What’s New for Asphalt Production?

AsphaltPro sets the standard for equipment and service information by focusing on what’s new in the industry. As components require tweaking—or complete overhaul—to meet new codes or standards, these pages serve to bring you information about those modifications. As companies revamp complete systems, software, iron and parts to make completely new products or controls to address different needs in the aggregate and asphalt production realm, these pages provide a platform for those rollouts as well. This month, I asked OEMs and others in the industry to provide on their most recent launches as they relate to mix production. In alphabetical order, let’s see what they have to share to enhance your bottom line.

From Clarence Richard Co., Minnetonka, Minn.

The Ez-Flo drag speed controller is designed to adjust the speed of the drag conveyor  to production,  automatically keeping the drag  speed just fast enough to get the product up the conveyor without overloading the motor. This saves energy and reduces the high speed repetitions drag slat conveyors typically have to make. With this Ez-Flo controller, both the speed and the repetitions are reduced, which the manufacturer says significantly increases the life of the motor, gear box, chain, slats and slat floor.

Added features include forward/reverse, soft starts and using only the electricity required to do the job.

For more information, contact Clarence Richard at (952) 939-6000 or Clarence@clarencerichard.com

Caterpillar announces updates and enhancements to its M Series medium wheel loader product line, which has applications for plant and quarry owners.

From Caterpillar, Peoria, Ill.

Caterpillar is pleased to announce the 2016 product update to the Cat^® M Series medium wheel loader product line, which includes the 950M, 962M, 966M, 972M, 966M XE, 972M XE, 980M and 982M, to use around the plant yard. The 2016 product updates include all new Cat Connect Technologies, additional safety features and reduced operating costs.

In the category of Cat Connect Technologies, the new Product Link™ Elite system is now offered as standard equipment for cellular and satellite connection capabilities. In addition, the standard machine is shipped from the factory ready to accept the Cat Production Measurement system. Version 1.2 of the system now indicates when the linkage is in the weighing range, allowing operators to confirm that an accurate scaled weight is being determined. The system also allows operators to manually activate the tip-off feature for those applications in which “auto” tip-off detection is not ideal.

In the category of extra safety, the machines offer new cab steps that improve boot contact, according to the manufacturer. Longer-lasting, lower power-consuming LED lights replace the auxiliary halogen-type light option providing four or eight LED work lights at the front and rear of the machine, and two in the rear hood. An optional 4-point seat belt restraint system provides superior protection from frontal collisions. Additionally, a new, easily visible, roof-mounted, seat belt indicator LED light shines green when the seat belt is buckled, promoting operator safety. Optional wheel chocks are mounted to the front frame of the machine, reducing the opportunity for the machine to roll. Additional mounting provisions in the cab allow operators to customize their machine and mount items such as a fire extinguisher or a radio.

In the category of reduced operating costs, the XE models—966M XE and 972M XE—feature a new Economy Mode that provides up to 4 percent improved fuel economy during general machine operation and up to 8 percent improved fuel economy in aggressive truck-loading applications, according to the manufacturer. An updated touch-screen display now allows operators to select information displayed on the “quad screen,” which can simultaneously display, for example, axle oil temperatures, instant fuel rate, electrical system voltage, and temperatures for fluid in the torque converter and hydraulic system. A newly designed engine hood allows easier routine service and features a new actuator that speeds opening to ~35 seconds.

For more information, visit www.cat.com.

The UltraRAP® drum from Gencor is designed to assist the producer in making mixes with up to 60 percent RAP material.

From Gencor Industries, Orlando

The UltraRAP® 60% recycle plant from Gencor Industries is the latest innovation from Gencor. The manufacturer states it is a new leap forward in processing 60 percent recycled asphalt with less energy and without superheating and oxidizing the process materials.

The UltraRAP concept uses a staged convective heat transfer design to preheat and advance the release of internal moisture in the recycled pavement. The unique, patented combustion zone allows the release of moisture at lower temperatures, thus creating an even and staged release of water vapor in the drying process without oxidation. The material process flow starts at the feed end of the Ultradrum where aggregates are quickly heated to the correct temperature as they approach the burner. While the aggregates approach the combustion zone, the recycled asphalt is introduced into the combustion zone, behind specially designed combustion flighting. The specially designed flighting allows the RAP material to cascade around the combustion zone absorbing conductive and convective energy, allowing 60 percent RAP capability with lower aggregate temperatures and no reduction in plant capacity. The heat releases the internal moisture from the product before it enters the mixer. RAP, virgin aggregate and baghouse fines combine in the mixing zone, away from the direct radiant zone. Asphalt cement (AC) is then added into a thoroughly dried mixture of primary dust, baghouse fines, virgin aggregate and RAP to form a fully coated and homogenous mix before exiting the drum. Any hydrocarbons or steam vapors generated during the mixing process are captured by Gencor’s patented Volatile Reclaim System and returned to the burner as fuel, making UltraRAP an environmentally clean drum mixer, according to the manufacturer. The UltraRAP drum is designed to provide added flexibility for the addition of RAP fines or shingles (RAS) to meet production requirements for greater productivity and efficiency.

For more information, contact Gencor at (407) 290-6000 or visit www.gencor.com.

From Heatec, Chattanooga

Three new brochures are available from Heatec. These brochures cover the products and services that Heatec provides for asphalt terminals and emulsion plants. Their titles are as follows:

• Heatec Asphalt Terminals, Publication 10-15-288
• Heatec Asphalt Emulsion Plants, Publication 10-15-289
• Heatec Polymer Blending Systems, Publication 10-15-290

Call (800) 423-235-5200 to obtain a free printed copy.

Also check out the new RECON™ monitor system from Heatec, designed to keep plant operators informed about the status of asphalt storage tanks and hot oil heaters. The web-based system uses your smart phone, tablet or PC to show real-time status of the hot oil heater, of asphalt stored in tanks, of trend data and other options.

The new, portable K300/6203CC mobile crushing and screening plant from KPI-JCI and Astec Mobile Screens is designed to produce up to three finished products on one chassis.

From KPI-JCI and Astec Mobile Screens, Yankton, S.D.

The new Wizard Touch® stockpile automation system is designed to prevent material segregation and degradation. The refined system features an expanded selection of stockpile options. Jodi Heirigs, product manager for KPI-JCI and Astec Mobile Screens said it is capable of inputting multiple stockpile recipes for operation diversity. The Wizard Touch system includes a fully programmable PLC controller and a new, 12-inch colored touchscreen for enhanced usability. It is exclusively for KPI-JCI and Astec Mobile Screens’ SuperStacker® telescoping radial stacker.

The new portable K300/6203CC is a highly mobile crushing and screening plant designed to provide application versatility and serve as a rental tool for producers in sand and gravel, quarry or recycle applications. It combines a heavy duty, roller bearing Kodiak® Plus K300+ cone crusher with a triple-shaft, low-profile horizontal screen, and has the axle configurations to fit transportation requirements. In its closed-circuit configuration, the K300/6203CC allows producers to use a single chassis to produce up to three finished products, or supplement existing demand in a small footprint, according to the manufacturer.

The tow-behind conveyor from KPI-JCI and Astec Mobile Screens includes an 11-foot discharge height to load material directly into trucks or build a windrow alongside the track plant. The conveyor also uses a hydraulic drive, which allows it to be powered off the track plant.

The manufacturer has also released a new portable tow-behind conveyor, designed to eliminate double-handling of material. It’s a match for the exclusive FT line of continuous crushing and tracking impactors. The tow-behind conveyor is constructed with a hitch to attach to a track plant and travel behind the plant as it moves. A bolt-on hopper side wall allows the conveyor to rotate 180 degrees to discharge material to either side, or rotate 90 degrees to transport inline.

For more information, call (605) 668-2524 or visit www.kpijci.com.

From Larson Electronics, Kemp, Texas

The EPEXC-3X-12.3-30 is an explosion-proof, heavy duty, extension cord designed to provide secure connection in hazardous locations. It’s fitted with three explosion-proof twist-lock receptacles constructed of non-sparking aluminum to allow for connection of equipment. The cord is terminated with a 20-amp explosion-proof plug. The cord, plug and three receptacles are a 3-pole, 2-wire design. Larson specializes in portable industrial lighting equipment, high mast light towers, explosion-proof light fixtures and more.

For more information, contact Larson at (800) 369-6671 or visit larsonelectronics.com.

Meeker Equipment released the latest version of its Liquid Vision tank farm control and monitoring system during World of Asphalt in March.

From Meeker Equipment, Belleville, Pa.

Meeker Equipment recently released its latest version of Liquid Vision System, a tank farm valve control and level monitoring system. The latest version was introduced at the World of Asphalt Show and Conference in Nashville in March. The system features a graphical interface to automated asphalt valves for the supply, return and fill lines on an asphalt tank farm. The system also reads radar, pressure or ultrasonic level control to monitor tank levels. If tank levels get too high or too low, the system alerts the operator of tank level conditions and will even stop an asphalt unloading pump if levels get too high in a tank. If the tank is equipped with a high level shutoff switch, the system can use the switch to alarm the operator or also stop a pump.

The system allows operators to normally pump liquid AC from one tank and return to the same tank. But the system also allows the operator to move liquid from one tank to another if needed.

The system is configurable so that a plant can start with level control and add valve control later or vice versa. The system also allows for a graphical unloading station control. The unloading station provides a graphical interface of tank level and also shows valve control. The system will not allow an operator to fill a tank if the level is too high. The system automatically closes all fill valves except the tank the operator is filling.

Liquid Vision gives the plant operator complete control. He/She can take all control at the control room or distribute some of the control at the unloading station in a “Remote/Local” mode.

Liquid Vision also is web-based so all tank levels can be seen on the internet or on smart phones.

The benefit of the system is the safe monitoring of tank level at a tank farm and the security of valve control to minimize tank contamination and overfill protection.

For more information, contact Meeker at (888) 333-0323 x120.

PHCo’s Lo-Density® unitized storage tank heaters may be installed into any tank or vat, and dissipate controlled heat as low as three watts per square inch on the heater’s sheath to prevent coking or damaging of temperature-sensitive material. Unitized heaters feature the company’s unique drywell-style elements that reside inside the sheath, making them accessible from outside of the tank and eliminating the need to drain the tank to service the elements.

From Process Heating Co., Seattle

With the Diamond Achievement Commendation for asphalt plants submissions process now under way for 2016, it’s timely to discuss the clean-operating electric heat option from Process Heating Co. The company’s Lo-Density^® unitized storage tank heaters can provide unique environmental benefits to help asphalt producers achieve sustainability goals, including NAPA’s Diamond Achievement Commendation and its new Diamond Achievement Sustainable Commendation.

The manufacturer states that electric heat is safe, consistent and friendly to the environment because it heats without combustion or emissions. The company explains that electric heat offers 100 percent energy efficiency because all of the energy is used to heat. In addition, the efficiency will always be 100 percent, even after many years of operation, without costly maintenance. Electric heat also eliminates stacks that must be monitored for emissions, along with eliminating air quality and boiler permits that must be pursued and maintained. Unitized heaters can be interfaced and coordinated with other plant electrical equipment so that the load of the heaters can be reduced to base rates, thus preventing increased demand charges or peak-use rates and lowering consumption cost.

The NAPA Diamond Achievement program began in 1999 to recognize asphalt plants that met or exceeded national best practices for operations, environmental practices, safety, permitting compliance, regulatory compliance and community relations. The Diamond Achievement Sustainable Commendation includes additional best practices for sustainable operations and community involvement, and challenges asphalt producers to strive for an even higher level of excellence. The new commendation requires plants to understand, quantify and control their energy use, emissions and use of recycled materials, as well as to articulate a corporate sustainability plan.

For more information, call (866) 682-1582 or visit www.processheating.com.

Systems’ TSC Motors Start/Stop Control

From Systems Equipment Corporation

Systems’ Total System Control (TSC) is a Windows-based plant control program used to start, stop and monitor motors used in plant operation, as well as to manually load from silos. TSC is designed for universal plant use, regardless of motors used and their functions.

With the TSC Motors Start/Stop Control, the operator sees an LCD touch screen display in a Windows environment in the control house. The system handles the work, complete with master start/stop with separate start/stop for recycle equipment, safety interlocks, and auto/manual interlock from the baghouse cleaning system to the asphalt injection. It includes countless features for monitoring systems, amps, temperatures and more from the control house.

The manufacturer also offers the TSC Silo Control, which is expandable from one to 12 silos. Again, a color, flat panel, touch screen display is the user interface in the control house. The system offers audible safety alarms for the user’s spout bindicator, slat amp, high silo indication and more. The system has interlocks built in so the operator has to “mean to” bypass a low silo switch to pull material from a silo with a low amount of material. Again, the control offers countless features for monitoring air, material levels, motor amperage, and more.

For more information, visit www.systemsequipment.com.