Batch asphalt mixing plant is also called batch asphalt mixing plant. It is the core special equipment for producing hot mix asphalt mixture (HMA) for high-grade roads and large-scale infrastructure projects. Its core characteristics are independent metering in batches, forced batch mixing, and loading capacity of single boiler finished material corresponding to single vehicle. It is distinct from continuous discharge mode of drum mixing plant. The whole set of equipment consists of core systems such as cold aggregate supply, drying and heating, hot material screening, precise weighing and batching, forced mixing, asphalt transportation, dust removal and environmental protection, etc. Large models can be equipped with finished material storage bins to effectively guarantee the supply requirements of large-scale continuous paving projects.
The production process of the equipment is standardized and highly controllable. After the aggregate is loaded, dried at high temperature and screened and classified, it is accurately weighed with mineral powder and asphalt respectively. The measurement error of aggregate can be controlled to ±0.5%, and the measurement error of asphalt is as low as ±0.25%. After forced uniform mixing, the material is discharged, and the automatic reset cycle operation is completed after single batch production. The biggest advantage of this equipment is high metering accuracy, flexible formula adjustment, rapid switching of mixing parameters without shutdown, support for fixed and mobile models, and with fully automatic PLC intelligent control system, it can realize the whole process recording and remote monitoring of production data, fully adapting to the quality inspection traceability requirements of various large-scale high-standard infrastructure projects.
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Expressway, airport runway, urban ring road, port park and other large-scale asphalt infrastructure projects, in terms of construction scale, construction period requirements, quality standards and environmental protection compliance, are far superior to ordinary small-scale road projects, complex construction conditions make it difficult for traditional drum continuous mixing station to adapt, which is also the core reason why large contractors prefer intermittent asphalt mixing station. The demand for mixture for large-scale projects is extremely large, and the materials used in a single day can reach thousands of tons. The whole set of production, transportation and paving links are highly linked, and the fault tolerance rate is extremely low. Roller type equipment adopts volumetric continuous metering, which is easy to cause proportion deviation during long-term high-load operation, which causes quality problems such as road surface flooding, aggregate segregation and insufficient compaction, greatly increases the maintenance cost in the later period, and cannot meet the stable construction requirements of large-scale projects.
The pavement structure of large-scale asphalt engineering is complex, and more than ten different mixture formulas need to be adapted for layered pavement. The requirements for mixture gradation, asphalt content and recycled material proportion are different for special sections such as bottom layer, middle layer, surface layer, ramp, bridge and airport runway. The drum type equipment needs to empty the remaining materials of the whole machine when replacing the formula, which takes a long time and causes a large loss of materials, which seriously delays the construction progress; while the intermittent mixing station can quickly switch the production parameters between batches without stopping the material cleaning, which perfectly meets the construction requirements of large-scale projects in layers, sections and multiple formulas. At the same time, this kind of project generally has a tight construction period, which often requires all-weather uninterrupted paving. Long-distance transportation is easy to cause temperature segregation of mixture. Only high-precision and high-uniformity mixture produced by intermittent equipment can effectively avoid early diseases such as pavement cracking, rutting and seepage, and ensure construction quality.
At present, the environmental protection control and quality inspection traceability standards of large-scale infrastructure projects continue to be upgraded. The bidding process generally requires that the asphalt production data can be checked and traced in the whole process, and at the same time, the dust, exhaust gas and noise pollution on the construction site shall be strictly restricted. Batch mixing station is equipped with perfect closed dust removal and waste heat recovery system, which can automatically record the raw material ratio, production temperature and discharge weight of each batch, easily passing quality supervision and environmental protection acceptance; while conventional drum equipment lacks independent accurate weighing and data archiving module, which makes it difficult to meet high standard compliance requirements. In combination with diversified requirements such as synchronous construction of multi-bid sections of large-scale projects, limited site and resource utilization of recycled materials, the intermittent mixing station with high precision, high flexibility and high compliance has become the core equipment for contractors to avoid construction risks and ensure efficient project performance.
Combined with the actual construction scenarios of tens of millions of large-scale infrastructure projects such as high-speed, airport and municipal ring roads, the industry head contractor chooses intermittent mixing station, which is not a strategic choice of comprehensive quality, cost, compliance and long-term benefits, but a strategic choice of comprehensive quality, cost, compliance and long-term benefits. Seven core advantages directly hit the pain points of large-scale projects:
The batch mixing station adopts independent bin weighing mode to accurately measure aggregate, mineral powder and asphalt respectively and automatically calibrate them, so that the aggregate error can be controlled within ±0.5% and the asphalt error can be controlled within ±0.25%, so as to ensure that each batch of mixture grading and asphalt ratio accurately conform to the design standard. For high-speed, airport runway and other high-load, high-durability requirements of large-scale projects, high-precision mixing can effectively improve road compaction, anti-rutting and temperature aging performance, greatly reduce the late disease and maintenance costs, to ensure the long-term quality assurance effect of the project; In contrast, the roller mixing station adopts volumetric flow metering, long-term continuous production is easy to occur ratio deviation, difficult to meet the strict quality requirements of high-standard infrastructure projects.
Large-scale road projects need to adapt to more than ten mixture formulas of different pavement scenarios such as bottom layer, middle layer, surface layer, ramp and bridge, with complex and changeable working conditions. However, intermittent asphalt mixing station relies on intelligent control system, which can pre-store multiple sets of proportioning parameters. It only takes 30-60 seconds to quickly switch formulas without emptying equipment surplus materials, with small material loss and no interruption of construction progress. At the same time, the equipment supports flexible adjustment of recycled asphalt (RAP) mixing ratio, which can stably realize 30%-50% high proportion recycled material mixing and accurately control the mixing ratio of old and new materials, which can not only reduce the cost of construction raw materials, respond to green infrastructure policy, but also be the core construction advantage that traditional drum mixing station cannot realize.
Batch asphalt mixing station adopts single batch independent discharge mode, which can sample single pot mixture at any time, only discard unqualified batch materials, greatly reduce material waste and rework cost, and avoid the problem of continuous production and large-batch waste after abnormal mixing ratio of drum mixing station. At the same time, contractors can realize vertical integration of industrial chain by independently equipping intermittent equipment, get rid of dependence on purchased mixture, independently control raw material procurement and production rhythm, and reduce comprehensive material cost by 15%-30%. Although the initial investment of equipment is higher, in the construction scenario of large-scale projects with large consumption, the saved materials, labor and outsourcing costs can be quickly recovered, and the long-term investment cost performance and economic benefits are far superior to drum equipment.
At present, large-scale infrastructure generally requires solid waste resource utilization. Most high-speed and airport projects clearly stipulate that asphalt mixture shall be mixed with RAP recycled material of no less than 20%. Batch mixing station is equipped with independent recycled material batching and screening system, which can accurately complete the proportion of old and new materials and forcibly mix them evenly. Under the condition of high recycled material blending ratio, the mixture performance can still be stable and up to standard for inspection. On the contrary, the traditional drum mixing station is limited by the continuous feeding structure, the mixing uniformity of recycled materials is poor, the bonding effect is not good, and the finished product quality is difficult to pass the regular inspection. Therefore, the batch equipment becomes the preferred equipment for the stable production of recycled materials in large-scale green infrastructure projects.
Modern batch asphalt mixing plant is equipped with bag dust removal, low nitrogen combustion, fully enclosed transportation, sound insulation and noise reduction, which can effectively control dust, exhaust gas and construction noise, and fully meet the construction requirements of environmentally sensitive areas such as Urban area and airport. The equipment supports real-time monitoring and full-process recording of production data, can easily pass environmental protection acceptance, effectively avoid shutdown rectification and fine risks, and is the compliance optimization equipment for large-scale municipal and high-standard infrastructure projects.
The high-capacity intermittent asphalt mixing station is equipped with intelligent Internet of Things control system, which can support 24-hour continuous production. It has functions such as remote monitoring, fault warning, automatic data storage, etc., which can realize intelligent control of the whole process and effectively reduce manual operation error. The complete production account can be directly used for project acceptance traceability. At the same time, the equipment optimizes the heating system, supports the production of warm asphalt at low temperature, widens the construction temperature range of mixture, prolongs the working time of transportation, and fully meets the construction requirements of continuous paving and long-distance transportation of large-scale projects at night.
Intermittent mixing station is not only suitable for a single scene of expressway. Fixed large-capacity models can undertake airport runway, port yard, large-scale industrial park and bridge deck pavement across rivers; Mobile intermittent station can serve urban ring road segment reconstruction and synchronous reconstruction and expansion projects of multiple national highways. One set of equipment can undertake a variety of high-standard large-scale projects, with high equipment reuse rate. For contractors who have long-term deep cultivation of road infrastructure, the utilization rate of equipment assets is much higher than that of drum mixing station with single function.
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Compare Dimensions |
batch asphalt mixing plant |
drum asphalt mixing plant |
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manufacturing technique |
Batch intermittent discharge, independent metering and mixing of each pot, reset cycle after completion of single batch |
Continuous discharge throughout the process, drying and mixing are completed simultaneously, without independent weighing and screening |
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measuring accuracy |
Independent weight measurement, aggregate error ≤±0.5%, asphalt error ≤±0.25%, high accuracy |
Volumetric continuous metering, limited accuracy, long-term high-load operation prone to ratio deviation |
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mixture quality |
High uniformity of forced mixing, suitable for modified asphalt, high content recycled materials, special mixtures |
Only suitable for single common hot mix, complex formula finished product stability is insufficient |
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Adapt scene |
Airport, multi-layered highway, urban trunk road, recycled material blending, multi-formula switching, public construction projects with strict environmental protection control |
Long-term rural high-speed, large-area single-layer paving, single-type mixture, low-standard linear engineering for ultimate continuous yield |
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Cost and Operation |
Higher procurement costs in the early stage, but low raw material loss, less rework, and controllable long-term operating costs |
Lower input in the early stage, lower energy consumption for continuous production of single material, but large waste of raw materials for formula switching and recycled material production |
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project type |
Core selection scheme |
Core adaptation advantage |
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High-standard large-scale public construction projects (airport, highway, municipal ring road) |
200-400 t/h high-capacity intermittent asphalt mixing station is directly selected |
Meet the requirements of high standard quality inspection, multi-layer pavement formula switching, compulsory blending of recycled materials and environmental protection control in Urban area |
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Long-term suburban low-standard linear engineering |
Roller type equipment produces base material, batch type equipment is responsible for high standard mixture of surface layer |
Considering continuous production yield and pavement surface quality, balancing cost and construction effect |
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The core value of intermittent mixing station ishigh precision, high flexibility and high compliance. In the following five types of large-scale infrastructure projects, the advantages of equipment can be fully released, and it is also the most widely used scenario for industry contractors:
The expressway is divided into three layers of pavement: bottom, middle and surface. The mixture gradation, asphalt grade and recycled material proportion of each layer are completely different. Some long expressways also include differentiated pavement design of tunnel, interchange ramp and parking lot in service area, which requires frequent switching formula. The intermittent mixing station has the characteristics of rapid parameter adjustment and accurate measurement to ensure the uniform pavement quality of the whole line, and the complete production records meet the requirements of the traffic quality supervision department for the whole traceability. It is the standard equipment for the domestic high-speed new construction and reconstruction projects.
The airport pavement bears heavy aircraft impact and high and low temperature alternating loads all the year round. The high temperature stability, fatigue resistance and anti-skid performance of asphalt mixture are required to meet the highest standards in the industry. Any deviation in proportion will bring flight safety hazards. Large-scale airport projects are generally equipped with fixed large-capacity intermittent mixing stations to produce customized high-performance modified asphalt mixtures on site. Each batch can be submitted for filing, which fully conforms to the strict acceptance specifications of civil aviation projects.
Large-scale road reconstruction projects in Urban area are mostly constructed by sections and periods. Traffic control is limited during the day and centralized paving at night. Meanwhile, dust and noise are strictly controlled in surrounding residential areas and schools. The intermittent mixing station is designed with closed dust removal and low noise to meet the environmental protection requirements of Urban area, flexibly switch repair materials, surface materials and intersection anti-skid materials, adapt to fragmentation and multi-specification construction requirements, and avoid the impact on people's livelihood caused by large-area road closure.
The pavement of port yard and heavy load industrial park needs heavy load anti-rutting special asphalt mixture, some projects are simultaneously equipped with various pavement structures of park roads, parking lots and sidewalks, and at the same time, the project generally requires a large amount of milling recycled materials for old sites. The batch mixing station can stably produce heavy-duty special mixture, efficiently digest solid waste recycled materials, and help the project complete green construction assessment.
Steel box girder deck and tunnel interior pavement need waterproof modified asphalt, ultra-thin wearing layer and other special mixtures, which are complex in formula and various in quality inspection indexes, and drum equipment is difficult to meet the standards stably. Intermittent mixing station can accurately control modified asphalt content and fiber addition ratio, and the mixing uniformity can meet the construction standards of special pavement of bridges and tunnels, so as to reduce the risk of water seepage and displacement damage of bridge deck.
The procurement of intermittent asphalt mixing station for large-scale projects cannot only depend on the hourly production capacity figures. The eight core configurations directly determine the equipment construction stability, finished product quality and long-term operation and maintenance cost. They are also the primary verification parameters for the head contractor to purchase:
High-precision weighing and batching system: As the core configuration to ensure the quality of asphalt mixture, the whole system is equipped with high-precision independent weighing sensors, which can accurately measure aggregates, mineral powder and liquid asphalt in different areas, and strictly control the aggregate measurement error to ≤0.5% and asphalt measurement error ≤0.25%. The equipment supports all-weather dynamic automatic calibration function, which can offset equipment vibration, temperature change, material adhesion and other disturbances caused by long-term high-load production, and eliminate measurement drift problems. Stable and accurate proportioning can avoid the imbalance of oil-stone ratio and grading deviation from the source, ensure the uniform performance of each batch of mixture, and fully meet the proportioning specifications of high-standard large-scale projects such as high speed and airport.
Fully intelligent PLC Internet of Things control system: equipped with mature PLC intelligent central control and Internet of Things remote monitoring system, it is the core standard of modern large-scale mixing station. The system supports mass mixture formula storage, and can switch various pavement ratio parameters with one key. At the same time, it has the functions of automatic recording, real-time export and cloud archiving of production data. Contractors can remotely monitor equipment operating status, production capacity, material consumption and discharge temperature in real time through mobile phones and computers, and are equipped with intelligent fault warning and abnormal alarm functions to predict equipment hidden dangers in advance. The complete production ledger can be directly used for engineering quality inspection traceability, supervision acceptance and project audit, which perfectly meets the standardized management requirements of large-scale infrastructure projects.
Special recycled material supporting system: For the rigid requirements of green construction and solid waste reuse of large-scale projects, the exclusive recycled material supporting system is equipped with independent RAP bin, precise screening structure and special weighing module, which is different from ordinary simple blending device, and can realize synchronous precise batching and uniform mixing of recycled asphalt and new aggregate. The equipment can stably realize 30%-50% high proportion recycled material blending operation, effectively activate old pavement milling waste, and greatly reduce raw material procurement costs. The whole system can completely solve the problems of uneven mixing, poor cohesiveness and substandard performance of recycled materials of traditional equipment, ensure the stability and compliance of mixtures with high RAP content, and meet the bidding requirements of green infrastructure in various places.
Efficient energy-saving drying and heating system: Thickened heat preservation drying drum with low-nitrogen energy-saving burner is adopted. After structural optimization design, the thermal conversion rate of the equipment is greatly improved, effectively reducing the overall fuel consumption, meeting the energy saving and cost reduction requirements of long-term continuous production of large-scale projects. The efficient heating system can quickly dry aggregates with different moisture content, accurately control the aggregate heating temperature, and adapt to various climatic construction scenarios. At the same time, it supports warm mix asphalt (WMA) low-temperature production process, which can reduce mixture production and paving temperature, reduce energy consumption and exhaust gas emission, and effectively extend the construction window period of asphalt mixture to meet the night construction and long-distance transfer paving requirements of large-scale projects.
Heavy-duty environmental protection dust removal device: suitable for environmentally sensitive construction scenarios such as urban Urban area, airport and residential area. The equipment is equipped with pulse bag dust removal system and fully enclosed aggregate conveying corridor to inhibit dust diffusion from the source. The whole set of dust removal equipment has high filtration efficiency, which can ensure that the construction dust and exhaust gas emissions fully meet the local environmental protection control standards. At the same time, it is equipped with professional noise insulation structure to effectively reduce the noise pollution of equipment operation. The equipment can operate stably 24 hours a day without frequent downtime for cleaning, continuously ensure environmental protection standards at the construction site, avoid risks such as environmental rectification, fines, and work stoppages, and adapt to the strict environmental protection requirements of large-scale municipal and airport key projects.
Double-horizontal shaft wear-resistant forced mixing machine: As the core component of mixture mixing, the main machine adopts heavy-duty double-horizontal shaft structure, equipped with thickened wear-resistant lining plate and high-strength alloy mixing blade, excellent wear resistance and impact resistance, and can adapt to 24 hours of uninterrupted high-intensity continuous mixing operation. Forced mixing mode can fully mix aggregate, mineral powder, asphalt and recycled materials, thoroughly solve the problems of mixture segregation, partial dry material and uneven asphalt coating, ensure the uniformity and stability of each pot finished mixture, effectively improve pavement paving flatness and service life, and adapt to heavy load and high standard pavement construction.
Modular large capacity structure: large-scale engineering special models adopt thickened steel structure modular design, mainstream capacity can reach 200-400 tons/hour, stable fuselage structure, strong bearing capacity, excellent anti-fatigue, anti-deformation performance, can adapt to large-scale projects for a long time High-intensity, long-cycle continuous production conditions. Modular split structure design layout is reasonable, equipment disassembly, transportation, easy to set up, sufficient maintenance space, easy to disassemble and replace wearing parts. It is not only suitable for fixed long-term on-site construction, but also flexible migration according to project requirements, greatly improving equipment reuse rate.
Perfect safety and operation and maintenance design: The equipment is equipped with a full set of intelligent safety protection mechanism, equipped with overload protection, emergency shutdown, fault self-locking and other protection functions, to avoid potential safety hazards of equipment operation in an all-round way. Standardized maintenance channels and operating platforms are reserved for the fuselage, which conforms to ergonomic design and reduces the risk of operation and maintenance. At the same time, the wearing parts of the equipment adopt universal and standardized design, which is convenient to replace and low in procurement cost. It is equipped with a complete set of after-sales technical training, all-weather technical support and spare parts supply system, which effectively reduces the difficulty of equipment operation and maintenance and downtime probability, and ensures continuous and stable production of large-scale projects.
In addition, the equipment can expand the optional modules such as finished material storage bin, multi-bin cold aggregate supply, asphalt multi-insulation storage tank, etc., customize the configuration according to the daily mixture demand and transportation distance of the project, and balance the equipment investment and construction efficiency.
Even if high-end intermittent mixing stations are selected, if operation and maintenance and production management are not in place, problems such as insufficient production capacity, fluctuation in mixture quality, and frequent equipment failures will still occur. Mature contractors in the industry use eight common management standards to maximize equipment output. and service life:
Plan raw material storage and production scheduling in advance: match the capacity of mixing station according to the total daily paving volume of the project, reserve 10%-20% capacity buffer space, stack aggregates and recycled materials with different particle sizes in advance, and avoid mixing of raw materials; formulate production plans by time according to the capacity of pavers and transport fleets to reduce the idle standby time of equipment.
Strictly carry out periodic preventive maintenance of equipment: check weighing sensors, stirring blades, dust removal bags and burners before starting work every day; calibrate a complete set of weighing systems every week; regularly replace wearing parts such as drying drum liners and conveyor belts to prevent downtime in high-load production.
Standardized control of aggregate moisture content and feeding: control rainproof measures for sand and gravel aggregate stacking, uniform and uniform feeding of cold silos, avoid deviation of discharge temperature and proportion caused by fluctuation of aggregate moisture content, and adjust the drying drum temperature in real time according to aggregate moisture content.
Standardized mixing operation process: fix the dry mixing and wet mixing time of each batch, unify the time sequence of asphalt and mineral powder, and prohibit shortening the mixing cycle at will; preheat the asphalt storage tank before production, maintain the asphalt constant temperature storage, and ensure the stability of binder fluidity.
Make full use of intelligent monitoring data analysis: daily export of production accounts, analysis of ton mixture fuel consumption, ratio fluctuations, equipment downtime, positioning production bottlenecks, optimization of raw material ratio and equipment operating parameters, reduce consumables costs.
Normalized mixture on-site sampling calibration: every 200 tons of finished material samples for screening, oil stone ratio, Marshall test, once the index deviation, immediately calibrate the weighing system, from the source to control the road quality hidden danger.
Synchronous operation and maintenance of environmental protection equipment: regularly clean dust removal bags and check exhaust gas treatment devices to ensure that dust and exhaust gas continue to meet standards and avoid shutdown of environmental protection inspection; complete aggregate yard enclosure and spray dust reduction in the plant area to reduce unorganized emissions.
Redundant supporting of key equipment: ultra-large long-term project is equipped with standby asphalt pump, standby burner and emergency generator set to deal with sudden equipment failure and ensure uninterrupted progress of paving process.
After implementing the above operation specifications, the effective production capacity of the mixing station can be increased by 10%-20%, the fuel and raw material consumption per ton of mixture can be reduced by about 15%, the equipment overhaul cycle can be greatly extended, and the asphalt mixture up to standard can be continuously and stably output within the large-scale project cycle of several months or even years.
For large-scale asphalt infrastructure projects with large scale, high standard and strict control such as expressway, airport, urban ring road and port park, intermittent asphalt mixing station has become the preferred equipment of engineering contractors by virtue of its core advantages such as accurate proportioning measurement, flexible formula switching, high proportion recycled material adaptation, perfect environmental protection system and full quality traceability. In contrast, although the drum mixing station has continuous discharge and lower procurement cost, it is only suitable for long-term base paving projects with uniform mixture specifications and low quality requirements, and cannot meet the construction, quality inspection and environmental compliance requirements of large-scale high-standard infrastructure.
In the selection of large-scale project equipment, the contractor shall select fixed or mobile intermittent mixing station with suitable capacity according to the project volume, mixture type, bidding specification and local environmental protection policy, and match with standardized operation and maintenance management system. This selection and operation mode can give full play to the core value of high precision and high flexibility of equipment, effectively avoid risks such as construction rework, construction period delay and environmental protection punishment, optimize the comprehensive cost of the project, ensure the high quality and timely delivery of the project, and realize the double improvement of construction quality and project economic benefits.
