Asphalt mixing plants have become an indispensable key equipment when carrying out global infrastructure construction and road projects. These plants ensure construction quality and improve efficiency. They are crucial for achieving the desired results while carrying out large-scale construction projects. Asphalt batching plants may face issues such as unstable output, poor temperature control, irregular oil/stone ratio, and environmental pollution.
Установка асфальтового завода в России превзошла ожидания. Процесс прошел гладко, и производительность завода была исключительной. Это демонстрирует передовые технологии, обеспечивая эффективное производство асфальта. Надежное вложение для качественного развития инфраструктуры.
These issues have become the primary challenges that need to be addressed. In this article, we will summarize the common faults that occur in asphalt mixing plants and provide you with effective strategies to ensure a smooth construction process and ultimately achieve efficient project completion.
Selection of Raw Materials Required for Asphalt Concrete Based on Existing Problems
Our company has defined criteria for purchasing raw materials for asphalt concrete based on long-term customer needs and technological improvements to ensure that asphalt mixing plants produce high-quality asphalt concrete. We recommend users to purchase raw materials according to the following criteria.
- The average static settling specific gravity of the cold hopper is 1.6 tonnes/cubic meter and the average moisture content does not exceed 5%.
- The cold aggregate of large particles (for subgrade) is generally not larger than φ60mm, and the cold aggregate of small particles (e.g. stone chips) must not contain too much dust and debris.
- The moisture content of powder must be less than 0.5 percent, and there should be no lumps and arches.
- The asphalt material should have good wrapping performance and the temperature should be controlled within the range of 150°C±1. 5. the fuel must have good fogging performance.
- Fuel oil must have good atomization performance, full combustion, heavy oil and residual oil need to be heated, and filtered, viscosity shall not be higher than 90SSU, and the use of inferior oil is strictly prohibited.
Pay Attention to Other Details to Improve the Performance of Asphalt Mixing Plants
Of course, users of our equipment must be prepared according to the above requirements. Otherwise, it may lead to a decline in the output of the equipment, the quality of the product can not be guaranteed, the effect of dust removal is not good, and may even damage the bag and burner. These raw materials are essential for producing high-quality asphalt concrete.
If you require an asphalt batch plant, please contact us. Choosing the right asphalt mixing plant manufacturer is crucial, and our team of technicians and experts will provide you with excellent services. Next, let’s have an analysis of common faults of asphalt concrete mixing plants and respond to the problems affecting the efficiency of asphalt mixing plants one by one, to guarantee the efficiency of our batch asphalt plant!
Unstable Output, Low Production Efficiency of the Equipment
First of all, when carrying out infrastructure and road projects, unstable output and low production efficiency of the equipment is a common problems. This will directly relate to the construction period and project efficiency. Not only that, the low output may lead to the delay of the project, while the low productivity of the equipment directly affects the overall efficiency of the project. Thus, in this problem, we analyze the following main reasons and propose corresponding solutions to ensure stable output and efficient production efficiency of the new asphalt plant.
Improper Mixing Ratios in Asphalt Production of the Asphalt Mixing Plants
Problem analysis: One of the common problems in projects is the unstable output of the asphalt batch mix plant, which affects the construction schedule. This is usually caused by improperly set mix ratios. Improper adjustment of the target mix ratio and the production mix ratio may lead to an unbalanced ratio of raw materials, thus affecting the productivity of asphalt mixing plants.
Solution: During the construction process, we emphasize close monitoring and flexible adjustment of target and production mix ratios. Timely adjustments are made according to the actual situation to ensure the reasonableness of the raw material ratio, thus improving the output and production efficiency of the asphalt mixing plant.
The Challenges of Failed Aggregate Grading in Asphalt Mix Plants
Problem analysis: On the other hand, the grading range of sand and stone aggregate exceeding the specified range may lead to a large amount of waste material, which not only increases the cost but also reduces the output. Besides, it’s one of these factors affecting the production quality of the asphalt batch plant.
Solution: To solve this problem, we suggest strengthening the testing and control of sand and stone aggregates in the feeding process to ensure that they comply with the specified grading standards, to effectively improve the output and production efficiency of asphalt mixing plants through the reasonable mixing ratios and high-quality sand and stone aggregates.
Low Fuel Combustion Value
Problem analysis: In addition, the fuel used in the asphalt plant affects production. The selection of non-compliant fuel may result in low combustion value. Finally it affects the heating capacity of the equipment, reduces the production capacity, and results in increased costs.
Solution: Therefore, when using an amp asphalt mixing plant, it is important to choose a fuel that meets specifications. Choose the fuel type reasonably to ensure that its combustion value meets the requirements of the equipment to increase production capacity.
Improper Setting of Operating Parameters of Asphalt Mixing Plants
Problem analysis: Finally, when solving the problem of unstable production, the improper setting of the operating parameters of the asphalt mix plant also needs to be careful. Reasonable setting of operating parameters, include the setting of dry mixing, and wet mixing time, as well as the opening and closing time of the bucket door. It can effectively improve the production efficiency of the equipment.
Solution: By optimizing the mixing ratio, controlling the quality and moisture content of sand and stone aggregates, choosing the right fuel, and setting the operating parameters of the equipment reasonably, the output and production efficiency of the asphalt mixer plant can be improved comprehensively.
Excessive Moisture Content in Sand and Stone
Problem analysis: Furthermore, high water content in sand and stone aggregate is also one of the factors affecting the output of the asphalt concrete plant.
Solution: Suitable equipment type and water content control is the key to solving this problem. When purchasing equipment, you need to make sure that the equipment model matches the production needs and pay attention to the water content of sand and stone materials to avoid the decline of the production efficiency of the asphalt plant equipment.
Of course, we have a wide range of asphalt concrete plant mix for you to choose from, as well as a professional service team, combined with your needs, to provide you with the most suitable solution for you, to recommend the right asphalt mixing plant equipment model including mobile asphalt mixing plant, mini asphalt plant and so on for you. Further, they can enhance your productivity and help your project succeed! If you need, please feel free to contact us.
In the production process of the asphalt batching plant, the instability of asphalt concrete discharging temperature is another issue that needs attention. In the next section, we will further analyze the causes of unstable discharge temperature and the corresponding solutions.
Unstable Asphalt Concrete Discharge Temperature
Secondly, in the process of producing asphalt concrete in asphalt mixing stations, it is crucial to ensure the stability of the discharge temperature, which directly affects the quality of the final concrete. Too high or too low a discharge temperature can lead to concrete quality issues and increased costs. The following are the main reasons for unstable asphalt concrete discharge temperature and the corresponding solutions.
Inaccurate Asphalt Heating Temperature Control From Asphalt Mixing Plants
Problem analysis: Unstable discharging temperature is another common problem that directly affects the final quality of asphalt concrete. Among them, inaccurate control of asphalt heating temperature may lead to the production of asphalt “paste” or “white material”. This ultimately leads to excessive waste and increased production costs.
Solution: To solve this problem, we suggest strictly controlling the asphalt heating temperature during the production process. Ultimately, we can ensure that the temperature is within a reasonable range through regular testing and adjustment of the asphalt heating system, to avoid the production of “paste” and “white material”.
Inaccurate Temperature Control of Gravel Aggregate Heating
Problem analysis: In addition, inaccurate control of the heating temperature of the gravel aggregate may also lead to instability of the discharge temperature. Unreasonable adjustment of the burner flame size or malfunctioning of the dampers will prevent the temperature from being effectively controlled.
Solution: You need to pay attention to the gravel aggregate heating system to ensure reasonably adjusting the burner flame and properly functioning the dampers . Regularly check and adjust the system to ensure the stability of the heating temperature.
While ensuring the stability of asphalt concrete discharge temperature, the reasonable control of the oil-rock ratio is also an important factor in ensuring the quality of concrete. Next, we will deeply analyze the reasons for the instability of the oil-rock ratio and the corresponding solutions.
Unstable Oil-Stone Ratio in Asphalt Mixing Plants
The oil and stone ratio refers to the asphalt concrete, asphalt quality, and sand and other filler quality ratio, which is the most important indicator to control the quality of asphalt concrete. The oil and stone ratio is too large, and paving and crushing road surface “oil cake”, oil and stone ratio is too small. Besides, the concrete material dispersion, crushing is not shaped. All of them are serious quality accidents. The following are the main reasons for the unstable oil/gravel ratio and the corresponding solutions.
The Content of Soil/Dust in the Sand Aggregate Is Seriously Over the Standard
Problem analysis: The stability of the oil/stone ratio in asphalt concrete is crucial for quality control. Excessive soil in gravel can unevenly combine with asphalt filler, affecting oil/stone ratio accuracy.
Solution: During production, we emphasized strengthening the testing and control of the sand and gravel aggregates to ensure that the soil and dust content is within the specified limits. By optimizing the quality of the filler, the uniformity of the concrete is improved to ensure the stability of the oil/stone ratio.
Weighing System Failure of Asphalt Mixing Plants
Problem analysis: In addition, the failure of the weighing system is also one of the causes of the unstable oil-rock ratio. Errors in asphalt weighing scales and mineral powder weighing scales may seriously affect the accuracy of the oil-to-rock ratio. System zero drift or metering error will directly affect the quality of asphalt concrete.
Solution: The weighing system, especially the zero point of asphalt measuring scale, needs to be calibrated regularly to ensure the accuracy of measurement. Repair the faults of the metering system in time to ensure the stability of the oil-rock ratio.
Choose More Accurate Asphalt Mixing Plants
In addition, we provide high-quality new asphalt plant, focusing on solving users’ common weighing system problems in the asphalt mixing plant (amp), and continuously improving the efficiency of the asphalt plant through continuous efforts. Here are some key advantages:
- Heated aggregate dosing hopper design: includes collective measurement, excess disposal, material loss adjustment, weight alerts, and precision lock feature. The design also incorporates a thickened steel plate to enhance wear resistance, extend service life, and reduce maintenance costs.
- Built-in upper and lower ventilation and dust removal piping design: this design effectively eliminates the airflow-induced weighing value drift. Besides, it ensures weighing accuracy, and thus improves the quality of the asphalt mixture.
- Dynamic and precise control of the secondary measurement technology: this technology, according to the number of stone materials to the asphalt secondary correction measurement, strictly guarantees the oil-stone ratio. This precise control ensures the quality of finished material. In addition, it also avoids the waste of asphalt, thus saving the production cost.
Our asphalt mixing machine at first solves common problems. Besides they are also designed to focus on improving precision, and quality, and reducing maintenance costs. If you need an asphalt batching plant, we will provide you with excellent technical support and professional advice. Finally, you will be confident to get twice the work with half the effort.
Overall, by controlling the quality of sand and gravel aggregates and regularly maintaining the metering system, the problem of unstable oil/stone ratio can be effectively avoided, thus ensuring the final quality of asphalt concrete. Ensuring a stable oil/stone ratio while maintaining a clean construction environment is crucial. Next will discuss in detail the causes and solutions to the problem of dusty and polluted construction environment.
Dusty, Polluted Construction Environment
The cleanliness and tidiness of the construction environment are directly related to the health of the staff and the quality of construction. A large amount of dust flying may affect the surrounding environment, increase air pollution, and cause adverse effects on staff. The following are the main causes of dusty and polluted problems in the construction environment and the corresponding solutions.
Too Much Mud/Dust in Sand and Gravel Aggregates
Problem analysis: Pollution in the construction environment often stems from too much mud and dust in the sand and gravel aggregate. Excessive mud and dust content can lead to a large amount of dust during the mixing process. Then it may pollute the environment by seriously exceeding the standard.
Solution: To avoid this problem, it is necessary to strengthen the detection and control of mud and dust content in the feeding process. Then you can ensure that the sand and gravel aggregates meet the environmental requirements. By controlling the quality of incoming materials, the mud and dust content can be reduced. Of course the generation of dust in the construction environment can be also reduced.
Failure of Dust Removal System
Problem analysis: Failure of the dust removal system may lead to dust and seriously affect the construction environment. Damaged dust bags or clogged systems are common problems.
Solution: Regularly inspect and maintain the dust removal system and replace damaged bags on time to ensure the system operates properly. Reduce dust emissions and improve the cleanliness of the construction environment by ensuring the effectiveness of the dust collection system.
Choosing Asphalt Mixing Plants With a More Advanced Dust Bag System
We invest in research and have developed advanced baghouses for our batch asphalt mixing plants to tackle challenges. We use a high-pressure pulse-type bag filter. It has a more thorough dust cleaning effect, and also has improved dust cleaning efficiency. This makes the dust removal effect more remarkable. It meets the local environmental protection requirements. It also avoids possible complaints due to environmental protection issues.
To further enhance safety, we have installed an over-temperature cease-fire protection device and a cold air valve in the flue. These design measures effectively prevent the high temperature from damaging the bag and ensure the safety of the bag. At the same time, it also reduces the frequency of replacement of wearing parts and related costs. Finally, it will provide you with a more reliable and economical operating environment.
Our asphalt mixing plant machinery offers multiple benefits. You can enjoy efficient dust removal and environmental protection effect. We use advanced bag filter technology for this purpose. Moreover, you can also reduce maintenance costs by choosing our machinery. It ensures long-term stable operation of the equipment. If you have any hot mix asphalt plant needs or concerns, we are willing to provide detailed technical support and solutions. Therefore, we can ensure that your choice is more assured and reliable.
Of course, solving the problem of a dusty and polluted construction environment is a part. It is also crucial to carry out good maintenance for the asphalt batching plant. The next section will detail mixing plant maintenance and its importance.
Maintenance Tips Of Asphalt Batch Mix Plant
As we all know, the asphalt mixing plant is an indispensable key equipment in construction. Regular maintenance can effectively improve the equipment’s integrity rate, reduce the occurrence of malfunction. Of course, it can also guarantee the quality of concrete and the safety of the construction site. The following is the main content of the mixing plant maintenance and its importance.
Tank Maintenance
Regular inspection of the tank, cleaning debris and residue, to ensure the cleanliness of the inside of the tank. A clean tank helps avoid debris in the concrete and improves the quality of the concrete.
Maintenance and adjustment of the winch system
Lubricate and adjust the components of the winch system to ensure the normal operation of the winch. A good winch system can ensure the stable operation of each component and improve the reliability of the equipment.
Adjustment and Maintenance of Travel Limiter
Regularly check and adjust the stroke limiter to ensure that the equipment operates within the normal stroke. Proper tuning of the travel stop ensures smoother functioning and enhances equipment safety.
Maintaining Wire Ropes and Pulleys
Check the wear and tear of wire ropes and pulleys, and replace aged or badly worn parts promptly. Proper upkeep of wire ropes and pulleys boosts the lifting system’s steadiness and lessens breakdown risks.
Maintenance of Lifting Hopper
Regularly check the lubrication of the hoisting hopper to ensure the normal operation of the lifting system. The good condition of the lifting hopper helps to ensure the even mixing of asphalt concrete and improves production efficiency.
Keeping Tracks and Track Supports in Good Condition
Ensure the track is securely attached and the brackets are tight for a smooth operation. Stable tracks and brackets help guarantee the operational stability of the entire equipment and reduce unnecessary vibrations.
By maintaining asphalt mixing plants, you can enhance reliability and reduce equipment failures. Furthermore, you can also ensure the safety of the construction site and the quality of asphalt concrete. Ultimately, you can make them lead to social and economic benefits.
Choose the Efficiency of Asphalt Mixing Plants &Amp; Create a Future
The stable operation of asphalt mixing plants is crucial when carrying out infrastructure and road projects. We offer a range of practical solutions by addressing issues such as throughput, temperature, oil/stone ratio, and the environment. The quality of asphalt concrete and the stable operation of the asphalt mixing plant are crucial for project success. Our solutions address root causes and ensure long-lasting efficiency and support.
We invite you to choose our high-quality asphalt mixing plants. As your reliable partner, we can provide a team of professional engineers, high-quality equipment, and spare parts. What’s more, we are also committed to the success of your project.
Choose our asphalt mixing plants and create a bright future together! Thank you for your trust and support!
