Counterflow Asphalt Drum Mix Plant
Gajjar Equipments Pvt. Ltd. is a well-known manufacturer, supplier, and exporter of Counterflow Asphalt Drum Mix Plants. We design our products keeping the requirements of clients in consideration. Our product is ideal construction equipment for manufacturing asphalt for building roads through batch mixing.
- STATIONARY
Counterflow Asphalt Drum Mix Plant
CONTINUOUS DUAL DRUM ASPHALT MIXING
GAJJAR makes an asphalt plant with two drums and one simple design. You can be assured with our proven technology and time-tested engineering principles. They combine the simplicity of existing continuous drum-mix plants with the added efficiency achieved through counterflow technology. The plants produce mix at a lower cost than traditional parallel-flow drum-mix plants. They require less energy to heat materials and therefore reduce emissions as well. In a counterflow drum mix plants, aggregates, and airflow in opposite directions through the drum, enabling more efficient heating of the aggregates and better control over the mixing process. This design enhances asphalt quality, making it ideal for applications where superior durability and performance are required. Counter-flow plants are often preferred for producing high-performance asphalt mixes for highways, airports, heavy-duty pavements, and other critical infrastructure projects. They offer excellent temperature control, ensuring thorough mixing and uniform distribution of asphalt binder throughout the mixture.
Exceptional Pavement Mix Output
Capacity Range: 90 TPH to 160 TPH
HIGHLIGHTS
- Efficient counterflow dryer drum
- Fuel savings through counterflow technology
- Use of RAP
- Reduced bitumen aging
- High-quality mix
- Optional bag filter and pre-separator which is environment-friendly
Advantages of Counterflow Drum Mix Plant
- Improved Heat Efficiency: The counterflow design ensures better heat transfer, reducing fuel consumption.
- Reduced Emissions: The efficient dust collection system minimizes the release of pollutants.
- High-Quality Mix: Uniform heating and mixing result in a consistent and high-quality asphalt mix.
- Continuous Operation: The plant can operate continuously, making it suitable for large-scale projects.
Working Principle
1. Weighing Virgin Aggregates
The virgin aggregates (such as sand, gravel, and crushed stone) are individually weighed from the cold feed bins using a variable, continuous, and automatic belt speed. The proportions are determined by the control systems. Once weighed, the aggregates are transferred to the dryer via a charging conveyor.
2. Drying and Heating
As the drum rotates, aggregates move towards the burner located at the opposite end. The burner heats the aggregates as they move through the drum. The hot air generated by the burner flows in the opposite direction to the aggregates, ensuring efficient heat transfer and drying.
3. Hot Aggregate Flow and Mixing
Once the aggregates are heated and dried, they move into the mixing zone of the drum. In this mixing drum, the hot aggregates are mixed with bitumen (asphalt binder). The bitumen is stored in a heated tank and pumped into the drum at a controlled rate. The mixing process ensures that the bitumen coats the aggregates uniformly, creating a homogenous asphalt mix.
4. Discharge
Once the aggregates are heated and dried, they move into the mixing zone of the drum. In this mixing drum, the hot aggregates are mixed with bitumen (asphalt binder). The bitumen is stored in a heated tank and pumped into the drum at a controlled rate. The mixing process ensures that the bitumen coats the aggregates uniformly, creating a homogenous asphalt mix.
Key Components of Counterflow Asphalt Drum Mix Plant
The aggregate feeding bins in GJJAR Asphalt Mixing plants are equipped with variable speed drive motors and gearboxes for each bin. These motors allow precise control and regulation of the aggregate flow individually, enabling the addition of the required proportions of individual aggregates according to the mix design.
The drying and mixing drum in a hot mix plant is a critical component. As its name suggests, it performs the task of drying the aggregates as they enter the drum. Later in the process, the aggregates are effectively mixed with bitumen and other minerals. The drum is equipped with specially designed flights that thoroughly treat each type of aggregate during the drying process. These flights also facilitate uniform mixing with bitumen and other minerals.
GAJJAR makes asphalt drum mix plant features an efficient, low-noise burner that can operate using diesel, LDO (Light Diesel Oil), and furnace oil (optional). This maintenance-free burner produces a strong flame, effectively heating the aggregates to their maximum temperature. By continuously reducing the aggregate moisture content, the burner ensures optimal production. The burner uses a two/three nozzle type pressure jet system with high- low intensity. This design enhances fuel efficiency.
The load-out conveyor serves to discharge the hot mix material into a truck. At the other end, it is equipped with a GOB (Gate-Operated Bin) hopper. The GOB hopper helps control the segregation of the mixed asphalt. It is beneficial to have hydraulically operated gates for efficient operation.
The load-out conveyor serves to discharge the hot mix material into a truck. At the other end, it is equipped with a GOB (Gate-Operated Bin) hopper. The GOB hopper helps control the segregation of the mixed asphalt. It is beneficial to have hydraulically operated gates for efficient operation.
Asphalt storage tanks come in cylindrical O-shaped or U-shaped designs. These tanks are insulated with 50 mm thick rock wool to prevent heat loss and reduce burner fuel consumption. They are mounted on a sturdy full chassis. The standard package includes an automatic pressure jet oil burner, a bitumen pump with a jacketed oil body, and a bitumen metering system with a variable speed motor and hot oil circulation motor.
Technical Information
| MODEL | CDMX-60 | CDMX-65 | |
|---|---|---|---|
| RATED OUTPUT @ 3% moisture content | TPH | 90 - 120 | 120 - 160 |
NOTE: The plant’s production rate can vary depending on the following factors: aggregate moisture, the altitude where equipment is installed, the percentage of fine aggregates in the mixture, mixture temperature, fuel’s calorific power, and the specific weight of the aggregates.
Per GAJJAR’s policy of constant upgradation of products, specifications are subject to change without prior notice.
- FAQ?
FAQs About Our Components of Counterflow Asphalt Drum Mix Plant?
A counterflow asphalt drum mix plant is a type of asphalt mixing equipment where the flow of aggregate and air occurs in opposite directions, resulting in better heat transfer and reduced emissions.
Improved Efficiency: Maximizes heat transfer by counter-directional air and aggregate flow.
Lower Emissions: Reduces pollutants by processing exhaust gases. Superior Mix Quality: Ensures consistent and thorough mixing of materials
The cold aggregate feeder consists of multiple bins that supply different types of aggregates in the required proportions. A conveyor transfers the aggregates to the drying drum.
The bitumen is stored in insulated tanks equipped with a heating system to maintain its flowability. The system ensures consistent temperature for optimal mixing.
Our plants use:
Diesel-fired burners.
Gas-fired burners.
Dual-fuel burners (diesel and natural gas). Each is designed for high efficiency and low emissions.
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