Description
- The Batch Type Fixed Asphalt Plant - 160 T/h is a fully automated facility designed for efficient asphalt production. It has a capacity of 160 tons per hour and includes various components like aggregate dryers, weighing systems for aggregate, filler, bitumen, and advanced mixing equipment. The plant operates either manually or automatically via a central control system, with an operator-friendly interface for monitoring and adjustments. It includes precise material measurement, temperature controls, and advanced filtration to ensure high-quality asphalt production. The plant is also equipped with safety features such as failure alerts and temperature monitoring to protect equipment and ensure consistent output. Additionally, it features a comprehensive reporting system for tracking material usage and plant performance.
Name Of Unit Quantity Feed Bunker 15 M3 5 Dozing Belt 2,2 Kw Motor-gear - 500 Mm Rubber Tape 5 Collecting Belt 4 Kw Motor-gear -600 Mm Rubber Tape 1 Dryer Sloped Belt 5,5 Kw Motor-gear - 600 Mm Rubber Tape 1 Rotating Dryer 10 X 2.000 X 8.500 Burner Ecostar 16,500 Kw 1 Jet-pulse Type Fi̇lter 50.000 M3/h 55 Kw 1 Fliller Si̇lo 50 Tons And Transfer Fi̇ller Screw 1 Filler Elevator 4 Kw 1 1 Aggregate Elevator 22 Kw 1 Vibrating Screen -two Vibrators- 5+1 Layer Screen And Bypass System 1 Hot Aggregate Silo 30 Tons 1 Aggregate Weighing Scale 2.200 Kg 4 Load-cell 1 Filler Weighing Scale 400 Kg 3 Load-cell 1 Bitumen Weighing Scale 150 Kg 3 Load-cell 1 Bitumen Weighing Scale 150 Kg 3 Load-cell 1 Mixer 30 Kw Duoble Reduce Rgearboxes 2.200 Kg 1 Hot Asphalt Stock Silos 15+15 30 Tons 1 Compressor 22 Kw 3.2 M3/min. 8 Bar 1 Control Cabinet 2.400 X 5.000 X 2.400 Mm 1 Bitumen Tank Capacity Of 40 Tons 2 750.000 Kcal/h Hot Oil Generator 1 Cold Aggregate Bunkers There 5 cold aggregate bunkers made of 6 mm St 37 sheet, they shall be approximately 15 m3 and each one shall be produced separately. There 1.500 mm high upper additions made of 5 mm sheet on the bunkers to prevent material overflow. Material cast of the bunkers made with mot.red group. 2,2 Kw 23 d/dk. Material cast flow rate of each bunker frequency controlled (speed controlled) dozing one by one if desired or adjustable from computer screen. The flow rate of the material flowing from bunkers adjustable from the manual gate to be placed on each bunker. In case of running out of the aggregate flowing from the bunkers, there a warning system and a warning sign shall be displayed on the computer screen to warn the operator. Vibrator engine controlled from computer screen placed to relieve material flow and prevent blockage in the bunkers with thin materials. Drive 0,55 Kw. A conveyor belt system shall be installed under each bunker to ensure material flow. Each bunker equipped with modular gratings consisting of 10x50 metal sheets 10mm rounds. Silo loading width 3.000x2.400 mm. There rope emergency stop system for emergencies. Possible failures on belts displayed on the computer screen. Sub-bunker Cold Aggregate Collector Belt Horizontal belt convey the material taken from each bunker separately in a controlled manner to the dryer sloped belt and be able to convey material to 160 t/h capacity plant. Rubber belt 10 mm thick; 600 mm wide 4 layered court fabric and have 4 EP 70 qualities. Belt Start/Stop operation performed from computer screen. When the materials in the bunker are desired to be discharged at the end of the season, the belt may be run reverse without running the other units. Horizontal belt chassis made of steel construction material by which the belt can operate smooth and produced with belt tensioning system. The belt with separator system from each end. The driving drum rubber coated and it 1 degree angle lathed. There rope emergency stop system for emergencies. Possible failures on belts displayed on the computer screen. The belt red./motor driven, driving drum rubber coated, the belt able to be driven triple roller chassis. The bearings in the roller enclosed type and maintenancefree. Located under the belt feeders, with direct feed onto the inclined conveyor.
| Dryer Group | |
| Dryer body manufactured from 10 mm thick 2,000 mm diameter,8.500 long SAE 950 C special alloy heat resistant manganese steel sheet metal. | |
| Inside of the dryer made of winged buckets made of heat and corrosion resistant special alloy steel sheet metal to ensure that materials dry and move homogenously thoroughly. | |
| There two peripheral rings to ensure that the dryer body rotates circularly smoothly on the chassis. | |
| Dryer body rotated by 4 x 11 kw red./motors on 4 idler rollers on chassis. | |
| The ring and the running surfaces of the idler rollers hardened by induction, thus avoiding corrosion of the running surfaces. | |
| Dryer body wrapped with a 50 mm rock wool and coated with stainless sheet metal to avoid heat loss during operation. | |
| There a frontal gate made of heat and corrosion resistant material in front of the dryer body and chassis for connection of the burner and to ensure dried material is cast on the aggregate elevator. | |
| There a gate with gas outlet channel behind the dryer body and chassis for removal of the dust in the body through filter during operation and to ensure material from feed sloped belt is cast in the drier. | |
| The design of the dryer made to ensure the incoming material moves forward smoothly. | |
| Dryer body rotate between the gates placed in the front and behind. | |
| There a maze system to avoid the material to flow out in the rotation places. | |
| An electronic heat indicator shall be put at the point where the aggregate heated in the dryer is cast on the elevator, thus tracking the aggregate heat from the control cabinet. | |
| Dryer chassis produced from durable material suitable for the body, sub conveyor legs connected to the chassis with joints and leg intervals enforced with cross connections. | |
| Dryer driving system shall be equipped with soft-starter, which prevent Ring and ring rollers from exposing to impacts and their economic life shall be extended. | |
| The current value drawn by the drier motor shall be displayed on the computer screen. | |
| Thanks to this system, the automation system and operator shall prevent the drier from being overloaded and protect the drier system from possible failures or damages. |
| Drayer Burner | |
| Dryer burner full automatic industrial type suitable for 160 t/h plant at 3 % humidity rate. | |
| Diesel oil can be used as fuel in the burner 16.600 kW . | |
| Burner fired from the cabinet and fuel system supported with a pump and suction of the pump protected with a filter. | |
| In case of using fuel oil in the burner, the preheater heat exchanger group. | |
| Outer surface of the piping system coming to the burner isolated. | |
| Flame height of the burner increased or decreased from computer screen. | |
| Flame height of the burner adjusted from computer screen (in %). | |
| Start/Stop operation of the burner performed from computer screen and the phases after the burner is ignited and failure details displayed on computer screen. In case of failure connected to the burner, the operator see the where the failure has occurred and immediately respond to the failure. | |
| Aggregate temperature, filter inlet temperature and fuel oil temperature displayed on computer screen. | |
| When such temperatures exceed the limit values, warning signs displayed on the computer screen to warn the operator. After some time when such temperatures exceed the limit values, the burner automatically stop by the automation system, thus preventing the filter group or other units from being damaged. | |
| There a censor (vacuum meter) system to measure the counter pressure in the drier. |
| Dry Dust Suppression Filter And Filler Silo Group | |
| Filter plant filter and remove the dust particles discharged from 160 t/h capacity dryer and screen top to the air via fan. | |
| Filter also filter the gas created by the burner. | |
| Fan value and motor power to be used in filter suction have required capacity for 160 t/h plant. | |
| There servo-motor driven valve in front of the fan to adjust the flow rate of the fan. | |
| The command of the valve in front of the chimney fan controlled automatically by the automation system by means of the vacuum meter measuring the drier counter pressure. Additionally, it can be controlled by the operator from the computer screen if desired. | |
| Through such system, the fan flow rate adjusted automatically depending on the system requirements, thus increasing economic lifetime of bags and saving power. | |
| The value of the counter pressure followed up on computer screen in mmSS. | |
| Filter dust bag and cassette type or reverse flow, pneumatic controlled valve cap, and there pre-separator. | |
| Filter body installed on a bunker and rough particles avoided to harm being collected in a separator and bunker space and reaching to the bags. | |
| Filter connected to the dryer via a channel. | |
| Nomex filter cloth used in the filter system. | |
| There platforms, banisters and ladders where required in the filter. | |
| Reaching the material collected under the bunker to the filler elevator ensured with tube spiral. | |
| As soon as the filter body exceeds 180 degrees, fresh air adjustment valve put to cool the filter. | |
| On/off position of the fresh air adjustment valve of the filter seen on computer screen. | |
| In the event that the temperature of the filter cannot be reduced for any reason, the plant automatically stop to avoid burning of the bags. | |
| The surface of the filter isolated 50 mm glass wool and coated with aluminium sheet. | |
| The system incorporate a 30 ton capacity of filler silo. | |
| The filler silo installed between the filter and the filler elevator and designed to automatically stock up the filler in the hot aggregate bunker and to deliver to production when needed. | |
| The filler silo equipped with a level indicator and a filler discharge spiral. | |
| Start/Stop operation of the filter group performed from computer screen. | |
| Possible failures can be seen on computer screen. |
| Tower Group Filler Elevator | |
| Filler elevator body produced from 5 mm sheet metal to be delivered in complete and mounted. | |
| Filler elevator designed to convey the filter bunker and the filler in the filler silo to the filler weight stock bunker. | |
| Body joining parts of the filler elevator flange connected and sealed. | |
| There maintenance gates on the filler elevator body for bucket replacement and maintenance. | |
| In the event that the filler elevator stops for any reason during operation, there a return lock installed in the drive group to ensure the loaded buckets become upside down and block elevator. | |
| There a weighted type chain tensioning system on the filler elevator. | |
| Filler elevator driven by Motor/red, chain and chain gear group. | |
| Filler elevator buckets produced from st 52 3 mm sheet metal and bucket edges reinforced with 6 mm st 52 material. | |
| Filler elevator driven by Motor/red, chain and chain gear group. | |
| Aggregate elevator chain HRC 35 – 45 hard special produced chains. | |
| There a platform and banister group where there is the drive group of the filler elevator. | |
| Filler elevator able to feed 180 t/h plant. | |
| The red.motor cable of the drive group of the filler elevator pass through the tube welded on the body in a steel tube suitable for cable diameter and be connected mot.red. | |
| Start/Stop operation of the filler elevator performed from computer screen. | |
| Failure details of the filler elevator can be seen on computer screen. |
| Fi̇ller Si̇lo 50 Tons – 1pcs | |
| If the filler which is come from filter is not enough and filler silo is empty then filler which is in this silo is tarnsported to the filler elevator and fresh filler silo. | |
| Filler Tranportation from the Reclaimed Filler Silo to the Filler Elevator. | |
| Filler is transported from the Reclaimed Filler Silo to the Filler Elevator via one screw | |
| Reclaimed Filler Silo Filler Discharge Unit. | |
| Filler discharged via a special discharge pipe and a diameter 250 mm manual gate from the reclaimed filler silo. |
| Tower Vibrating Screen | |
| Vibrating screen produced 5 layered to sort the heated aggregate from aggregate elevator into 5+1 types. | |
| Vibrating screen placed on helical springs from 4 lateral points and designed to be working with 2 vibrational motors system. | |
| Tensioning system of the internal screens spring tensioning system. | |
| To ensure the asphalt plant operates by-pass, there shall be pneumatic cylinder controlled twoway valve at the vibrating screen entrance. | |
| Start/Stop operation of the screen performed from computer screen. Failure details oft he screen can be seen on computer screen. | |
| Screen/by-pass selection made on computer screen. | |
| In case of a failure of the screen, the system taken to by-pass position and production can be continued. | |
| There a conveyor channel to avoid blockage of the screen by possible material on the screen or excessive aggregate; such material conveyed to a stock silo through the conveyor channel. |
| Tower Group Sub- Screen Hot Aggregate Bunker | |
| Hot aggregate bunker produced to consist of 5+1 chambers with 30 tons volume in total to send the material screened to the weighing scale. | |
| Pneumatic controlled gates placed on the outlet passage of each chamber under the hot aggregate bunker and a separately controlled gate placed on the outlet passage of the 0,5 material for fine weighing. | |
| There a 2 m3 filler stock chamber whose outlet is emptied with a star valve. | |
| There an air shocking system to avoid blocking in the filler chamber. | |
| Hot aggregate bunker produced from 5 mm sheet metal and its outer surface produced to be insulated with 50 mm glass wool and aluminium trapeze sheet. | |
| Each sub-screen hot aggregate silo shall be equipped with a maximum level indicator. | |
| Before the silos are filled fully, a warning sign displayed on computer screen and the operator respond to cold silos before the silos overflow. |
| Aggregate Mixture Weighing Scale | |
| There an aggregate mixture weighing scale on the tower mixer chassis to weigh the material required for mixture. | |
| Aggregate mixture weighing scale produced to weigh approximately 2.200 kg material with load-cell from 4 points and automatically smoothly and quickly discharge. | |
| Material amount in the aggregate mixture weighing scale displayed on digital indicator and computer screen in the control cabinet. | |
| Weighing made manually or automatically by computer depending on the choice. | |
| Material values required to make weighing automatically (receipt values) entered from computer screen. | |
| Limitless number of receipts can be created. Receipt values and receipt name can be changed any time. | |
| Any desired sub-screen silo gate can be opened from computer screen by the operator even if weighing is automated. | |
| In case of overloading of the weighing scale, a warning sign displayed on computer screen and the operator warned. The information that the pneumatic gate of the aggregate weighing scale is open displayed on computer screen. | |
| In the event that the gate does not open completely for some reasons during automatic production,the production suspended by automation system and the information about the failure displayed on computer screen. |
| Filler Mixture Weighing Scale | |
| There a filler weighing bunker on the tower mixer chassis to weigh the filler material required for mixture. | |
| Filler mixture bunker produced to weigh approximately 400 kg material with load-cell and its discharge passage able to discharge with pneumatic cylinder controlled valve. | |
| There 273 mm diameter mot./red. Driven pipe spiral to send the material weighed filler mixture weighing bunker to the mixer. | |
| Material amount in the filler weighing bunker displayed on digital indicator and computer screen in the control cabinet. | |
| Weighing made manually or automatically by computer depending on the choice. | |
| There pneumatic or electric vibromotor system to prevent possible jams in filler weighing scale. Such systems activated automatically in case of a jam. | |
| The operator can control such systems from computer screen when desired. | |
| In case of overloading of the weighing scale, a warning sign displayed on computer screen and the operator warned. |
| Bitumen Mixture Weighing Scale | |
| Bitumen mixture weighing scale produced to feed the mixer of 160 t/h plant and to be 10 l/sec. | |
| Bitumen mixture weighing scale isolated to preserve the heat of the bitumen. | |
| Bitumen mixture weighing scale designed to ensure that bitumen discharge passage is heated with hot oil. | |
| Material amount in the bitumen mixture weighing scale displayed on digital indicator and computer screen in the control cabinet. | |
| Weighing made manually or automatically by computer depending on the choice. | |
| In case of a load cell failure in bitumen weighing scale, the precaution required to avoid overflowing of the bitumen weighing scale taken by the automation system. | |
| In case of overloading of the weighing scale, a warning sign displayed on computer screen and the operator warned. | |
| The bitumen weighed pulverised with a pump or by direct discharging and introduced to the mixture. |
| Mixed Material Storage | |
| There are 1 hot asphalt stock silos with max.35 (15+15) 1 PCS tons capacity. | |
| There a sub-mixer hot asphalt loading silo in the tower and it shall have a 4.100 mm loading space with the capacity of 35 tons and a pneumatic controlled double cast gate. |
| Mixer | |
| Capacity : 2.200 kg | |
| Drive motor : 2 x 30 kW (softstarter) | |
| Mixer body produced from 10 mm sheet metal to mix 2.200 kg | |
| Internal surface of the body produced to be able to be replaced against corrosion by manganese steel cast modular sheet plates. | |
| Mixture arms lined up to make a homogenous mixture on a double square (100x100) shaft. | |
| Mixture arms and caps produced from manganese steel to be able to be replaced. | |
| Mixture placed to shaft beds to ensure it affected by heat, be driven by planet reduction systems and diving point ensured to grip with a rubber coupling. | |
| Sub discharge gate of the mixer driven by pneumatic cylinder and the gate produced to be with lateral bearing or slide system. | |
| Mixer gate surface produced to be demountable with corrosion plate. | |
| A manhole gate placed to make maintenance and spare part replacement of the mixer smoothly. Such gate protected with a safety switch. | |
| Joining point of the mixer and aggregate weighing scale closed with a rubber and tight cuff. | |
| The information that the pneumatic gate of the mixer is open/closed displayed on computer screen. | |
| In the event that the gate is not closed for some reasons during automatic production, the production suspended by automation system and the information aboutthe failure shall be displayed on computer screen. | |
| During manual or automatic production, mixing time of the material in the mixer adjusted from computer screen by the operator. | |
| The time elapsed after the material is discharged into the mixer displayed on computer screen. | |
| There a sub-mixer hot asphalt loading silo in the tower and it have a 3850 mm loading space with the capacity of 30 tons and a pneumatic controlled double cast gate. | |
| Hot asphalt silo have a weighing system optionally. |
| Bitumen Tank (50 Tons) | |
| Tanks capacity 50 tons. | |
| Tanks produced in accordance with TSE and highway commission practices. | |
| The tank incorporate a hot oil heating, | |
| The bitumentemperature up to mixer mixing temperature. | |
| The fuel tank incorporate level and heat indicator, suction nozzle, filling orifice, ventilation system, inspection hatch and drain outlet. | |
| There support legs under the tank and its surface isolated with 50 mm rock wool and covered with 0,80 mm galvanized sheet. | |
| Length : 12.000 mm (included insulation) | |
| Diameter : 2.500 mm (included insulation) | |
| Head type : Flat | |
| Heating pipes : Not welded Body sheet thickneess : 6 mm |
| Hot Oil Generator | |
| Generator capacity 750.000 kcal/h | |
| The system made according to diesel fuel system. | |
| The generator incorporate a 500 l filling tank. | |
| The generator horizontal, have seamless steel drawn hot oil pipe, double wall and circulation body. | |
| Generator body isolated with 100 mm rock wool and covered with aluminium sheet | |
| Thermal Oil Heater TR 100 (Diesel-oil) | |
| Burner Capacity : 50-150 kg/h (Diesel-Oil) | |
| Thermal Oil Volume : 400 l Max. Operating Temperature : 280C | |
| Thermal Oil Pump Drive : 11 kW | |
| Delivery Pump : 60 m3/h | |
| Expansion Tank : 750 | |
| Outlet Tank : 750 | |
| Burner Type : Diesel-oil | |
| Oil Feeding Pressure : 500 mBar | |
| Generator system produced according to manufacture standards and it incorporate an expansion tank, degasser, oil filter, valves and full automatic ignition controlled burner, control panel, pomp and necessary safety equipment. | |
| The serpentine be made of min. 36 m2 seamless steel drawn pipe. | |
| The generator equipped with coupled warning system to protect the complete system in case of dangerous situations showing hot oil level or a decrease in heat transfer oil level. | |
| The burner system designed to activate automatically depending on the adjusted operation temperature of the heat transfer oil. | |
| The system produced in the form of a complete package. |
| Bitumen Dosing Pump | |
| Bitumen pump with integrated overpressure ball valve and electric heating elements. | |
| Thermostat controlled by a PT 100 sensor. | |
| Capacity : 460 l/min | |
| Drive Capacity : 11 Kw | |
| Pressure Range : 1-4 Bar | |
| Heating : 2 x 630 W |
| Service Pump | |
| Capacity : at least 28 m³ / h | |
| Engine : At least 15 kW | |
| At least one pump will serve the bitumen scale while another pump will allow filling of tanks and transfer of bitumen between tanks. |
| Bitumen-fuel Tank And Hot Oil Generator Piping System | |
| Piping, tank inlet and outlet valves and line ventilation valve (globe hot oil valve) between hot oil generator and fuel and bitumen tanks of the system and all connections of the system made in compliance with the system. |
| Control Cabinet And Power Boards | |
| Control cabinet have 2.400x4.000x2.500 PVC doors and windows isolated against hot and cold. | |
| Cabinet placed where the operator can have a control over entire of the plant. | |
| An empty cabinet with the sizes of a main cabinet to be used as a compressor chamber or maintenance chamber put under the control cabinet. | |
| An air conditioner installed in the control cabinet for heating or cooling. | |
| The materials to be used in the power board Moeller, Phoenix Contact, ABBTelemecanique etc. | |
| PHOENIX CONACT PLC system used in automation system. | |
| The panel containing the main switch incorporate a Multimeter indicating current-voltagepower-power factor details and lambs indicating R-S-T phases. | |
| Capacity : 3,2 m3/min. 8 bar. | |
| Motor : 22 kW | |
| Air storage tank : 1.000 lt. |
| 100 T/h Asphalt Plant Automation And Control System | |
| Operation of the asphalt plant controllable manually or automatically on the computer on the operator desk in the control cabinet. |
| Manual Operation | |
| Performed by following up working order of the plant by the unit motors in the asphalt plant; material flow among such units is locked electrically on the reverse direction of the material flow. | |
| Upon starting all the units, aggregate, filler and bitumen weighing is done checking the computer screen. | |
| Aggregate weighing scale, filler weighing scale gates is opened manually and cast in the mixer. | |
| Bitumen amount also is realised manually during casting. | |
| Mixer mixing and gate opening duration is done by the operator manually. | |
| Filter and burner are started manually. Filter damper and burner flame tube and degree are done pressing on/off button by the operator monitoring on the heated aggregate heat indicator on the dryer. | |
| There will be a manual button automation system in the control bank. |
| Full automatic operation | |
| The asphalt plant operates automatically the same as it does manually. After the plant enters the system, and upon manual/automatic selector switch on screen turned to automatic position, weighing and mixing system is performed automatically. In addition, continuous adjustment of filter damper valve is done automatically. | |
| The weighed aggregate, filler and bitumen is cast in the mixer automatically. Mixer mixing duration is done continuously in the set value. | |
| Upon completion of the mixing duration, mixergate opens automatically, mixture is poured into the hot silo, mixer gate closes automatically. | |
| Operator can observe on the screen that how many kilograms material he has taken from which aggregate silo, how many materials he needs and for which material a delay occurs, if any and which aggregate silo must be adjusted following up the periods when gates remain open. | |
| He can monitor aggregate temperature, bitumen temperature introduced to the mixture, filter chimney temperature, flame height, drier current, aggregate elevator current, damper valve opening amount or vacuum value, fresh air on/off position and aggregate feed silos cast speed and rates. | |
| In case of a failure of any unit, illuminated and acoustic failure signal can be seen on the same page. | |
| Dryer boiler industrial type proportional burner control brain is performed by SIEMENS or LAMTEC controller. | |
| Whether there is a flame can be checked with flame detector. If there is not any flame, or if it has stopped while burning, fuel route is closed and fuel pump stops, which can be seen on the screen. | |
| All the units of the filter group are started or stopped by single button. In case of heat increase, cool air is introduced activating fresh air adjustment valve placed in the exhaust channel to protect the filter unit. | |
| If the introduced cool air is insufficient, burner stops automatically and filter is protected. | |
| Filler cast valve and star valve for weighing operate on automatic program. |
| Reporting | |
| Daily used aggregate, filler and bitumen amount and their total amount until reporting day can be seen on reporting section and printed out | |
| and archived if desired. Retrospective interrogations can be made in the reporting section. Namely, depending on the desired date, much information such as production amount, amount of materials used, aggregate-bitumenfilter-fuel oil temperature, mixing time, receipt used etc. can be accessed. | |
| All failures starting from commissioning of the asphalt plant until the day when the reporting is made can be reported. | |
| Air compressor automation supporting the pneumatic system incorporated in it. | |
| Hot aggregate silos, manufactured asphalt hot silo, waste material silo, filler silo and filler weighing silo are equipped with level indicator and material levels can be checked on the screen. |
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