof base to form a waterproof coating. Bitumen melting machine can accurately control the bitumen melting temperature, to ensure the fluidity and adhesion of asphalt, for the roof waterproofing project to provide quality assurance, suitable for all types of industrial plants, civil construction of roof waterproofing construction.

The field of seepage control project: in water conservancy, municipal, construction and other seepage control project, asphalt is often used to make seepage control membrane, seepage control layer, the need to melt solid asphalt into a fluid state after processing. Bitumen melting machine can melt asphalt efficiently to provide a stable supply of raw materials for the production of seepage control materials, applicable to reservoirs, cisterns, basements and other seepage control projects.

Other application scenarios: In addition to the above three core areas, the bitumen melting machine can also be used in asphalt emulsion production, asphalt modification processing scenarios, such as various types of asphalt deep processing projects to provide molten asphalt raw materials, but also can be used for emergency road maintenance, small-scale construction and other scenarios, to meet the needs of the different scales of production and construction.

The heating source of the bitumen melting machine can be flexibly selected, either integrated with the existing thermal oil boiler or the integrated drum stripper with its own burner. Among them, the self-burner supports three fuel options: diesel, natural gas or heavy oil, which can be flexibly adapted according to the user's on-site fuel supply situation to meet the heating needs of different scenarios.

The melting time of a single drum of asphalt depends mainly on the heating source used. ZOOMLINE high efficiency asphalt stripper adopts high temperature heat transfer oil coil system, which can usually melt a single drum of bitumen in 40-60 minutes with stable efficiency, which can effectively guarantee the production schedule.

Regular maintenance is to extend the service life of the bitumen melting machine, to ensure the stable operation of the equipment is the key to routine maintenance should pay attention to the following four points:

First, to keep the environment around the equipment is clean, the equipment shutdown, clean up the operating site in a timely manner, sorting and organizing the discarded asphalt barrels, to avoid accumulation of debris to avoid the impact of the equipment operation; and at the same time, regularly check the equipment's various types of valves, instrumentation, to ensure that the instrumentation At the same time, we regularly check the various types of valves and meters of the equipment to ensure that the meters are accurate, the valves are flexible, and the anomalies are dealt with timely.

 The second is to regularly check the asphalt pump, gear oil pumps, electromagnetic reversing valves, cylinders, electric hoists and other core components of the operating state, to see whether there is leakage, abnormal noise and other problems, found faults in a timely manner to repair or replace parts, to avoid the expansion of the fault.

 Third, regularly check whether the asphalt outlet is smooth, to prevent asphalt solidification blocking the outlet; equipment operation for some time, the need to clean up the lower part of the melting chamber through the drainage holes of the dirt, to avoid the accumulation of dirt affecting the heating efficiency and asphalt quality.

Fourthly, check and clean the hydraulic system regularly to see whether the hydraulic oil is contaminated and deteriorated, etc. If the oil is found to be contaminated, it needs to be replaced in time to ensure the normal operation of the hydraulic system.

Regular cleaning of the bitumen melting machine can effectively avoid the accumulation of asphalt residue, to protect the equipment heating efficiency and asphalt quality, the cleaning process needs to follow the following eight steps, to ensure safe operation, clean and thorough:

Preparation

Before cleaning, the operator needs to wear good personal protective equipment, including high-temperature gloves, goggles, face masks, etc., to prevent high-temperature equipment or residual asphalt scald; at the same time, turn off the power of the equipment, waiting for the equipment to cool completely, to avoid the safety hazards of high-temperature operation; ready to clean tools and materials, including scrapers, wire brushes, special asphalt solvents, high-pressure cleaners, etc., to ensure that the tools are complete.

Empty the Equipment

Open the discharge valve of the equipment, the melting chamber of the remaining molten asphalt discharged into a special container to ensure that no residual asphalt in the equipment; discharge is complete, with a scraper gently scrape off the melting chamber wall and the bottom of the solidified asphalt, pay attention to avoid scratching the inner wall of the equipment, if there are stubborn residues, can be moistened with solvent before scraping.

Disassemble the Parts

In order to achieve a thorough cleaning, the need to disassemble some of the core components of the equipment, including heating elements, asphalt pumps, valves, filters, etc., the disassembly process should be in strict accordance with the instructions for the use of the equipment to avoid damage to the components; will be disassembled after the parts into a container containing a special solvent, soak for a few hours or overnight, so that the solvent to fully dissolve the parts on the surface of the asphalt residue.

Clean the Parts

After soaking the components, use a wire brush or soft cloth to gently scrub the surface of the components, thoroughly remove asphalt residues and dirt, focus on cleaning the surface of the heating element, to avoid residual asphalt affect the heating efficiency; scrubbing is complete, rinse the components with water to remove the solvent residue, and then the components will be thoroughly dry, to prevent rust and corrosion after installation.

Clean the Melting Chamber

Use a high-pressure cleaner to spray the special solvent on the inner wall and bottom of the melting chamber, starting from the top, gradually downward cleaning, focusing on cleaning the corners, crevices and other parts of the asphalt that are prone to build up; spraying is complete, scrubbing again with a wire brush or scraper to remove stubborn residues, and then rinse the melting chamber thoroughly with water to ensure that there is no residue of solvents and dirt.

Reassembly

Clean and dry the parts in accordance with the requirements of the equipment instruction manual, re-installed on the equipment, to ensure that the parts are firmly installed, bolts, interfaces connected tightly to avoid leakage, loosening and so on; after the assembly is completed, inject the right amount of water into the equipment, start the equipment running for a few minutes, rinse the residual solvents and dirt inside the equipment, and then discharge the water cleanly.

Final Inspection

After the equipment is assembled and cleaned, carry out a comprehensive inspection to see whether the parts are running normally, there is no leakage, abnormal noise and other situations; then put a small amount of asphalt for the test machine to check whether the  temperature is stable, and whether the material is smooth, to ensure that the equipment can be operated normally after cleaning.

Preventive Measures

 In addition to regular cleaning, the daily use of the need to do a good job of prevention, the use of high-quality, low-viscosity asphalt, reduce asphalt residue; strict control of bitumen melting temperature, to avoid asphalt overheating carbonization buildup; to avoid overloaded equipment, not more than the rated capacity of the equipment, to extend the service life of the equipment.

Among many brands of bitumen melting machine, ZOOMLINE has become the preferred partner of many asphalt-related enterprises around the world by virtue of its advanced technology, high-quality products and perfect service, and its core advantages are reflected in five aspects:

Advanced Technology

Adopting the technology of asphalt drum turning, which can significantly reduce the labor intensity of manpower and improve the production efficiency, and at the same time, avoid pollution and waste caused by dripping and leaking in the process of asphalt transferring. At the same time, it avoids the pollution and waste caused by dripping during asphalt transportation, ensures a clean working environment and reduces the loss of raw materials.

Environmental Protection Design Concept

The equipment adopts a fully enclosed structure design, minimal pollution during operation, in line with environmental requirements; at the same time can achieve the complete melting of bagged asphalt, minimize the waste of asphalt, enhance the utilization rate of raw materials, reduce production costs.

Strict Quality Assurance

The use of thermal oil heating coil design, through the indirect heating method, to avoid direct contact between asphalt and flame, effectively preventing asphalt aging, degradation, to ensure that the quality of molten asphalt is stable, to provide strong support for the quality of subsequent projects.

Cost-effective Advantage

Scientific and reasonable equipment design, taking into account the practicality and economy, can effectively reduce the loss of raw materials, extend the service life of the equipment, reduce energy consumption and maintenance costs; at the same time to provide equipment modification services, can be upgraded according to the user's existing equipment, to further enhance the utilization rate of the equipment, to create higher economic benefits for the user.

Perfect After-sales Service

It provide users with a full range of after-sales service, including equipment installation and commissioning, operation and maintenance training, spare parts replacement, etc., professional technical team to follow up the whole process, and timely solution of all kinds of problems encountered by the user in the process of using the equipment, to ensure the stable operation of the equipment, to relieve the user's worries.