Hot Mix Asphalt

Production

• Plant types and basic components

• Plant calibration
• Dust extraction
• Filler handling and control
• Aggregate heating
• Procurement / handling of raw materials
• Finished product storage
• Delivery
Drum Mix Plant -
Conventional Hot
Exhaust Filter Primary Storage
Fan Baghouse dust Bins
collector
HMA made
Bitumen continuously
Tanks and sent to
storage silos
Scalping screen to
remove oversize
aggregate Drying and mixing
drum
Belt scale

Cold Feed Bins

TWIN DRUM PLANT : COUNTER-FLOW
Old Drum Mix Mix Plant:
 Plant filler
storage and
RAP Feed feed

Filter
Baghouse

Coating &
mixing
drum Aggregate
Finished
product feed
storage

Drying &
heating Drum

Twin Drum Plant

Parallel-Flow Drum-
mixer Zones

Combustion
Air Heating Drying
Mixing

BIT.
Hot Mix
Asphalt
Counter-Flow Drum-
mixer Zones

Aggregate
Mixing Combustion Heating Drying
Air

Hot Mix
Asphalt Bitumen
 Counter-Flow Batch
Plant Dryer Zones

Combustion Heating Drying

Air

Aggregate

Hot Aggregate
Batch Plant Elements
Primary Batch/Mixing tower
Filter Baghouse collector

Hot Storage
silos

Bitumen
storage
tanks
y er RAP Feed
Dr um
Dr
Cold feed bins
 Aggregate to screens
Screens size
aggregate

Hot aggregate
travels up bucket
elevator

Aggregate
weigh hopper Bitumen
weigh
pot
Pugmill
Hot mix
asphalt
Aggregate dispensed
from dryer into truck /
hot-bin
Aggregate and bitumen weigh
hoppers

Bitumen
Weigh-hopper
Aggregate
Hot Bins
Warren Brothers Patent Application Drawing:
Original Batch Plant
Belt Scale Calibration

Cold feed system

s ca l e
Belt Reference
scale
Cold Feed Bins and RAP Bin
“Graphing the Feeders”

Feeder #1
80
Tons per Hour

70
60
50
40
30
20
10
0
20 50 90

Belt Speed or Potentiometer Setting

Tachometer Mounted on Tail
Pulley of Cold Feed Bin Belt
“No Flow” Paddle at
Feeder Discharge
Induced Air Burner
 Fuel Reticulation and
Heating System

HFO
Tank

In-line heater HFO Sampling pt

Temperature Profile of
Counter-Flow Dryer
Combustion Drying Heating
800º C

760º C 120º C

400º C Gas
es

Aggregates

0º C Aggregate
150º C 150º C 100º C
300º F 20º C
Drum Flights / Lifters
Primary and Secondary
Emission Control
Primary Dust Filtered
Collector Secondary Air
Dust
Collector

Drying Fines
collected and
Drum
returned
Exhaust
Fan
Primary Collector:
Cyclone
Multi-Tube Collector

Outlet
tube

Gas inlet
Spin vanes

Inlet
tube

Collector
element
Valve
 Discharge Housing
Functions as a Knockout
Box
Air

Gas flow

Optional knock
down plate
Bitumen

Fines mix
with hot mix
asphalt
Cutaway Section of a
Typical Baghouse
Pulse Jet Baghouse
Exhaust fan Exhaust fan

Manifold Manifold

Dust screw Dust screw

Automatic Damper
Controls
Cyclone, Screw Collector, and
Hot Elevator
Hot Elevator

Cyclone feeding
fines directly back

Batch
tower
Filler Weigh-Pod After
Surge Silo
Emission Control
Summary
• Remove particulate matter
– Primary
– Secondary
• Return fines to the mix
– Affects void content
– Affects mix stiffness
– Difficult to control
Batch plant filtration
Aggregate storage
Aggregate Storage
Bitumen Storage

BITUMEN TANKS – ELECTRICALLY HEATED/

24 HR TEMPERATURE MONITOR AND CONTROL
Old Style
Operating Cabin
Plant automation:
Modern control cabin:
Plant automation
Roodepoort Op Screen
Plant Automation – Operating System Graphics
Batch Plant Schematic
Batch Plant Op Screen
Laboratory from the past
Modern Asphalt Laboratory
Quality Control Trends
Monitored
Binder Content
Binder Content

0.4

0.2

-0.2

-0.4

-0.6

-0.8

S a m ple No .

Voids in Mix
V. I. M.

2
1.5
1
0.5

0
-0. 5
-1
-1. 5
-2

Sa mp l e No .

Filler Content
Filler Content

1.5

0.5

- 0.5

-1

-1.5

S a m p l e No .
Slat Conveyor Feeding
Storage Silos
Hot Storage – Skip and
Winch System
Skip
Plant Bucket
Mixing
Tower

Winch
Storage Silo: 165 t
Capacity
Correct Loading
Sequence
The good old days

The End