Home » Products » Asphalt Mixing Plant » Installation, use and management methods of large asphalt mixing plants

Installation, use and management methods of large asphalt mixing plants

At present, the assembly and installation technology of large-scale asphalt concrete mixing equipment in high-grade highway construction is gradually improving. In order to improve work efficiency, it is necessary to analyze the pretreatment agent for the selection and matching of large-scale mixing equipment and auxiliary equipment, and clarify the installation and commissioning of asphalt stations. With the continuous change of highway construction methods, it is necessary to adopt production equipment according to the requirements of the development of the times. Intermittent asphalt mixing equipment is a widely used road construction equipment with the characteristics of simple operation and high work efficiency. Relevant staff are required to master the installation, construction and management methods of mixing equipment.

Rated 4.7/5 based on 529 customer reviews
Share:
Content

At present, the assembly and installation technology of large-scale asphalt concrete mixing equipment in high-grade highway construction is gradually improving. In order to improve work efficiency, it is necessary to analyze the pretreatment agent for the selection and matching of large-scale mixing equipment and auxiliary equipment, and clarify the installation and commissioning of asphalt stations. With the continuous change of highway construction methods, it is necessary to adopt production equipment according to the requirements of the development of the times. Intermittent asphalt mixing equipment is a widely used road construction equipment with the characteristics of simple operation and high work efficiency. Relevant staff are required to master the installation, construction and management methods of mixing equipment.

[1]. Installation of large-scale asphalt mixing station
At present, large-scale asphalt mixing equipment should pay attention to site selection and application technology, master the installation methods of foundation and equipment, and the following will analyze the installation of large-scale asphalt mixing stations in detail.
1. Foundation and equipment installation
In addition to considering many factors in site selection, asphalt mixing plants must be located away from residential areas and farmland. Before installation, the equipment must be debugged to confirm whether there are scratches and wear, and lubricate the bearings according to the established conditions. Secondly, the technicians must confirm the normal operation of the equipment and electrical system during the inspection. If there are abnormal conditions, they must be checked in time to eliminate safety hazards. Since the mixing station involves many materials, all surrounding resources must be considered. The asphalt mixing station should be reasonably selected according to the geological conditions. It is mainly divided into two types: field and soft foundation. Since the field soil is relatively hard, the bottom layer should be properly established and paved after digging. Secondly, the foundation concrete construction procedure should be considered, and the filling degree after excavation should be analyzed. After the soft foundation is laid out and excavated, different technical processes can be selected to reinforce the bottom of the foundation, generally in the form of plum blossom piles and vibration protection tubes.
In order to prevent the foundation area at the bottom from gradually increasing and reach the bearing capacity of the foundation, it is necessary to analyze the potential dangers of cracking and sinking equipment in practice. During the foundation construction process, attention should be paid to the foundation pouring of the main building part and the aggregate drying part. During the foundation installation process, it is necessary to ensure that the same horizontal plane does not exceed the standard height, thereby reducing the harm of resonance. Through an effective installation procedure, the main building is established as the center and the installation is radiated to three sides. While large equipment occupies land, the basic tasks of large cranes must be completed in a short time, thereby achieving the purpose of cost saving.
2. Cable installation
In recent years, with the continuous increase in the number of mixing stations, the power consumption of the entire motor has also increased, and the general power is about 500-1000kw. Due to the large cross-sectional area of ??the power supply line, in the process of controlling the original parts, it is necessary to use cable troughs and dark trenches to arrange them reasonably. During the arrangement process, the cable table should be carefully checked. In order to avoid the phenomenon of circuit breaker, self-adhesive high-pressure tape should be selected for effective connection.
In the process of controlling the system circuit, the signal must be shielded first and arranged according to the established requirements. In order to reduce the impact of external electromagnetic interference on the system, the line needs to be concealed and protected, and safety protection warnings should be made. The circuit direction should try to choose oil circuits and high-temperature areas. If the coordinates are unclear in practice, it should be put aside first, and the line should be inspected and analyzed in detail during the debugging process. In order to make up for the omissions, it should be improved one by one to avoid line damage.

[2]. How to effectively manage large asphalt mixing plants
In view of the problems that need to be paid attention to during the installation of large asphalt mixing plants, in order to manage them in a refined manner, it is necessary to start from multiple aspects and master multiple management methods to improve the overall management effect. The following will conduct a detailed analysis of the effective management of large asphalt mixing plants.
1. Strengthen the management of production personnel
In the daily management of asphalt mixing plants, production personnel occupy an important position. Since the actual management involves the main building, storage, material supply and asphalt supply, etc., it is necessary to conduct a detailed analysis of the auxiliary components. In addition to the conventional application system, if the setting and effective management of other systems are ignored, the mixing station will be paralyzed, and then the system will be damaged. In order to ensure the further development of the mixing station, professional management personnel should be arranged to manage it, so as to promote the normal operation of the mixing station. First of all, the relevant leadership organizations should clarify their own responsibilities, analyze the overall mixing station information resources, do a good job in the relevant work of automatic operation, and practice according to the established procedures. Secondly, the operators must understand the basic operating principles, master the electric welding skills, and be proficient in the application and operation procedures of the mixing equipment. Other supporting personnel must be familiar with the management and operation content, clarify the basic work flow of the mixing station, and have a strong sense of responsibility and enthusiasm in practice.
2. Strengthen the management of production technology
Due to the differences between the operating system of large asphalt mixing plants and the original small operating system, most of them are controlled by the working server as the terminal, and must be operated according to strict operating instructions. However, in actual management, there are cases of improper operation that affect the effectiveness of operation. Therefore, the team members need to conduct detailed inspections on each operating procedure, including: the lubrication of each bearing, whether the switch handle is correct, whether the heating of the asphalt pump meets the requirements, and whether the parameters of each system are within the allowable range. After the inspection, it can be started. Since road construction involves many influencing factors, in order to reduce capital investment, it is necessary to preheat the machine in advance. After the relevant operating procedures are completed, other fuels can be used for combustion. Since heavy oil uses other fuels for combustion, in order to obtain better fluidity, the oil point should be heated to 100℃~120℃. If it is a cold machine, it must be preheated for at least 15 minutes, and when the basic temperature drops to 80℃~90℃, moisture can be evaporated. During the operation, it is necessary to strictly follow the procedures for preparation. The server and industrial computer can be connected online, and the actual situation of the server and the online connection can be observed to prepare for the use of the instrument.
3. Cost management
Large-scale asphalt mixing plants require a large amount of capital during the installation process. If the capital investment in each link is not properly controlled, it is easy to cause waste. Therefore, cost management should be done well in the overall management. Since the processing cost of asphalt mixture is relatively expensive, 1t is about 400 to 500 yuan. If it is wasted for a long time, it will directly cause economic losses. In the process of cost control, the loss of mixture must be controlled first. Professional supervisors must review the quality and quantity of materials in a timely manner. In order to avoid serious waste, aggregates must be effectively controlled. In addition, the fuel system must be transformed and optimized. Practice has proved that a fully functional burner needs to heat the aggregate to 180°C, which is greater than the required diesel 8L. According to the current oil price standard, it will consume about 40 to 50 yuan. If heavy oil is used, the cost can be reduced. Therefore, under the premise of ensuring the stable operation of the equipment, the fuel type must be reasonably selected to improve the overall economic benefits.
4. Related data management
Since a large asphalt mixing plant is a set of complete operating equipment, each component has specified technical standards and application parameters. In the process of equipment maintenance and care, it is necessary to collect and manage relevant data and important components. In order to avoid material loss or other situations, the data should be backed up. In addition, the daily production and maintenance of the machine should be registered and managed, and various types of data should be classified and managed for easy reference and processing in the future. In data management, relevant staff should master computer management technology. There are many types of aggregates involved in the asphalt mixing process. The amount and function of each type of data are different. In order to manage the data reasonably, it is necessary to use information technology as a management platform to manage the data technically to avoid information loss.

[3]. Conclusion
Since the installation and application of large asphalt mixing plants involve many influencing factors, they should be taken seriously in practice. In order to avoid serious improper installation or other technical problems, a detailed analysis of the management method is required. In combination with the actual situation, the relevant staff should do their own work well and determine their own responsibilities according to the practice content. In order to ensure the effectiveness of management, it is necessary to start from the management of production personnel, production technology, cost management, and related data management, and conduct a detailed analysis of the influencing factors, so as to achieve the purpose of enhancing management effectiveness.

Inquiry


    More Asphalt Processing

    I. The basis for the classification of asphalt mixing plant models
    The models of imported asphalt mixing plants are mainly divided according to the following three aspects:
    1. Production capacity: According to the size of production capacity, asphalt mixing plants can be divided into small (30-60 tons/hour), medium (60-300 tons/hour) and large (300 tons/hour or more).
    2. Functional characteristics: Different models of asphalt mixing plants have different functional configurations, such as asphalt batching system, interference screening system, thermal regeneration system and asphalt storage system, etc., to meet the needs of different road construction projects.
    3. Additional equipment: According to customer requirements, imported asphalt mixing plants can also be equipped with additional equipment such as environmental protection equipment, intelligent control systems, oil storage tanks, etc., which will also affect the classification of models.
    II. The difference and application scope of different models of asphalt mixing plants
    1. Small asphalt mixing plant: suitable for smaller-scale road construction projects, such as community or village roads. Although the production efficiency is low, it occupies a small area and is affordable.
    2. Medium-sized asphalt mixing plant: suitable for medium-sized road construction, such as county and township roads. Its production efficiency is high, it has certain requirements for the quality of raw materials, and the price is moderate.
    3. Large asphalt mixing plant: suitable for large-scale construction projects such as highways and airports. The production efficiency is extremely high, and the requirements for asphalt materials are also higher, but it occupies a large area and has a high price.
    In summary, the selection of a suitable imported asphalt mixing plant model requires comprehensive consideration of factors such as production capacity, functional characteristics and additional equipment, and selection and purchase according to the needs of the actual road construction project.

    The renovation of the combustion-supporting system of the asphalt mixing plant and the use of DC frequency conversion CNC machining technology are all renovations of the original system. In addition to the above renovation plans, with the existing equipment and personnel, what other measures can be taken in the application to reduce the operating costs of concrete mixing plants?
    At present, China has no mandatory national industry standards for heavy residual oil, and the quality of fuel oil varies greatly. Even from the same dealer, the quality difference between batches is very large, and it contains more residues. Therefore, bridge inspection equipment should be installed on the construction site, and professional personnel should inspect various performance parameters of gasoline and diesel to strictly control quality.
    When the burner is working, if the flame of the combustion aid is red and the smoke from the ash removal chimney is black, this is the manifestation of poor atomization of gasoline and diesel and insufficient combustion aid. At this time, the following measures should be taken to deal with it: properly adjust the distance between the nozzle and the vortex plate, generally push it inward to a suitable distance, the purpose is to prevent the atomized oil cone sprayed from the nozzle from spraying into the vortex plate; effectively adjust the ratio of gasoline and diesel to gas, so that the gasoline and diesel increase the mass conversion law slowly, or the gas increase the mass conversion law quickly; promptly remove the carbon deposits and coke around the nozzle to prevent the flame from deflecting; heavy residual oil contains more residues, which can easily cause serious damage to the high-pressure oil pump and increase the working pressure, affecting the actual effect of atomization and the shape of the flame, so the high-pressure oil pump must be repaired or replaced in time; install metal filter devices in front of the first and second high-pressure oil pumps, and clean them frequently to prevent the residues in the gasoline and diesel from blocking the nozzle.
    The operators should be trained in professional skills on a regular basis to strengthen their job responsibilities and moral education, so that they can establish their respective job responsibilities, understand the importance of their positions, understand the content of their work, and improve their professional level. Skilled operators can properly control the temperature of the asphalt mixing plant mixture to avoid gasoline and diesel waste.
    In order to improve the combustion-supporting effect and effectively reduce the operating costs of asphalt mixing stations, Sinoroader Group kindly reminds that the following issues should be noted when using the burner in the asphalt mixing station: To improve the maintenance of the burner, the burner nozzle should be cleaned of charred materials and carbon deposits on the ignition electrode regularly. The nozzle can be disassembled according to the atomization status; the air-oil ratio of the burner is generally not adjusted, and the fuel pump pressure can be adjusted according to the smoke status and the temperature of the asphalt mixture; the sulfur dioxide generated by the combustion of light fuel oil has a strong corrosion to the bag, so the bag should be maintained regularly and the air pressure changes in the bag should be paid close attention to; water deashing will produce more foam, causing the sand settling tank to flow out, so the sand settling tank should be cleaned in time, and a watering design should be carried out to settle the foam; when the steam pressure decreases or the gear oil pump noise increases, the gear oil pump must be replaced.
    When the burner is started, the fuel oil circulation system should be completed through the valve, and then the burner control box should be opened to start the burner. If the electronic ignition of the fuel oil fails, you can change the inlet tee and use the diesel engine for ignition. After the ignition is successful for 2 minutes, you can convert it into fuel oil. In this way, even the light fuel oil of lower quality can ensure combustion.

    The asphalt mixing plant is a complete set of equipment for mass production of asphalt concrete. The whole machine of the equipment consists of multiple systems, such as batching system, drying system, combustion system, powder supply system and dust prevention system. Each system is an important part of the asphalt mixing plant.
    The working condition of the combustion system of the asphalt mixing plant has a great impact on the whole system, which is related to the economic efficiency of the whole system, temperature control accuracy and flue gas emission indicators. This article will briefly introduce how to judge the working condition of the combustion system of the asphalt mixing plant.
    Generally speaking, due to the complexity of the detection equipment and methods, there are no conditions to achieve in the working process of most asphalt mixing plants. Therefore, it is more convenient to judge the working condition by a series of relatively intuitive factors such as the color, brightness and shape of the flame. This method is very simple and effective.
    When the combustion system of the asphalt mixing plant is working, when the fuel is burning normally in the drying cylinder, the user can observe the flame through the front of the cylinder. At this time, the center of the flame should be in the center of the drying cylinder, and the flame is evenly distributed around it and will not touch the cylinder wall. The flame is full. The whole outline of the flame is relatively clear, and there will be no black smoke tail.
    The abnormal working state of the combustion system includes, for example, the diameter of the flame is too large, which will cause serious carbon deposits on the furnace tube and affect the subsequent working state of the combustion system.

    The drive unit is one of the important components of the asphalt mixing plant, so whether it can be reliably operated must be highly valued to avoid adverse effects on the entire asphalt mixing plant. In order to ensure that the drive unit in the asphalt mixing plant is indeed complete and reliable, the following maintenance measures are essential.
    The first thing to pay attention to is the universal rotating part of the drive unit of the asphalt mixing plant. This part has always been a fault-prone part. In order to reduce the occurrence of faults, grease should be added on time, and the wear should be checked frequently, and repaired and replaced in time. Users should also prepare the universal shaft assembly to avoid affecting the working process of the entire asphalt mixer.
    Secondly, the cleanliness of the hydraulic oil used in the asphalt mixing plant must be ensured. After all, the working environment of the equipment is relatively harsh, so it is necessary to prevent sewage and mud from entering the hydraulic system. The hydraulic oil should also be replaced regularly according to the requirements of the manual. Once water or mud is found mixed in the hydraulic oil during inspection, the hydraulic system should be stopped immediately to clean the hydraulic system and replace the hydraulic oil.
    Since there is a hydraulic system, of course, a matching cooling device is also required, which is also an important focus in the drive system of the asphalt mixing plant. To ensure that its function can be fully exerted, on the one hand, the hydraulic oil radiator should be cleaned regularly to prevent the radiator from being blocked by cement; on the other hand, the radiator electric fan should be checked to see if it is running normally to prevent the hydraulic oil temperature from exceeding the standard.
    In general, as long as the hydraulic oil of the asphalt mixing plant drive device is kept clean, there are generally few faults; but the service life varies from manufacturer to manufacturer, so pay attention to its alkalinity observation and replace it in real time.

    Never stop, escorting the quality of road construction
    Inheriting decades of technical accumulation, asphalt mixing station has become an indispensable part of building and maintaining high-level roads. This seemingly ordinary device carries the important mission of ensuring road safety and improving driving experience. As the core technology of modern road engineering construction, asphalt mixing station goes all out to continuously strive for a better, safer and more efficient travel environment.
    Fast drive, tenacious progress
    Asphalt mixing station plays a role in road engineering. It uses mature technology and processes to ensure the smooth progress of road construction with efficient mixing capacity and stable production quality. From conveying raw materials to the precise proportion of oil and aggregates, to the uniform mixing of the final product, the asphalt mixing station, with its professional working attitude, ensures the quality and stability of road materials, and provides a solid foundation for the construction of high-standard road projects.
    Innovation leads, environmental protection takes the lead
    Asphalt mixing station plays an important role in promoting sustainable development. Faced with increasingly urgent environmental protection requirements, mixing stations continue to innovate technology, improve production efficiency, and also pay attention to environmental protection responsibilities. By introducing advanced dust removal and purification devices, intelligent equipment control systems and combustion equipment, the asphalt mixing station effectively reduces environmental pollution and makes positive contributions to protecting the surrounding ecological environment.

    Judging from the situation of highways in our country, asphalt pavement is the most used, which is one of the reasons why asphalt mixing plants have developed so rapidly. Under the situation of rapid economic development, the quality problems of asphalt pavement are gradually increasing, which puts forward higher and higher requirements for the quality of asphalt. It is understood that the primary factor that affects the quality of asphalt is the ratio of raw materials. This is also covered in the introduction of asphalt mixing stations. You can discuss it together.
    In order to obtain high-quality asphalt products, in addition to the asphalt mixing equipment meeting the requirements, selecting the appropriate asphalt mixture gradation type is also a top priority. According to my country’s current regulations, the maximum particle size of the asphalt mixture in the upper layer of the highway should not exceed half of the layer thickness; while the maximum particle size of the aggregate in the middle surface layer of asphalt mixture should not exceed two-thirds of the layer thickness; and the asphalt layer should not exceed half of the layer thickness. The maximum nominal aggregate size of the pavement structural layer mixture should not exceed one-third of the layer thickness.
    Based on this analysis, if an asphalt surface layer with a certain thickness is selected according to the above specifications, the particle size of the asphalt mixture aggregates will generally be larger, which will inevitably bring insurmountable construction difficulties to the construction of asphalt concrete pavement. After investigation, testing, analysis, and comparison, it can be seen that the lower layer has a wider choice, so the AG-201 gradation type can be used; while the selection of the upper layer mixture type is more difficult, and it is necessary to achieve a reasonable choice of this mix ratio. , on the one hand, we must examine as many aggregate resources as possible, and on the other hand, we must also consider the model of the mixing equipment.
    In order to ensure the quality of the project, strict selection and inspection of engineering materials must be carried out. Therefore, the selection and determination of raw materials should be based on the requirements for pavement structure and use quality, combined with the supply of floor materials, and inspection in accordance with the requirements of relevant test procedures, and then Select the best materials so that all technical indicators of the materials meet the specified technical requirements.

    Bitumen is a polymer mixture composed of asphaltene, colloid, aromatic hydrocarbons and saturated hydrocarbons. Asphaltene is dispersed in aromatic hydrocarbons and saturated hydrocarbons with the help of colloid to form a colloidal structure. When the asphaltene content is low, the bitumen has good adhesion, plasticity and fluidity, but poor temperature stability and elasticity
    Bitumen modification principle:
    Bitumen is a polymer mixture composed of asphaltene, colloid, aromatic hydrocarbons and saturated hydrocarbons. Asphaltene is dispersed in aromatic hydrocarbons and saturated hydrocarbons with the help of colloid to form a colloidal structure. When the asphaltene content is low, the bitumen has good adhesion, plasticity and fluidity, but poor temperature stability and elasticity. The polymer modifier is similar to the asphaltene in bitumen. Its addition, after fully swelling with bitumen, absorbs the aromatic hydrocarbons and colloid in bitumen to form a new colloid, which not only retains or increases the adhesion, plasticity and fluidity of the original bitumen, but also improves the temperature stability and elasticity of bitumen, thereby achieving the purpose of improving the road performance of bitumen.
    Bitumen modification process:
    The modifier and additive are evenly and finely dispersed into the matrix bitumen, and the contact area between the original bitumen and the modifier is increased as much as possible to ensure full swelling and development, which not only improves the utilization rate of the modifier but also makes the original bitumen performance the most perfect improvement.
    The modified bitumen complete production equipment has the following advantages:
    1. It is suitable for a variety of modifiers, such as SBS, EVA, PE, etc.;
    2. The ratio of modifier to bitumen can be set at any time according to user needs;
    3. The production volume of each cycle can be set arbitrarily within the maximum productivity;
    4. The modified bitumen has high quality, and the modifier has a small particle size and uniform distribution after emulsification;
    5. The production process is fully automatically controlled, and the production records can be queried at any time;
    6. The weighing system is accurate in measurement, and the weighing error is less than 1%;