EN 
RU Counter Flow Drum Mix Plant (60-120 TPH)
Forget your conventional old technology drum mix plant and switch to our new Technology COUNTER FLOW DRUM MIX PLANT with THERMIX DRUM with upto 30% RAP addition.
Introduction
Asphalt is the backbone of modern road construction, and the quality of asphalt used directly affects the durability and safety of roadways. Counterflow asphalt plants are revolutionizing the way asphalt is produced, making it more efficient and environmentally friendly. In this article, we will take a closer look into the workings of counterflow asphalt plants, their advantages, applications, components, maintenance, and much more.
Cold Aggregate Bins
Slinger Conveyor
Dryer Drum
Control Cabin
Gob Hopper
Load Out Conveyor
Long Nose Dryer Burner
Mineral Filler Unit
Fuel Tank
Bitumen Tank
Venturi Type CV
(Wet Scrubber Unit)
Cold Aggregate Bins
Slinger Conveyor
Dryer Drum
Control Cabin
Gob Hopper
Load Out Conveyor
Long Nose Dryer Burner
Mineral Filler Unit
Fuel Tank
Bitumen Tank
Venturi Type CV
(Wet Scrubber Unit)
Technical Specification
| PLANT TYPE | CFD 90 (60-90 TPH) | CFD 120 (90-120 TPH) |
| PLANT CAPACITY @ 3% MOISTURE | 90 TPH | 120 TPH |
| PLANT CAPACITY @ 5% MOISTURE | 70 TPH | 100 TPH |
| NO. OF COLD FEEDERS | 4 | |
| COLD FEEDER CAPACITY (With Extension Plates) | 8 m3 | 8.5 m3 |
| GATHERING CONVEYOR BELT AND DRIVE | 550 x 3.75 KW | 600 x 3.75 KW |
| BIN VIBRATOR MOTOR | 0.18 KW | |
| SLINGER CONVEYOR BELT AND DRIVE | 550 x 3.75 KW | 600 X 3.75 KW |
| DRYER DRUM TYPE (‘THERMIX DRUM’) | Cylindrical, Inclined Counter Flow Type with RAP Ring | |
| THERMIX DRUM (L X D) | 7.5 X 1.6 m | 8.5 X 1.8 m |
| DRUM DRIVE | 7.5 KW x 4 | 7.5 KW x 4 |
| MODULATING BURNER OUTPUT | 10 MW (Long Nose Burner) | 14 MW (Long Nose Burner |
| POLLUTION CONTROL BAG HOUSE | ||
| FILTER CAPACITY | 31000 m3/hr | 33500 m3/hr |
| FILTER SURFACE | 260 m2 | 290 m2 |
| EXHAUSTER CAPACTIY | 55 KW motor with VFD Drive | |
| LOAD OUT CONVEYOR CAPACITY | 200 TPH | |
| LOAD OUT CONVEYOR BELT WIDTH | 600 mm | |
| LOAD OUT CONVEYOR DRIVE | 5.5 KW | |
| GOB HOPPER CAPACITY | 1.5 MT | |
| HYD POWER PACK | 3.75 KW | |
| FILLER UNIT | Mineral Filler Unit of Capacity 1.5 m3 | |
| OPTIONAL ITEMS : | ||
| BITUMEN TANK | 30 MT Horizontal type Direct Heating/ Indirect Heating | |
| VENTURI TYPE DUST COLLECTING UNIT | ||
| EXHAUSTER CAPACITY | 22.5 KW | 37.5 KW |
| HOT MIX STORAGE SIL | 25-50 MT | |
| RECYCLING ADDITION | Through RAP addition ring in the drum. | |
Advantages
| Advantage | Old Drum Mix Plant | Counter Flow Drum Mix Plant | Benefits |
| Technology | Old technology in which heating and mixing occurs at same place. | New technology in which mixing zone and heating zone are at different places in same drum. | Viscosity of bitumen as well as properties of mixed aggregate doesn’t get affected. |
| Recycled Material | Facility to add RAC is not available | RAC can be added upto 30% | Recycled material can be used |
| Filler | Filler cannot be added | Filler can be added directly into mixing zone via RAP Collar | Filler material can be used to produce homogenous mix |
| Pollution | Only Venturi Type Dust Collector is provided for pollution control which requires large area for Dust Collection | Pollution Control Bag House is provided which ensures pollution free operation of plant | Pollution Free plant |
| Hot mix quality | Hot mix quality gets deteriorated since mixing and heating occurs at same place | Homogenous Mixing since mixing zone and heating zone are separate | Gets Homogenous mix |
| Dryer Drum | Parallel flow heat transfer which deteriorates the properties of mix as well as bitumen | Counter Flow heat transfer with mixing zone behind the burner and attached RAP Collar provides homogenous mix | Filler, RAP can be added and mixing takes place behind the burner flame |
| Fuel Consumption | Consumption of Fuel is more | Consumes less fuel as compared to drum mix plant | Less Fuel Consumption leads to cost saving of fuel |
RAP Addition - Efficiency Burner - Separate Mixing Zone
Efficient RAP Addition
High Efficiency Burner
Separate Mixing Zone
Alltech’s Thermix drum allows efficient RAP addition of upto 30% into the drum by the help of the RAP Coller.
Drying drum is equipped with a modulating long nose burner, which results in increased efficiency and low emission levels.
Thermix Drum heats up the aggregates in the heating zone and the mixing with bitumen is done in a separate mixing zone to provide homogenous mix.
What is a Counter Flow Asphalt Plant?
What is a Counter Flow Asphalt Plant?
A counterflow asphalt plant is an innovative facility designed to produce high-quality asphalt mix. It operates on the principle of counterflow, where the heating and mixing of aggregates and asphalt occur in separate compartments. This design offers several advantages, such as improved energy efficiency and reduced emissions.
How Does a Counter Flow Asphalt Plant Work?
In these plants, the aggregates enter the plant at the opposite end of the exhaust gases. This arrangement allows for a gradual increase in temperature and improved mixing. The heated aggregates move towards the mixing chamber, where they are combined with hot asphalt to produce a homogeneous mix.
Advantages of Counterflow Asphalt Plants
Advantages of Counterflow Asphalt Plants
Energy Efficiency
Counterflow asphalt plant saves energy by using the exhaust gases to preheat the aggregates. This reduces fuel consumption and operational costs.
Reduced Emissions
Since the heating area and mixing area are separated, counterflow plants emit fewer pollutants, making them environmentally friendly.
Quality of Asphalt
Counterflow design ensures the consistency and quality of the asphalt mix according to industry standards.
Common Applications
Common Applications
Counterflow asphalt plants are versatile and can be used in many construction projects. They are generally used in the construction of highways, airports and large-scale infrastructure projects.
Key Components of a Counterflow Asphalt Plant
Key Components of a Counterflow Asphalt Plant
All key components of counterflow asphalt plant such as:
Drying Drum
The drying drum is where aggregates are heated and dried before they enter the mixing chamber.
Mixing Chamber
In the mixing chamber, hot asphalt and aggregates are blended to create the final asphalt mix.
Exhaust System
The exhaust system is responsible for capturing and cleaning the gases produced during the process, reducing emissions.
Control Centre
The control centre manages the entire plant, ensuring the process runs smoothly and efficiently.
Choosing the Right Counterflow Asphalt Plant
Selecting the right counterflow asphalt plant depends on various factors such as:
Capacity and Throughput
The plant’s capacity should align with the project’s requirements to ensure timely completion.
Fuel Options
Consider the availability and cost of fuel options, as this will affect operating costs.
Environmental Compliance
Ensure the plant complies with environmental regulation and emission standards.
Installation and Maintenance
Installation and Maintenance
Proper installation and regular maintenance are essential for the efficient operation of a counterflow asphalt plant. Regular inspections and maintenance will prolong the plant’s lifespan and maintain its performance.
Counterflow vs. Parallel Flow Asphalt Plants
Compare counterflow and parallel flow asphalt plants to understand their differences and decide which is right for your project needs.
Case Studies: Real-world Applications
Explore real-world examples of how counterflow asphalt plants have improved construction projects, highlighting their efficiency and cost-effectiveness.
Counterflow Asphalt Plant Manufacturers
Discover reputable manufacturers of counterflow asphalt plants, ensuring you choose a reliable and high-quality product.
Cost Considerations
Examine the costs associated with purchasing, operating, and maintaining a counterflow asphalt plant to make an informed investment decision.
Future Trends
Stay updated on the latest developments in counterflow asphalt plant technology and their potential impact on the industry.
Conclusion
Conclusion
Counterflow asphalt plants have transformed the way asphalt is produced, offering enhanced energy efficiency, reduced emissions, and consistent quality. Choosing the right facilities and following maintenance procedures is crucial to the success of your construction.
Frequently Asked Questions
Yes, counterflow asphalt plants come in various sizes to accommodate projects of all scales.
Counterflow plants separate the heating and mixing zones, resulting in fewer emissions.
With proper maintenance, a counterflow asphalt plant can last for many years.
Operating these plants may require specific training, which can be provided by the manufacturer.
Some models are designed to run on alternative fuels, promoting environmental sustainability.
Operating temperatures vary, but they are carefully controlled to achieve the desired asphalt mix.
Yes, their energy efficiency and reduced emissions often result in long-term cost savings.
Many modern counterflow plants come equipped with advanced automation for efficient operation.
Yes, manufacturers often offer customization options to meet project-specific needs.
These plants produce fewer emissions, helping to reduce the environmental impact of construction projects.
Any questions you want to ask?
We will be happy to answer your questions.
