Continuous Asphalt Mixing Plant

As a professional road construction equipment manufacturer, ZOOMLINE's continuous asphalt mixing plant can be customized according to the project requirements and is divided into three series, which are suitable for different scenarios of construction needs.

ZAP-C Series Continuous Asphalt Mixing Plant

The core components of ZAP-C series continuous asphalt mixing plant cover cold aggregate supply system, drying drum, continuous mixer, combustion system, dust removal system, etc. The production capacity ranges from 20-200 tons/hour, which is suitable for large-scale stationary projects with high demand for production capacity by virtue of the stable output capacity, and it can provide even and high-quality asphalt mixture for the project for a long time.

DHB Series Asphalt Mixing Plant

The basic configuration of DHB series asphalt mixing plant includes cold material supply system, filter, drying drum, elevator, dust collector, finished product silo, photoelectric control system, etc. With a capacity range of 20-80 tons/hour, the plant achieves a balance between efficiency and cost, and it is the preferred equipment for small and medium-sized projects, which is widely used in scenarios such as municipal road repair and county highway construction.

ZAP-CM Series Super Mobile Drum Mix Asphalt Plant

ZAP-CM series super mobile drum mix asphalt plant is optimized and reconstructed on the basis of stationary and semi-mobile equipment, which combines portability and the stability of stationary equipment, with the capacity of 20-200 tons/hour, and the ability to flexibly switch between mobile and stationary modes of operation, which is especially suitable for road construction projects that require quick turnaround time, such as Temporary emergency works, rural road reconstruction and so on.

Continuous asphalt mixing plant is widely used in all kinds of infrastructure construction projects, covering highways, airport runways, urban roads and other core engineering fields, especially suitable for large-scale, time-sensitive construction projects, to ensure the progress of the project by virtue of the uninterrupted operation capacity.

Different series of continuous asphalt mixing plant can accurately match the needs of the scene:

ZAP-C Series Continuous Asphalt Mixing Plant is suitable for large-scale stationary projects, such as highway reconstruction and expansion, urban ring road construction, etc.;

ZAP-CM Series Super Mobile Drum Mix Asphalt Plant is suitable for projects with high mobility demand, such as rural road reconstruction, emergency rescue projects, etc.;

DHB Series Asphalt Mixing Plant is suitable for small and medium-sized municipal projects, such as urban branch road repair, park road construction, etc., to achieve a balance between efficiency and cost. Balance.

The stable operation of the continuous asphalt plant depends on the cooperative work of the core components, each of which bears a key function and has targeted advantages.

Cold Aggregate Feeding System

Cold Aggregate Supply System consists of cold silo, belt feeder, primary aggregate feeder and conveyor, recycled aggregate feeder and conveyor, which adopts modular design and is equipped with environmental protection system, which not only realizes the precise delivery of aggregate, but also reduces the dust leakage in the process of operation, and adapts to the synergistic supply demand of primary and recycled aggregate.

Drying & Heating System

The drying and heating system consists of primary material drying drum, recycled material drying drum, burner, air compressor, heavy oil tank and light oil tank. The core function is to dry and heat the cold aggregate uniformly, to ensure that the temperature of the aggregate reaches the requirement of subsequent mixing, and to lay a foundation for the stability of the quality of the asphalt mixture.

Lifting System

The lifting system consists of hot aggregate lifter, recycled material lifter and powder lifter. After the aggregates are heated to the set temperature, the hot aggregate and recycled material lifter will transport the materials to the corresponding screening equipment, while the powder lifter will send the virgin and recycled fillers to the storage bin respectively, so as to realize the orderly transfer of materials.

Mixing System (Continuous Mixer)

Equipped with horizontal twin-shaft paddle mixer, vibrating mixer, centralized lubrication system and main frame, it can fully mix the aggregate, filler and bitumen after quantitatively weighing according to the set ratio to ensure the homogeneity of the finished mixture and meet the project quality standard.

Baghouse Dust Removal System

Bag-type dedusting system consists of snail shell collector, main dust collector bag and induced air system, and regeneration material induced air system, which can not only increase the pressure difference between the two ends of the drying drum, improve the passing rate of the hot airflow, optimize the heating and drying effect, but also reduce the concentration of flue gas and dust emission, which is in line with the environmental standards; at the same time, the duct connects with vibrating screen, which can remove the floating dust in the screen bin, provide a negative-pressure environment for the aggregate conveying channel, and reduce dust leakage of each sealing part. Meanwhile, the air duct is connected to the vibrating screen, which can remove floating dust in the screen bin and provide a negative pressure environment for the aggregate conveying channel, thus reducing the dust leakage in all sealed parts.

Filler Feed System

The powder supply system includes primary filler bin, regeneration filler bin, regeneration filler storage bin, filler screw conveyor and waste powder screw conveyor. Primary and regeneration filler can be put into use directly after weighing, and waste powder with high impurity content will be discharged from the system through a special conveyor to ensure the purity of filler.

Bitumen Supply System 

The bitumen supply system consists of high-temperature bitumen tank, high-temperature bitumen mixing tank, bitumen discharge tank, bitumen pump and heat-conducting oil system, which is responsible for storing and delivering asphalt quantitatively to ensure the stability and accuracy of the asphalt supply to meet the rhythm of continuous production.

Pneumatic Circuit System

The pneumatic system is equipped with air compressor, air filter, dryer and pneumatic components, and there is one set of independent pneumatic circuit for each raw material and recycled material system, which ensures the stable operation of each pneumatic component and avoids the impact of the overall production efficiency due to the failure of the pneumatic circuit.

Control System

The control system adopts German Siemens electrical components, which can operate stably under adverse working conditions; with Japanese OMRON PLC and touch screen, it has strong data processing capability, supports automated data table control, and can store all kinds of real-time operating data; all system power switches can be operated through the control panel, which is convenient and efficient, and the protection level of the control cabinet reaches IP55, which is in line with the highest standards of the global industry.

The core working principle of all continuous asphalt mixing plants is based on a calibrated cold material supply system, which is used to accurately proportion the aggregate before it enters the drying drum, and is then divided into two mainstream processes depending on the type of plant:

Drum mixing is the most common type of continuous plant, where the rotating drum performs the functions of drying and mixing: the aggregate is dried in the drum, and then added at the back end of the drum to the dryer. The aggregate is first dried in the drum, then asphalt and filler are added at the back of the drum, and all materials are mixed in the same chamber. This integrated design makes the equipment compact, simple mechanical principle, with strong maneuverability, suitable for mobile operation needs.

The continuous mixing plant with external twin-shaft mixer adopts the design of separating drying and mixing. After the aggregate is dried and heated in the rotating drum, it is transported to the independent external twin-shaft mixer, where the asphalt is added and mixed with the aggregate and filler. This process provides better control of the mixing process, reduces hydrocarbon emissions, and produces a homogeneous mix that is superior to that of a drum mix plant.

Enhanced Efficiency and Output

Outstanding high efficiency output is the core highlight of continuous asphalt mixing plant. Compared with batch asphalt mixing plant equipment, its uninterrupted mode of operation significantly reduces the downtime, and it can continuously and stably output asphalt mixture, providing continuous supply of materials for the project to ensure the construction progress.

Cost-Effective Production

The continuous asphalt mixing plant equipment does not need to start and stop frequently, significantly reducing energy consumption, while the simplified process reduces the need for labor, long-term operation can achieve considerable cost savings, is the ideal choice for enterprises to optimize the budget, taking into account the quality and efficiency.

Consistent Quality of Asphalt Mixture

Relying on the advanced control system, the mixing ratio can be adjusted accurately, and the uninterrupted production process avoids quality fluctuations between batches and ensures that each batch of finished product meets the project specifications.

Flexibility in Material Usage

Continuous asphalt mixing plant can flexibly handle recycled asphalt mix (RAP), various types of aggregates and additives, and can adjust the material ratio according to the asphalt specifications of different projects, widely adapting to diverse construction scenarios.

Environmentally Friendly Operations

ZOOMLINE continuous asphalt mixing plant meets the environmental requirements of today's infrastructure projects by optimizing fuel consumption, reducing emissions and waste generation, and with a highly efficient dust removal system, it can effectively control dust and fume pollution to meet environmental regulations.

Simplified Operation and Maintenance

The automated control system of continuous asphalt mixing plant reduces the need for manual intervention, fewer mechanical parts, less wear and tear on the equipment, and significantly reduces the daily maintenance workload, lowering the equipment failure rate and maintenance costs.

Rapid Installation and Mobility

Compared with batch asphalt mixing plant equipment, continuous asphalt mixing plant has a shorter installation and commissioning period, and many models have mobility, so they can be quickly transferred to different project sites, reducing logistics and installation costs, and guaranteeing the rapid start of the project.

Increased Production Capacity

The capacity of the ZOOMLINE continuous asphalt mixing plant ranges from 20-200 tons/hour, which can meet the large-scale material demand of large highways, airports and other projects, without worrying about insufficient capacity to affect the progress of construction.

As the mainstream asphalt mixing equipment, there are significant differences in the workflow, core system, performance parameters, etc.between the continuous asphalt mixing plant and batch asphalt mixing plant, which need to be reasonably selected according to the project requirements.

Working Process

Continuous asphalt mixing plant adopts uninterrupted production mode, aggregate, filler and asphalt are continuously fed into the equipment to complete the processing;

Batch asphalt mixing plant is operated in cycles, each cycle is about 45 seconds, and mix production is realized through phased operation.

Mixing System

In terms of mixing system, continuous asphalt mixing plant mostly adopts drum integrated mixing or external mixing mode, while batch asphalt mixing plant needs to weigh and sieve the aggregate, filler and asphalt first, and then send them to the mixing pot for mixing.

Weighing System

Continuous asphalt mixing plant relies on manual weighing or conveyor belt electromagnetic regulator control, which requires high quality of aggregate; batch asphalt mixing plant is equipped with a first-class coarse weighing and second-class fine weighing system, which measures aggregate, asphalt and filler accurately, and the control accuracy is better.

Output

In terms of production capacity, the continuous asphalt mixing plant has a capacity of 20-200 tons/hour, focusing on efficient continuous output; the batch asphalt mixing plant has a capacity of 40-400 tons/hour, with high-quality mixes as the core target.

Cost and Structure

Continuous asphalt mixing plant has simple structure, no mixing tower and vibrating screen, lower cost of equipment purchase and installation, and shorter commissioning cycle; batch asphalt mixing plant has complex structure, higher cost, but better environmental performance.

How to choose?

If the need for uninterrupted material supply, suitable for small and medium-sized projects, low-grade road construction, budgetary constraints, or the need for mobile operation, give priority to the choice of continuous asphalt mixing plant;

if the project on the weighing accuracy of the material, screening effect requires high quality projects such as highways, airports, and other high-quality projects, the need to add special mixes, such as foam, fibers, rubber particles, or strict environmental protection requirements, it is recommended that Select batch asphalt mixing plant.

Importance

Doing good maintenance work is crucial to ensure the stable operation of continuous asphalt mixing plant. Regular maintenance can maintain the rated capacity of the equipment, avoiding breakdowns and downtime affecting the construction progress; at the same time, it can improve the operating efficiency of the equipment, reduce unplanned downtime, and ensure the continuity of production; it can also eliminate safety hazards, preventing mechanical failures, fires, explosions and other hazards, and protecting the safety of the operators; in addition, it can slow down the wear and tear of the equipment to extend its service life, reduce the cost of repairs and replacements, and at the same time, ensure that equipment In addition, it can slow down the wear and tear of the equipment, extend its service life, reduce maintenance and replacement costs, and ensure that the equipment meets the requirements of safety and environmental regulations to avoid fines and other penalties.

Daily Plan

Daily need to formulate a comprehensive maintenance plan for continuous asphalt mixing plant, focusing on lubrication and mechanical inspection: regular lubrication of bearings, motors, gears and other key components, using lubricants recommended by the manufacturer to match the temperature; regular visual inspection, checking for corrosion, cracks, abnormal noise and other problems, monitoring the vibration and coaxiality of the moving parts, and adjusting the deviations in a timely manner.

Maintenance Plan

Carry out special maintenance for each core component of continuous asphalt mixing plant: the drying drum needs to be cleaned regularly of dust, gravel and asphalt residue to avoid clogging, leading to overheating and uneven mixing of the equipment; the dust removal system needs to be cleaned of filters and bags in a timely manner to ensure the quality of the air, and to prevent the operation of the backpressure from being too high; the asphalt tanks and pipelines need to be flushed regularly to avoid the deposit of impurities and clogging, especially after long-term storage; conveyor belts and bucket elevator need to be cleaned of adhering asphalt residue. The conveyor belt and bucket elevator need to be cleaned of asphalt residues, check the belt tension and wear to prevent slipping and material leakage; burner and combustion system should be cleaned of nozzles and fuel lines on a regular basis to improve combustion efficiency and reduce fuel consumption.

Troubleshooting of Common Failures

Be alert to common failure signals in daily operation of continuous asphalt mixing plant, including abnormal temperature of drying drum, clogging of aggregate or asphalt feeder, malfunctioning of control panel or sensors, and clogging of dust in dust removal system. Promptly clean and adjust the problem after discovery. If the fault continues to be unsolvable, consult the equipment manufacturer or professional certified technicians to deal with the problem to avoid the expansion of the fault.

Keeping the continuous asphalt mixing plant clean is the foundation, dust, oil accumulation is the main cause of equipment failure, regular cleaning can avoid component performance damage, reduce the incidence of malfunction, combined with regular maintenance inspections, can comprehensively guarantee the optimal operation of the continuous asphalt mixing equipment and improve the overall efficiency.

Introducing advanced tools and technologies, investing in automation and maintenance equipment, real-time monitoring of equipment operating status through the control panel, collecting operational data, providing a basis for subsequent performance optimization; at the same time, according to the demand for adding optional accessories such as bag filter, storage silo, etc., to adapt to individual construction needs, further enhance the practicality of the equipment.

Strengthen personnel training, continuous asphalt mixing plant structure is complex, the operator of the professional ability of the high requirements, regular professional training to enhance the operator's proficiency in the operation of the equipment and safety awareness, standardize the operating procedures, while stimulating the enthusiasm of employees to help find the optimization of the equipment operation space to improve overall production efficiency.

The implementation of systematic parts inspection, the core components of the continuous asphalt mixing plant for a comprehensive, regular inspection and maintenance, the establishment of a complete maintenance ledger, in advance to avoid potential failures, reduce the equipment failure rate, to protect the long-term stable operation of the equipment.