Why Quality Matters in Asphalt Drum Mix Plants Manufacturing
Freeway, municipal road, airport runway and parking lot construction are inseparable from the core equipment of stable production of high quality hot mix asphalt mixture-asphalt drum mix plant.
Different from batch production mode of asphalt batch mix plant, asphalt drum mix plant relies on continuous process flow to realize large production capacity and uninterrupted discharge, which is standard equipment for large-scale infrastructure projects.
Many construction enterprises only compare equipment quotation when purchasing, ignore the manufacturing quality of the whole machine, and finally appear a series of problems such as mixture gradation fluctuation, frequent shutdown maintenance, excessive fuel consumption, environmental protection failure, etc., which seriously delays the construction period and raises the operating cost.
This article from the equipment principle, quality five core values, production quality out of control incentives, selection standards four plates, a comprehensive dismantling drum asphalt mixing plant manufacturing quality importance, for engineering procurement, equipment operation and maintenance to provide professional reference.
What is an Asphalt Drum Mix Plant? Continuous production core advantages
Asphalt drum mix plant is a complete set of equipment that can continuously produce asphalt mixture. The core logic is synchronous continuous transportation and synchronous heating mixing of aggregate, asphalt, mineral powder and additives. There is no intermittent loading, weighing and unloading in the whole process.
Core Workflow
The cold storage bin stores sand aggregate of different specifications by classification, and completes accurate quantitative feeding according to the construction ratio standard;
Graded aggregate is conveyed into the integrated drying mixing drum at constant speed through conveying equipment;
Use the combustion system at the front of the drum to dry the aggregate at high temperature, completely remove the moisture in the aggregate, and ensure the basic mixing conditions;
In the mixing area in the second half of the drum, asphalt binder and mineral powder filler are accurately sprayed, and the materials are fully and evenly mixed through continuous rotation of the drum;
The dust removal system collects dust particles generated in the production process in an all-round way, and the molded hot mix asphalt mixture can be transferred to a hot storage bin for temporary storage or directly loaded for discharge through conveying equipment;
The whole production process is centrally controlled by PLC intelligent central control system, which supports multiple sets of pavement mixing ratio parameter storage and one-key switching to adapt to different construction conditions.
Outstanding advantages compared with asphalt batching plant
Greater production capacity: continuous discharge, adaptation to tight construction period, large volume of high speed, airport projects;
Lower comprehensive cost: equipment investment, basic construction and transition cost are better under the same production capacity;
Strong mixture uniformity: continuous mixing at constant temperature, stable asphalt ratio, better pavement durability;
Smaller footprint, convenient disassembly, mobile modular models can quickly transfer maintenance projects.
Asphalt drum mix plant manufacturing quality, directly determine the success or failure of the project
Equipment manufacturing process, steel materials, precision of core parts, automation design, is the key to distinguish between high and low mixing stations. Poor quality equipment will cause chain risks such as mixture quality out of control, frequent equipment failure, safety and environmental protection standards. High-quality equipment creates long-term value for the project from five dimensions.
Stable production of homogeneous asphalt mixture to avoid long-term road diseases
Most of the early rutting, cracking, sanding and water damage of pavement are caused by unstable asphalt mixture quality, and equipment manufacturing defects are the primary causes.
High-quality mixing plant equipped with high-precision electronic weighing system, cold bin dynamic feeding, asphalt pump, mineral powder spiral metering error strictly controlled, oil-stone ratio, aggregate grading constant throughout;
The roller adopts counter current heat exchange structure, high heat exchange efficiency, uniform heating of aggregates, no local overheating aging, local poor water coating;
Abrasion resistant material and reasonable arrangement of lifting blades inside the drum, full coating of aggregate and asphalt, no agglomeration and segregation problems.
On the contrary, there are some problems such as poor precision of weighing sensor, fast wear of drum lining plate, temperature control failure, etc., mixture is good or bad, pavement diseases occur frequently after paving, and the investment in later maintenance is doubled.
Efficient operation of the whole process, greatly reducing the production cost per ton of materials
The long-term profitability of the project depends on the energy consumption per ton of asphalt mixture, downtime loss, labor maintenance cost, and manufacturing quality directly determining the operation efficiency.
High-quality burner adopts low-nitrogen energy-saving design, natural gas/diesel/heavy oil multi-fuel adaptation, high heat utilization rate, significantly reduced fuel consumption per ton of mixture;
The whole machine structure welding, transmission parts standardization precision manufacturing, reducer, conveyor belt failure rate is low, reduce unplanned downtime;
Intelligent closed-loop control system, according to the aggregate moisture content automatically adjust the feed, fire, asphalt flow, no manual repeated adjustment, save labor costs.
Low-quality equipment often has insulation layer cutting, burner heat loss, transmission parts damaged, fuel consumption higher than 15% under the same capacity, frequent downtime delay construction progress.
The whole machine is durable and resistant to construction, extending the service life of the equipment and reducing the overhaul investment.
Road construction year-round open-air operation, high-intensity continuous operation, sand wear, high temperature baking, dust erosion on equipment wear is great.
High-quality drum mixing plant manufacturing standards:
Thickened wear-resistant steel plate is adopted for roller, bin and screening structure, and the service life of wear-resistant lining plate and stirring blade is doubled;
The whole machine frame is sandblasted + multi-layer anti-corrosion coating, suitable for wet, mountainous and coastal corrosion conditions;
Core motor, sensor, central control components use industrial standard accessories, not easy to dust, high temperature interference failure.
Low-cost equipment is generally thin material reduction, ordinary carbon steel instead of wear-resistant plate, use 1-2 years on the occurrence of drum deformation, bin leakage, support corrosion, overhaul, replacement parts cost is high.
Environmental protection configuration up to standard, easy to pass local environmental protection supervision
At present, the environmental protection control of infrastructure projects is becoming stricter, and the dust and flue gas emissions are not up to standard, which will directly order the shutdown. High quality equipment factory that complete environmental protection system.
Standard bag dust removal/wet dust removal device, sealed bin, fully enclosed conveyor corridor, dust emission below the national standard limit;
The low nitrogen burner suppresses the generation of flue gas harmful substances, and is equipped with a tail gas waste heat recovery structure, giving consideration to emission reduction and energy saving;
The whole machine is sealed, no dust spills, the factory environment is clean, and the risk of environmental protection punishment is avoided.
The dust removal system of small workshop manufacturing equipment is simplified and has no sealed structure, and the production dust is full of dust, which is easily stopped by the environmental protection department, resulting in the loss of construction period.
Improve safety design to avoid safety accidents in field operations
Regular large factories embed a full set of safety protection systems in the equipment manufacturing stage, which is a key part of small factories to simplify and omit:
Protective fence and emergency stop switch shall be installed in dangerous areas such as drum, transmission and elevator;
High-temperature asphalt tank insulation, overflow prevention, over-temperature alarm;
Automatic shutdown, overload protection and remote warning function of central control system fault;
The standardized design of anti-skid operation platform and maintenance channel reduces the risk of scalding and mechanical injury of operators.
Equipment manufacturing defects causing fluctuations in asphalt mixture quality and productivity
Even if the drum-type continuous mixing station is selected, if the equipment manufacturing process is poor, there will still be unstable discharge and insufficient production capacity, sorting out the four common manufacturing shortcomings and corresponding consequences:
Cold material feeding system manufacturing accuracy is insufficient
Defects: coarse bin separation, low accuracy of feeding frequency conversion metering system, bin leakage;
Consequences: continuous fluctuation of aggregate mix ratio, deviation of mixture gradation from design standard, insufficient compaction of pavement;
Optimization scheme: choose multi-bin independent weighing, closed cold bin, high-precision frequency conversion feeding model.
Dry mixing drum technology stolen reduction
Defects: downstream simple roller, material lifting blade thin, no thickening wear-resistant liner, insulation layer missing;
Consequences: uneven drying of aggregates, excessive moisture content, poor asphalt coating; rapid wear of rollers, half a year to overhaul;
Optimization scheme: priority counter-current roller, whole machine thickening insulation, wear-resistant alloy lifting blade equipment.
Weighing and asphalt conveying system rough workmanship
Defects: cheap weighing sensor, asphalt tank without constant temperature insulation, asphalt pump flow instability;
Consequences: the ratio of oil stone fluctuates, the mixture is oily or dry, and the paving molding is poor;
Optimization scheme: the whole machine adopts industrial weighing module, asphalt tank full insulation + automatic temperature control circulation system.
Central control automation system simplified reduction
Defects: no real-time data monitoring, no remote operation and maintenance, no moisture content linkage adjustment program;
Consequences: When the aggregate is wet, it is impossible to automatically increase the firepower and reduce the feeding speed, and the production capacity is greatly reduced; manual adjustment is frequent, and the human error is large;
Optimization scheme: standard PLC intelligent central control, SCADA data acquisition, remote monitoring, multi-formula storage function.
Choose high-quality drum asphalt mixing plant, five core selection criteria
Understand the manufacturing quality, select equipment from 5 dimensions when purchasing, and avoid the trap of low-cost and inferior equipment:
Match the actual production capacity of the project
According to the daily asphalt mixture demand, reserve 10%-20% capacity buffer interval.
40-60t/h: rural roads, minor municipal maintenance;
80-160t/h: reconstruction and expansion of municipal trunk roads and expressways;
More than 160t/h: new supporting roads for expressways, airports and large industrial parks.
Do not blindly pursue ultra-large production capacity, idle equipment will increase maintenance costs; insufficient production capacity will continue to rush, equipment overload loss.
Check the quality of materials and core parts of the whole machine
Focus on confirming the three major structural materials: drying drum, cold bin, hot material conveying channel wear-resistant plate thickness; at the same time confirm the burner, weighing sensor, PLC control system, dust removal host brand configuration, reject miscellaneous brand simple accessories models.
Investigating the integrated configuration of energy saving and environmental protection
Low-nitrogen energy-saving burner, fully enclosed dust removal and whole machine insulation structure shall be preferred; dust and flue gas emission parameters of equipment shall be confirmed to meet the latest local environmental protection standards, and space for environmental protection upgrading shall be reserved in the later stage.
Support engineering customization requirements
High-quality manufacturers can customize according to project requirements: mobile modularization, hot regeneration supporting, multi-bin cold material expansion, high-temperature modified asphalt special system, etc., suitable for special conditions such as mountainous areas, remote construction sites, night repair, etc.
Perfect after-sales manufacturing supporting services
High-quality equipment manufacturers complete after-sales system: on-site installation and commissioning, operator training, regular equipment inspection, rapid supply of spare parts nationwide; long warranty period for equipment manufacturing, more guaranteed warranty period for core rollers and control systems, reducing the risk of later operation and maintenance.
Summary: Equipment manufacturing quality is the bottom guarantee of long-term engineering benefits
As the core fixed asset of road engineering, drum asphalt mixing plant should not only look at the purchase price in the early stage, but also comprehensively consider the manufacturing process, durability, energy consumption, environmental protection and long-term maintenance cost.
The roller mixing plant with excellent quality can continuously and stably produce qualified homogeneous hot mix asphalt, ensure the quality of pavement construction, reduce downtime loss, fuel consumption, environmental protection fines and overhaul costs, and create long-term economic benefits for construction enterprises.
On the contrary, crude equipment seems to be low in price, but it will cause mixture quality defects, construction delay, high operation and maintenance costs, safety and environmental protection hidden dangers, and the comprehensive investment is much higher than that of high-quality equipment.
Under the long-term development trend of infrastructure industry, intelligent, energy-saving, environmentally friendly and highly durable high-quality drum asphalt mixing plant is the best long-term investment choice for all kinds of road projects.
