Time: 2020.08.27—-2020.10.24
Location: Aktobe, KZ(Kazakhstan)
Equipment: ZAP-S120 120T/H stationary asphalt plant
Kazakhstan is a core landlocked country in Central Asia and the largest landlocked country in the world. At the same time, as a friendly neighbor of China and an important cooperative participant in the “the belt and road initiative” initiative, Kazakhstan has continuously increased the construction and upgrading of road traffic infrastructure in recent years. By constantly improving the regional traffic network and optimizing the business environment, the country continues to attract foreign investment, activate the cultural and tourism industry, and steadily improve the quality of life of local people. However, for a long time, the local lack of large-scale, stable operation, energy-saving and environment-friendly standardized asphalt mixing plant, short capacity, backward technology, environmental protection and other problems have seriously restricted the construction progress and quality of regional infrastructure projects. Based on the real pain point of Kazakhstan infrastructure industry and the actual investment dilemma of customers, this paper expounds in detail how our ZAP-S120 asphalt mixing plant accurately solves the local production bottleneck, fills up the regional industrial gap, becomes the first large-scale asphalt production facility put into operation in Kazakhstan, and injects core power into the long-term and high-quality development of local road traffic infrastructure.
Before the implementation of this project, there was no large-scale standardized asphalt plant in operation in this area of Kazakhstan. Local municipal reconstruction, highway upgrading, traffic infrastructure and other engineering projects can only rely on small scattered bitumen mixing plants for operation, or maintain construction through purchasing finished asphalt materials from other places. Small asphalt batching plants have limited production capacity, scattered production mode, low degree of process standardization, which can not match the local infrastructure project volume increasing year by year. Problems such as insufficient asphalt material supply and interruption of construction process frequently occur, which greatly drag down the construction speed of regional infrastructure.
Traditional small-scale asphalt mix plant technology is simple, mixing accuracy is insufficient, it is easy to appear asphalt mixture ratio uneven, finished product qualification rate is low and other problems, resulting in pavement quality is not up to standard, later rework repair frequency is high. At the same time, the finished asphalt extracted externally depends on long-distance transportation, the transportation cycle is uncontrollable, the logistics cost is high, and it is easily affected by extreme weather and cross-border supply chain fluctuation, and the stability of material supply cannot be guaranteed, which directly causes uneven project quality and frequent delay of construction period, which brings great operation risk and economic loss to customers ‘engineering investment.
The multiple superposition of long-distance material transportation costs, project rework costs, frequent commissioning of small equipment and operation and maintenance costs continuously increases the comprehensive construction costs of local infrastructure projects and continuously reduces the profit margin of project investors. The long-standing production difficulties of insufficient production capacity, unstable quality and high cost not only restrict the investment layout of customers ‘large-scale projects, but also hinder the upgrading and development of Kazakhstan’s local infrastructure industry in the direction of standardization, standardization and intensification.
The dust removal system of local traditional small asphalt batch plant is simple in configuration, with large dust and exhaust emission and weak environmental protection performance, which is difficult to adapt to the increasingly strict ecological and environmental protection supervision policy of Kazakhstan. In addition, the traditional equipment is highly dependent on manual operation, with low automation level and large human operation error. Not only the labor operation cost remains high, but also the production stability and consistency cannot be guaranteed. It is completely unable to adapt to the construction standard of modern intelligent infrastructure. The demand for iterative upgrading and green transformation of asphalt mixer plant is very urgent.
In view of the long-standing four core pain points of insufficient production capacity, unstable quality, high cost and substandard environmental protection in the local infrastructure field, the customer has defined clear investment and construction targets, officially launched the procurement project of large-scale standardized asphalt mixing plant, and focused on five dimensions of core construction and production demand:
Build a localized large-scale standardized asphalt production base, realize the independent self-sufficiency of infrastructure asphalt materials, completely get rid of the dependence on purchased finished materials, and grasp the initiative of project construction;
The batch mix asphalt plant shall have a stable production capacity of 120 tons/hour, which can meet the operation requirements of multi-project synchronous construction and all-weather continuous large-scale production;
Equipped with an efficient integrated environmental protection dust removal system, the exhaust dust emission meets the standard, conforms to the environmental protection control standards in Central Asia, and realizes green, low-carbon and safe production.
Fully automatic intelligent control system is configured to reduce manual intervention, reduce operation errors and labor costs, and comprehensively improve material matching accuracy and production standardization.
The batch mix plant has stable operation and low failure rate, and is equipped with a perfect cross-border after-sales technical service system to avoid economic losses caused by idle equipment and failure shutdown, so as to ensure the long-term stable operation of the project.
Through multi-dimensional comparative screening of industry equipment performance, complete configuration, overseas landing cases, regional working condition adaptability and after-sales service system, customers finally selected our ZAP-S120 120T/H stationary asphalt batch mix plant. The equipment accurately matches the core requirements of local infrastructure projects in Kazakhstan in terms of capacity output, complete configuration, environmental protection performance, working condition adaptation, intelligent operation and maintenance, etc., and is the best solution to solve pain points in local industries and assist customers to improve quality and efficiency.
ZAP-S120 bitumen batch mix plant has a stable mass production capacity of 120 tons/hour, supports all-weather uninterrupted continuous operation, large-scale production capacity can fully cover the material demand of local large-scale municipal and highway infrastructure projects, completely solves the industry problems of insufficient production capacity and construction interruption under traditional production mode, and can support the synchronous construction of multiple road projects at the same time, greatly improving the overall construction efficiency of regional infrastructure projects.
The whole asphalt hot mix plant has mature technology and perfect configuration. The core system consists of 4-bin cold material supply system, drying drum, German brand valve assembly burner, cyclone + bag integrated dust removal system, new regenerated mineral powder bin, integrated mixing main building, pneumatic control system, supporting asphalt storage tank and heat transfer oil heating system, automatic computer control system, etc.
The core electrical components of bitumen hot mix plant adopt international first-class imported brands such as Siemens, which greatly improves the operation stability and durability, can realize accurate proportioning and uniform mixing of materials, control the quality of finished asphalt from the source, eliminate hidden dangers of pavement construction quality, and lay a solid quality foundation for project construction.
The asphalt hot mix plant is equipped with cyclone primary dust removal + bag fine dust removal double filtration process to construct an efficient integrated environmental protection dust removal system, effectively intercept dust, purify tail gas, greatly reduce pollutant emission, fully meet the local environmental protection production standards of Kazakhstan, and realize green, low carbon, compliant and safe production.
At the same time, the full-automatic intelligent control system can complete the automatic operation of material proportioning, mixing, discharging and real-time monitoring with one key, greatly reduce manual intervention, avoid human operation errors, reduce long-term human operation costs, and help customers realize standardized, intelligent and refined construction production.
In view of the special climate characteristics and outdoor construction conditions in Central Asia of Kazakhstan, our company has carried out special localization optimization and upgrading of ZAP-S120 hot mix asphalt plant, strengthened the weather resistance, anti-interference performance and operation stability of the equipment, effectively reduced the equipment failure rate under extreme weather environment, completely solved the industrial pain points of common imported hot asphalt mixing plant acclimatization, frequent failure and high operation and maintenance cost, and perfectly adapted to the local long-term outdoor continuous production operation demand.
In order to meet the urgent project schedule and large-scale production needs of customers, our company provides customized adaptation, production and manufacturing, cross-border delivery, on-site installation and commissioning, technical training and after-sales operation and maintenance full-closed-loop one-stop exclusive services for this Kazakhstan project, ensuring efficient landing, timely production and stable operation of the project in the whole process.
Early stage of project: professional technical team tailor-made equipment configuration scheme and project landing scheme in combination with local project scale, environmental protection control standards and climate conditions to ensure that asphalt mixing plant fully meets local production needs;
Production stage: strictly follow the industrial standardized production process, implement multiple quality inspection procedures, strictly control the quality of equipment in the whole process, and ensure the stable performance and compliance of the asphalt mixer machine.
Installation and commissioning stage: The project cycle is from August 27 to October 24, 2020. Our overseas professional engineering team is stationed on site for construction, and the whole process of equipment mobilization, assembly and installation, linkage commissioning and complete machine commissioning is efficiently completed.
After the project is implemented: the technical team carries out systematic special training for local operators, covering core contents such as standardized operation of equipment, daily maintenance and common troubleshooting, helping the customer team to quickly master operation and maintenance skills and realize independent and standardized production.
The complete set of ZAP-S120 bitumen mix plant completed all commissioning work on schedule, successfully passed the acceptance and put into commercial mass production, accurately meeting the customer’s time limit and large-scale production requirements.
Since it was officially put into operation in October 2020, ZAP-S120 asphalt mixing machine has maintained stable and efficient operation, stable production capacity output, accurate material ratio and qualified rate of finished asphalt as high as 100%, fundamentally solving the core pain points such as insufficient local production capacity, uneven material quality and delay in construction period, and continuously providing stable and high-quality asphalt material support for various infrastructure projects in the region, fully meeting customers ‘large-scale and high-quality production expectations.
After ZAP-S120 asphalt mixing plant was put into use, the local government completely bid farewell to the production model of long-distance outsourcing of asphalt materials and realized localized and large-scale independent production of asphalt mixtures, which greatly saved additional expenses such as long-distance logistics, rework, and frequent equipment debugging, and effectively reduced infrastructure construction. The comprehensive cost of the project significantly improves the project profit margin of customers and helps customers achieve low-cost, high-efficiency, and standardized normalized construction and production.
Customers highly recognize and praise the operation stability, green environmental performance, intelligent operation experience of ZAP-S120 asphalt plant equipment, as well as our full-process and full-cycle exclusive landing service. The whole set of equipment accurately solves the long-standing production and construction difficulties in the local infrastructure industry. Since it was put into operation, there has been no major failure, and the production effect is stable and excellent. It has become the core reliable equipment for customers to carry out long-term engineering investment and large-scale infrastructure production.
The ZAP-S120 asphalt mixing plant launched this time is the first large-scale professional and standardized asphalt production facility in this region of Kazakhstan. It completely rewrites the current situation of the local industry without large-scale bitumen plant equipment and fills in the core shortcomings of the regional infrastructure supporting industry., marking that Kazakhstan’s local road infrastructure supporting industry has officially entered a new stage of development of scale, standardization and intelligence.
As a benchmark project of China-Kazakhstan “One Belt and One Road” practical cooperation, the stable operation of the asphalt mixing plant provides solid material guarantee for the upgrading of local municipal road network, reconstruction of trunk roads and improvement of traffic system, and continuously enables the iterative upgrading of regional infrastructure industries.
At the same time, the project has effectively promoted the development of local supporting industries, created stable jobs, improved people’s livelihood and travel conditions, empowered the long-term development of Kazakhstan’s regional economy, further deepened the results of cooperation between China and Kazakhstan in the field of infrastructure, and provided guidance for the subsequent Central Asian region. The implementation of similar infrastructure projects has accumulated mature and replicable practical experience.
If you are faced with various production problems such as insufficient asphalt production capacity, unstable material quality, high construction cost, substandard equipment environmental protection and poor working condition adaptability in the layout of infrastructure projects in Central Asia and other overseas countries, our ZAP series customized asphalt mixing plant solutions can be tailored to different regional climate conditions, environmental protection standards and production scale requirements. Complete sets of equipment solutions with strong adaptability can accurately solve pain points of various projects. Welcome to contact our overseas technical sales team at any time to obtain customized equipment solutions and accurate project quotations.
