Increase Your Production
BY AsphaltPro Staff
This February edition of AsphaltPro focuses on recycling, but that doesn’t mean we take a month off from production. Far from it—we include information on increasing recycled material at the production facility. Look specifically at the use of high percentages of reclaimed asphalt pavement (RAP) in the mix designs at your plant. The team at Ammann, Langenthal, Switzerland, has recently introduced a continuous plant to the North American market to handle up to 60 percent RAP without burning the light ends off the replacement binder. Take a look at the information they provided:
The plant’s name—ACP ContiHRT—stands for “Continuous High Recycling Technology.” The Ammann plant incorporates a high percentage of recycled material by taking an innovative approach to the heating process.
Heating is where complications arise. RAP must be heated to between 120 and 130 degrees C. Bringing RAP to this target heat level requires temperatures much higher than 160 degrees C, but temperatures above that range will damage the asphalt cement (AC) that coats the RAP.
When a parallel flow dryer is used, the gas (and heat) moves in the same direction as the aggregate. Specifically, the RAP enters near the burner and is heated as it works its way toward the opposite end of the dryer before being discharged. The dryer is hottest where the RAP enters, and the temperature would have to be well above 160 degrees C to properly heat and dry the aggregate. Therefore, at first glance, the parallel flow process seems unworkable because AC would be damaged upon entry to the dryer.
With a counterflow dryer, the material flows toward the heat, creating the same problem—only at the opposite end. The RAP would be fine when first entering the dryer, but would be damaged as it approaches the burner. The RAH60 dryer, the unique heating system used on the ACP ContiHRT, is designed to solve this.
First, the engineers utilized a parallel flow system that runs at a lower temperature and gently heats the RAP to prevent damage to the AC. The RAP can still reach its target temperature of 120 degrees C when the new aggregate comes into play.
Fresh aggregate is heated in a separate dryer—and at a much higher temperature—because there is no AC to worry about. After heating, the hot, fresh aggregate is mixed with the RAP and in so doing brings the recycled material to its target temperature. The fresh aggregate acts as a second heat source. The gentle heating process does more than protect the coating. It also minimizes fuel usage and emissions. See the related Here’s How it Works department.
Get more information at https://www.ammann.com/us-en/plants/asphalt-plants.
In this month’s product gallery, we have the latest from original equipment manufacturers and service providers to enhance the bottom line when it comes to production. For your convenience, we include live links at asphaltpro.com to the companies who partner with and support AsphaltPro. Make sure you check out the digital version of the magazine’s articles and departments for easy clicking and following.
Atlas Copco Power Technique, Rock Hill, South Carolina, has updated its QAS 250 and QAS 330 generators with a more powerful John Deere 6090 engine. The generators are designed to be versatile for several applications including construction, the oil field and special events. Both generators feature a John Deere 9-liter, 6-cylinder Tier 4 Final diesel engine. The QAS 250 runs at 290 horsepower (hp), while the QAS 330 operates at 399 hp.
The units come in two different configurations: a dual axle trailer (standard) or a skid mounted unit with forklift pockets (option). This allows flexibility for the user in matching the machine to the correct applications. The internal 385-gallon fuel tank runs for 34 hours at 75 percent load on the QAS 250 and nearly 26 hours at 75 percent load on the QAS 330.
For more information, visit AtlasCopco.com.
Caterpillar has launched several new design enhancements for its small wheel loader (SWL) line—Cat® 926M, 930M and 938M models—centered on improving attachment visibility, operator comfort and machine performance. The line’s new Fusion Quick Coupler is designed to improve visibility to the attachment in material handling applications. With its electro-hydraulic coupler application system activated from inside the cab, the single piece cast coupler frame with relocated actuation cylinders increase attachment visibility through the coupler by up to 85 percent, according to the manufacturer.
Available LED lighting options help improve machine visibility. Featuring integrated LED indicators, new high-performance LED front roading lights improve light coverage in dipped and main beam modes. A new auxiliary lighting package now includes a light inside the Diesel Exhaust Fluid (DEF) fill tank compartment to improve visibility in low-light conditions.
Powered by the Cat C7.1 engine, the re-engineered 930M now meets EU Stage V emissions standards along with U.S. EPA Tier 4 Final and Japan 2014 standards. The new 930M also delivers a 5 percent boost in gross horsepower, 5 percent increase in breakout force and a 5 percent higher full-turn tip load when compared to the previous 930M. With the new updates and refinements, the new 930M with Aggregate Handler package now aligns in a higher performance class. This offers customers lower end-to-end costs and reduced owning/operating costs compared to running a larger wheel loader. CPM confirms sufficient weight in the bucket before the operator leaves the pile, ensuring the right amount of material is loaded to reduce the number of cycles and maximize profit potential.
For more information, visit your local Cat dealer.
CWMF Corp, Minnesota, announced this summer the official release of its new product line, the Honey Badger Rap Crusher. The Honey Badger Rap Crusher is equipped with replaceable AR steel wear liners and a ½-inch steel pulverizing hopper. The Honey Badger rotor assembly includes 3-inch premium grade cast carbide hammers, a precision-machined shaft, ¾-inch rotor disks and grease lubricated pillow block bearings. Included is a two-way valve hydraulic power pack that allows for easy interior access but, most importantly, performs a controlled close of the hopper top so that safety is never compromised.
CWMF offers two models, the HB-30 and HB-40. The HB-30 has a feed opening of 23 x 31 inches, a 50-horsepower TEFC motor, and rated at 20-50 tons per hour. The HB-40 has a feed opening of 23 x 35 inches, a 60-hp TEFC motor, and rated at 30-60 TPH. To get the RAP to the proper size, CWMF offers ½-inch, ¾-inch, 1-inch, 1-1/4-inch and 1-1/2-inch AR steel grates in both models.
Portable and stationary setups are available. The Honey Badger portable chassis is also equipped with a CWMF Tremor shaker and conveyor to get RAP processed on-site at any asphalt location.
For more information, call (877) 457-3938 or visit cwmfcorp.com.
EvoQuip, a Terex Brand, used its “Experience Days” Nov. 21, 2019, in Ireland to reveal plans for a new innovation—the Colt 1600 scalping screen. EvoQuip Business Line Director Matt Dickson told the 200-plus attendees the Colt 1600 is “a brand new EvoQuip model, the first of which will be available to ship to customers in early 2020. We are confident that this highly aggressive scalping screen will open up new opportunities for EvoQuip customers globally.”
The Colt 1600 will be the largest screen in the EvoQuip range, capable of processing up to 661 US tph (600 tph), depending on application. It will have a high capacity incline apron feeder as standard. It is designed to work in both primary and secondary screening applications, incorporating a double deck screen of 16 feet x 5 feet (4.8m x 1.53m). The variable screening angle and numerous screen media options enables the machine to operate in both heavy duty scalping and precision screening applications, according to the manufacturer. It has three interchangeable screenbox options (Single Shaft, Triple Shaft and Spaleck). The Colt 1600 is available with Hybrid technology giving the flexibility to be powered by an external power supply or the standard on-board engine.
For more information, contact an EvoQuip or Terex dealer.
HAVER & BOECKER
Haver & Boecker Niagara, St. Catharines, Ontario, offers the Niagara F-Class portable plant for use in quarry and mining operations. The portable plant features a custom-built chassis equipped with six hydraulic run-on jacks to quickly level the plant and keep the chassis level during operation.
Producers can move and set up the portable F-Class in less than 30 minutes, according to the manufacturer. The chassis’ hydraulic system raises the vibrating screen to its inclined operating position, which is usually 20 degrees.
The portable plant offers up to three screen decks. Its feed conveyor, cross conveyor and fines conveyor are hydraulically operated. The fines chute has a full-width access door and an oversize chute features AR liners that are bolted on for easy replacement.
The F-Class vibrating screen has an advanced double eccentric shaft design, supported by four double-spherical roller bearings.
Haver & Boecker Niagara offers the Pulse vibration analysis program to monitor the ongoing health of vibrating screens through real-time views, logged reports and data analysis.
For more information, contact Kristen Randall at (905) 688-2644.
Heatec Inc., an Astec Industries Company, Chattanooga, has recently introduced its dish bottom storage tanks for liquid asphalt cement (AC) binders. These tanks are designed to eliminate the need for expensive, time-consuming tank cleaning through their dish-shaped design and drain positioning. The tanks also feature optimum agitation and heat distribution in any capacity the asphalt facility needs.
For more information, visit www.heatec.com/products/tanks
Hotmix Parts & Service, Louisville, offers the Accu-Level™ AC tank & silo level indicator to replace the antiquated lever-and-pulley systems for determining the amount of material left in your asphalt cement (AC) tank. This piece of equipment affixes to the top of the tank and uses radar technology to detect the accurate amount of liquid AC in your tank without radar beam disturbance from the internal agitator. The use of radar allows for accurate readings even in situations of heavy build-up and gases associated with asphalt storage, according to the manufacturer. The AC tank level monitor can be incorporated into your current PLC or be a stand-alone control. With the Hotmix Parts & Service new remote monitoring system, any computer, phone or tablet on the same network as the Accu-Level can be assigned roles and monitor levels anywhere in your plant or at home.
For more information, visit www.hotmixparts.com or contact (502) 245-1977.
Kleemann, a division of Wirtgen Group, Antioch, Tennessee, offers the Mobirex mobile impact crushers which are designed to produce accurately-sized, cubical-shaped end product. The crushers work well as stand-alone plants, or are an ideal choice for smaller-scale recycling operations, on-site recycling, or for tight-space urban and roadside recycling, according to the manufacturer.
Kleemann’s Mobirex MR 130 Zi EVO2 mobile impact crusher has a crusher inlet size of 52 by 36 inches. Maximum input capacity of 496 tons per hour can easily be attained, according to the manufacturer. The smaller MR 110 Zi EVO2 crusher has an inlet size of 44 by 32 inches and input capacity up to 386 tph.
For more information, contact Matt Graves at (615) 501-0600 or email@example.com.
Kolberg-Pioneer Inc., Yankton, South Dakota, has added a two-deck, 4-foot x 7-foot pre-screen option to its FT4250 mobile impactor plant. The new option allows producers to scalp the feed, crush the material and post-screen all on one unit. By pre-screening the feed, users can maximize their scalping ability and minimize the amount of undersized material passing through the chamber, reducing wear costs and increasing the amount of final product by 30 percent, according to the manufacturer.
“Several of our customers are trying to produce products that have a significant amount of fines in the feed material. The pre-screen allows producers to remove those fines while also minimizing the amount of rejected in-spec product,” said Tim Harms, crushing and screening product manager at Kolberg-Pioneer.
For more information, contact Tim at firstname.lastname@example.org.
Libra Systems is pleased to announce that Curtiss Dorr has been named director of sales & marketing—GPS Asset Tracking. Dorr joins Libra with extensive experience in the GPS space for the construction industry. His leadership experience includes helping asphalt, aggregate and concrete producers optimize their truck fleet and “yellow iron” to drive profits to the bottom line.
Contact Dorr at (480) 536-3262 or CDorr@LibraSystems.com.
MAJOR, Candiac, Quebec, is expanding the manufacturing capacity of its production plants for the company’s signature Flex-Mat® high vibration wire screens. MAJOR’s “Next Generation Project” will begin this year and incorporate robotics as a means to automate production of the high performance screens. Building FLEX-MAT screens is a multi-step manufacturing process, with each production line requiring multiple people.
Until now, the labor-intensive process involved assembling each piece of media by hand.
The addition of automation will increase MAJOR’s daily capacity, according to the manufacturer.
Minds Inc., Kelowna, British Columbia, is pleased to showcase its PlantManager multi-plant dashboard software.
PlantManager, an enterprise asset management software, is designed to allow asphalt plant managers to gain a 30,000-foot level view of their company’s plants, all in one dashboard. Managers then spot issues at a glance and drill down into critical production and job data.
The PlantManager software has opened windows into multiple plant processes, according to the manufacturer, thanks to the use of aggregated data and Minds’ software development. The software allows all the Minds-equipped plants in a company’s arsenal to share relevant data, which gives management teams a one-stop shop for viewing plant production, configuring and generating reports, tracking plant health, and more.
Managers can use this asphalt plant control system to look deeper into their individual plants, where analog-style gauges make it easier than ever to track the temperature, energy consumption and mix rate of production, according to the manufacturer.
The PlantManager asphalt plant software is available to managers who operate multiple sites that use Minds’ individual plant management systems, and can be used on tablets and PCs.
“PlantManager is one of the very exciting applications we have launched in 2019,” said Pierre Vidaillac, CEO of Minds Inc. “Customers who have many systems from us wanted a simple, meaningful dashboard to monitor all their asphalt production assets in real time. PlantManager does exactly that, and will also be used as an entry point to dive into more granular layers of information.”
For more information, contact MINDS USA, (833) 646-3787 or email@example.com.
Ken Monlux is the proprietor of Vital Signs, his consulting service for the improvement of plant operational management, including such areas as:
- plant log documentation (plant reporting);
- management coaching and mentoring;
- recruitment and retention; and
- special projects.
- Monlux is committed to providing a way you can invest in your team members to
- improve the morale of the team as a whole while retaining managers that will be
- more devoted to the outcome of your company. The core of his services is a plant
- documentation program designed to drive down costs and improve efficiency.
For more information, contact (209) 495-1017 or firstname.lastname@example.org.