Continuous/Batch Mix Plants

History, Operation with Recycle Asphalt

• The Ultimate Goal is to Produce Quality Asphalt,
no matter what plant, make, model or
configuration….
- Test,test,test material CS in CS out
- Clean Aggregates, Clean Recycle
- 6 % Slope for Stockpiles if possible
- Pave under Stockpile if possible, moisture is
highest in bottom 6 ft or less
- rule of thumb, for every 1% moisture equal to
10% in production $$
- QC is ahead of all the Canadian Provinces with
covering materials…..
Retrofit concrete mixer…. 3 tph
Hetherington & Berner Railcar Portable, 1908
Warren Brothers Portable
 Batch Plant – One Bin Cold Feed
Screen separates into
4 sizes

Single Bin
 Batch Plant – Four Bin Cold Feed

Aggregate sizing
moved back to the
quarry
 Process Flow For Batch Plants

Separated Here

Together Here
Separated Here

Put back
Together
Here
Batch Tower
Gradation Control
• Bin 1 contains from 75%
to 90% of mix surface
area
• Screen effects only 10%
to 25% of mix surface
area
• Fines problem in
coldfeed bins show up in
Bin 1
• Gradation controlled in
coldfeed bins
Process Flow for Continuous Plants

Together Here

Separated Here
 Surge Bins and Silos
The one thing that has changed the industry more than anything else
Benefits of Surge Bins and Silos

• Allowed plant to keep running

– Prevented segregation in bins caused by multiple start/stop
– Could continue to load trucks during breakdown

• Helped reduce labor cost

– Crew could start at a normal time, not hours before first truck

• Allowed for most common mixes to be stored; also

helped reduce the "need" for special mixes
Recycled Asphalt Pavement (RAP)
How much is recycle worth?
 6% Bitumen

RAP is worth the virgin material it replaces

Recycle makes a better road

Why?
SUSTAINABILITY

Rock Quarry
+
Oil Well

Rock Quarry
+
Oil Well
Concept of using RAP not a new idea.
Trinidad Lake Asphalt… Very Expensive
Recycle Asphalt Pavement (RAP)
Price of bitumen low

“Artificial” bitumen from crude

Low oil prices (1920’s, 1930’s)

Little interest in recycle

History Intervenes: 1960’s, 1970’s
Global petroleum demand increases

Aggregate sources less accessible

Lower quality aggregate

Growth fuels demand for roads

Renewed interest in recycle

RAP + Virgin Aggregate ONLY

25% RAP 10% RAP

300F(149C) 300F(149C)
Counterflow Drying Drum

Batch plants use an efficient dryer, but…

don’t do well with high levels of recycle.

 Running RAP is like… Warm
Cold Hot Water
Water Water

+ =
Virgin
RAP Aggregate Mix
(Ambient Temperature) (Mix Temperature)
(Superheated Temperature)
 What affects the level of superheat?
Virgin Mix
RAP Aggregate

+ =

Mix
% Moisture
% RAP Superheat Temperature
In RAP
 Water expands in volume over 1700x

Mass: 1 lb of water 1 lb of steam

Volume: 3 inch cube 3 foot cube

Density: 62.30 lb/ft3 0.035 lb/ft3

Volume of Steam per batch

Batch RAP % RAP Moisture Steam Density

4 ton 0.035
25% 5%
8000 lbs lb/ft3
Additional Baghouse Airflow

Typical Batch Plant Batch RAP Feeder

“Dump In” “Meter In”

Rap Entry Rap Entry

Time Time

Additional Additional
Airflow Airflow
Requirement Requirement
Additional Baghouse Airflow

Typical Batch Plant Batch RAP Feeder

“Dump In” “Meter In”
Dump in over 5 Seconds… Meter in over 25 Seconds…

Values are approximate and do not indicate design requirements for any
specific plant or location. See Astec Engineering for exact equipment sizing.
 Batch versus Continuous Baghouse Size Requirements

143 shortTPH using 25% RAP (5% Material Moisture)

50000

45000
Required Exhaust Volume (ACFM)

45,000
Dump in RAP
(Typical Batch Plant)
40000

35000

32,000
30000 Meter in RAP
(Astec Batch Plant, 1%
per second)
25,000
25000
First Batch Second Batch Double Barrel
Unified Drum
20000 (continuous metering)
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
Time (Seconds)
 Baghouse Size Requirement vs. %RAP
143 shortTPH using 25% RAP (5% Material Moisture)
50000
Required Exhaust Volume (ACFM)

45000
Dump in RAP
(Typical Batch Plant)
40000
30% RAP 50% RAP
Practical Limit Capability

35000

30000
Meter in RAP Double Barrel
(Astec Batch Plant, 1%
per second) Unified Drum
25000 (continuous metering)
Tower
Scavenge
20000
0 5 10 15 20 25 30 35 40 45 50
Introducing RAP as continuously as possible
% RAP limits the baghouse size required.
RAP Controlled Feed System

Weigh Hopper

Controlled Feeder
Mixer
RAP Controlled Feed System

Weigh Hopper

Feeder Hopper

Controlled Feeder

Mixer
RAP Controlled Feed System
 RAP Controlled Feed System

Weigh Hopper

Feeder Hopper

Controlled Feeder
 RAP Controlled Feed System

Weigh Hopper

Feeder Hopper

Controlled Feeder
Batch Tower with
Rap Collar on
Dryer
• Stored aggregate
temperature determines
mix temperature.
• No more then 10-15%
across screen…screen will
blind
• Same for entry at boot of
elevator
• Chutes are habitual at
plugging up
Counterflow Drying with Rap Collar
Diffuser Ring
Early Entry Rap Collar on Agg Dryer
Screen Bypass Causes Segregation
Batch Tower…Conti
• Can be made into bypass
using bin 1 or Bin 1 and 2
by simply removing the
wall
Batch + Continuous = Hybrid
Batch Tower 5th Bin
• 40% Recycle capability
• Up to 20% recycle across screen
• No steam explosion
• No “hot rock” storage issue

52
 Batch + Continuous = Hybrid

• Advantages and disadvantages of each:

• Not very portable
• Quick change capability “on the fly”
• Continuous Process is RAP friendly
• Batch process serves small markets well
• Batch still RAP limited
• Equipment can get complex…
Processing Recycle
Limited use on batch plants
– Scavenge system limitations

– Limits flexibility for mix changes

• Stored “super hot rock” problems
Cost of Batch Plants
• Batch Plants cost more because of the tower
• Higher maintenance costs
– Screens to maintain in hot, dusty conditions high in the air
– More wear on components
• Dry mixing time in pugmill
• Abrupt starts and stops of mixing
– Pugmill and bucket elevator to maintain
• Higher electric costs
– Heat loss from tower
– Pugmill and bucket elevator to power
• Less efficient production
– More opportunities for delays at plant
(i.e. trucks having to wait on mixer; can’t load trucks during tower breakdown)
– Segregation issues in tower
Cost of Continuous Plants
• Continuous Plants cost less than batch plants (no tower)
• Less maintenance costs than batch plants
– No screens to maintain in hot, dusty conditions high in the air
– Less wear on components
• Dry materials are not mixed as long
• Mixing that does occur is milder and continuous
– No bucket elevator to maintain
• Less electric costs than batch plants
– No heat loss from tower
– No pugmill or bucket elevator
• Higher production efficiency than batch plants
– Continuous production means less delay at plant
– Continuous production helps prevent segregation
Answer: Continuous Production
• Gradation control in coldfeed bins
– Gradation control is in coldfeed bins anyway

• Increased Productivity

• No more steam explosion

• Ability to change mix quickly

• Solves stored “super hot rock”

• Lower Cost vs Batch Plants

Parallel Flow Drum Mixer
Parallel Flow Drum Mixer with Coater
 Parallel Flow Drum Mixer Advantages

• Simple
• Highly Portable
• Low Maintenance
• Continuous Process is RAP friendly
• BUT…
Parallel Flow Drum Mixer Disadvantages
• Radiation loss.
• Stack energy loss – Parallel flow.
• Drum gas velocity limitations.
• Bag life decreased due to higher temp.
• RAP fines, coated fines, and light ends on bags.
• Blue smoke with RAP.
• Not ideal for polymer mixes. High exhaust temp.
• BAGHOUSE FIRE
• Requires a larger baghouse for the same tph.
Counterflow Drying Drum with Coater
Counterflow Drying Drum with Coater

Problem with RAP Steam

Counterflow Drum Mixer
High Surface Temperatures
High Surface Temperatures
Astec Unified Drum
Double Barrel Design
Gas Flow Hydrocarbons and Steam
Double Barrel® Combination Dryer Mixer
Vigorous mixing in the dryer.
Gentle mixing in the mixing chamber.
Gentle mixing in the mixing chamber.
 Double Barrel® Material Timeline
Material Material Time Total Time

Virgin Aggregate Only 160 to 200 sec 160 to 200 sec

RAP + Virgin Aggregate 20 to 27 sec 180 to 227 sec

Fines + RAP + Virgin

40 to 45 sec 220 to 272 sec
Aggregate

Bitumen + Fines + RAP +

40 to 45 sec 220 to 272 sec
Virgin Aggregate

Depends upon injection Depends upon injection

Additives
point. point.
Design Advantages
• Low radiation loss.
• Counter flow – minimum stack temperature.
• Can operate with higher drum gas velocity.
• Easier on bags (temp. and hydrocarbons).
• Clear stack with high % RAP.
• Can have high mix temp. and low stack temp. –
Counter flow
• Can return dust with screw conveyor -- Lower
Maintenance.
• Ideal for additives (fiber, crumb rubber, mineral filler,
lime, shingles…)
WE THANK YOU!
Future of Rap…Rap Drying –
High Rap Plants – 100% is it possible
Rap Drying
• Recycle fines exposed to superheated gas
• Heat + Bitumen + Oxygen --> Oxidation
• Heat + Bitumen + Oxygen --> Carbon Monoxide
• Heat + Bitumen --> Volatile Organic Compounds
• RAP fines in baghouse increase fire potential
High Rap Plant Options
High Rap + 5th Bin Bypass = HR BP 60%
Vigorous mixing in the dryer.
Gentle mixing in the mixing chamber.
Batch Tower 5th Bin
 Batch versus Continuous Baghouse Size Requirements

143 shortTPH using 25% RAP (5% Material Moisture)

50000

45000
Required Exhaust Volume (ACFM)

45,000
Dump in RAP
(Typical Batch Plant)
40000

35000

32,000
30000 Meter in RAP
(Astec Batch Plant, 1%
per second)
25,000
25000
First Batch Second Batch Double Barrel
(continuous metering)
20000
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
Time (Seconds)
 Baghouse Size Requirement vs. %RAP
143 shortTPH using 25% RAP (5% Material Moisture)
50000
Required Exhaust Volume (ACFM)

45000
Dump in RAP
(Typical Batch Plant)
40000
30% RAP 50% RAP
Practical Limit Capability

35000

30000
Meter in RAP Double Barrel
(Astec Batch Plant, 1%
per second) (continuous metering)
25000
Tower
Scavenge
20000
0 5 10 15 20 25 30 35 40 45 50
Introducing RAP as continuously as possible
% RAP limits the baghouse size required.
Astec/Dillman Unified Drum
High Rap Design with V-Pack
Controlling Baghouse Temperature
Stack Temperature Control: V-Flights and VFD
The Problems:
• High Stack Temperature
– Limits production
– Increases cost of the mix

• Low Stack Temperature

– Condensation/corrosion in the baghouse
– Mudding/blinding of bags

• Running Multiple Mix Types

– Results in large swings in stack temperature
– Requires time consuming flight modifications
Stack Temperature Control
Utilization of V-Flights
Standard Flights V- Flights
 V-Flights – Elimination of hot spots

Flight must rotate further Hot gas

before angle of repose bypassing
reaches tip of flight occurs on
this side of
drum
 V-Flights – Elimination of hot spots

Veiling through notch

Hot gas
bypassing is
eliminated
V-Flights – Wider Veil
Veiling for standard flights Veiling for V flights occurs at
occurs only at tip tip AND notch
Wide veiling Narrow veiling
Starts sooner Starts later
V Flights Std Flights
Stacked view of multiple rows of flights show
improved showering when using V-flights
Stacked view of multiple rows of flights show
improved showering when using V-flights
Benefits of VFDs on a Drum
• Utilization of variable frequency drive enables running mixes
ranging from virgin WMA to high RAP and open grade mixes
without flight changes

• VFD allows the operator to control veil density by changing drum

rotational speed.

• Stack and mix temperatures can be controlled by increasing or

decreasing the drum speed
– Increase in speed will decrease stack temperature
– Decrease in speed will increase stack temperature
 Effect on Stack Temperature

400°F
Open Graded/
High RAP Mixes
Low TPH
Stack Temperature

Virgin/WMA Mixes
200°F

40 hz 60 hz 80 hz
Hertz (Drum Speed)
Production increase with stack temperature control

Percentage of Rated Capacity

100,0%

Std Production
90,0%
VFD Production
Std Stack
VFD Stack
80,0%

70,0%

Stack Temperature °F (°C)

360

330

300

270

240
0 10 20 30 40 50
Percentage of Recycle
• “Efficiency” is a misused term

• Burner “efficiency”… what does it

mean?

• Drying “efficiency” … what does it

mean?

• Plant “efficiency” …what does it mean?

V-Pack™ Stack Temperature Control

Control Logic
 Effect on Stack Temperature

400°F
Open Graded/
High RAP Mixes
Low TPH
Stack Temperature

Virgin/WMA Mixes
200°F

40 hz 60 hz 80 hz
Hertz (Drum Speed)
 How much money is 1.5% of fuel cost ?

Basis: 100,000 tons per year

5% average moisture
$3.00 per gal fuel

(100,000 tons per year) x (1.77 gal per ton) x ($3 per gal) x (0.015)
= $7965

300,000 tons per year = $23,895 fuel savings

Field Example
• Plant was experiencing stack temp approx 385°F
– Inlet breeching was opened to cool BH
– This limited production to 150 TPH

• VFD was used to increase the speed of the drum

• Stack temperature dropped to allow the inlet

breeching to be closed
– This increased production to 350 TPH
– Stack temperature was between 290-300°F
100% RAP UPDATE
• A short time ago at a ConExpo
not too far away….
• Experience

• Lower Capital Cost

• Less time to heat up and cool down (though still long by HMA standards)

• “Familiar” to customers… not exotic equipment

• 0% RAP or 100%RAP Paradox

• Still has a long heat up (1.5 hrs) and cool down time (1.5 hrs)

• Low tonnage capacity (100tph @ 5% moisture)

• Oxidation concerns

• It ain’t no SIX PACK.

0% RAP or 100%RAP Paradox
Still has a long heat up (1.5 hrs) and cool down time (?)
Low tonnage capacity (100tph @ 5% moisture)
Oxidation concerns
• Plant layout developing – pairing with existing Double Barrel

• Refining design and selecting materials

• It is not feasible
• Experience

• Lower Capital Cost

• Less time to heat up and cool down (though still long by HMA standards)

• “Familiar” to customers… not exotic equipment

100% RAP
100% RAP
WE THANK YOU!