TEREX E 100P ASPHALT PLANT E 100P ASPHALT PLANT

Transcription

1 TEREX E 100P ASPHALT PLANT E 100P ASPHALT PLANT

2 TEREX E 100P PRODUCES UP TO 100 t/h (aggregates moisture up tp 5%): greater productivity from a single chassis COUNTERFLOW DRYING SYSTEM: perfect and economical drying EXTERNAL ROTATIONAL MIXER: superb mechanical mixing energy LOW OXYGEN LEVEL AND LOW TEMPERATURE MIXING: longer working life for the HMAC BAG FILTER WITH LARGE FILTRATION AREA: in compliance with EPA emissions standards EXTREMELY STRONG, HEAVY-DUTY MATERIALS: minimizes maintenance downtime, increasing production time AUTOMATION: full control of processes TEREX E 100P Asphalt Plant E 100P complete portability and optional special paint job Terex Roadbuilding Latin America, with its more than half-century of experience on the market, in connection with the Terex Roadbuilding division, for its part a subsidiary of the Terex Group with its more than 60 companies - one of the three largest suppliers of construction equipment in the world - is able to ensure its robustness and has a deep understanding and knowledge of the market, new and larger distributors, a diversified product line and professionalization of its sales processes. As further confirmation of its commitment to excellence for its products and services, Terex Roadbuilding has developed the Terex E 100P Asphalt Plant. The plant has four axles, with the purpose of better distributing its weight, making it possible to transport it on highways in countries where weight-per-axle regulations are extremely strict. Even the standard version of the E 100P has an efficient, precise Hauck burner, known the world over as one of the best burners on the market. The Hauck can precisely control its flame, which makes it easy to adapt to many different working situations, thereby reducing unnecessary fuel consumption, avoiding wasted material at the beginning of production (very common in plants equipped with other types of burners) and even improving the plant's drying performance. Terex Roadbuilding, which pays close attention to all the factors that have an influence on final asphalt mix quality, is also focused on guaranteeing the equipment's durability, which is why it offers heavy-duty steel coverings on all of the main surfaces in contact with the mix. Areas such as the bottom of the mixer and conveyor, as well as the drying and mixing fins, are all made out of SS 400 AR steel, leading to greater durability and reducing maintenance downtimes, ensuring the equipment's higher productivity. Terex Roadbuilding used sophisticated computation and modern mathematic flow modeling tools to provide filters with high efficiency rates and particulate emissions of less than 50 mg/nm 3, in full compliance with the strictest environmental legislation. The E100P also has a larger filter area (480 Nomex bag filters) leading to perfect hot air circulation and better absorption of the fine aggregates in the mixture at high production. Also demonstrating Terex's concern for the environment and ecological awareness, the plant is equipped with a floodgate for the addition of reclaimed materials (RAP) and is able to process up to 40% old materials from the road to replace virgin aggregates while still maintaining the same high quality of the asphalt mix. Additionally, the height of the plant's conveyor makes it possible to load large volume dump trucks, without the need to lower the floor. Take a closer look at the details, main characteristics and innovative features of the Terex E 100P Asphalt Plant's components. 2

3 AGGREGATE FEED BIN SINGLE CHASSIS PLANT: Side-by-side quadruple feed bin; Loading is only from one side; Spacious top openings m widths make it possible to use large loaders to fill the bins; Individual capacity of the feed bins - 7 m 3 ; Feed bins with a loading height of only 3.8 meters on the highest side and extensions located on the other feed bins. Not only does this increase the volume of these feed bins, but this also makes them easier to load because they serve as an excellent referential for the operator. It is also possible to support the scoop on the extensions because they were built with very strong material. All of these factors together result in a perfect loading process that is free from contaminants between the bins; Simple maintenance - the design of the feed bins makes it possible to change their pads without the need to take apart the feed bin frame; New vibrating sieve - has two vibrators. The set is mounted on shock absorbers. Effective separation of materials of a size that is not within the range for the specified recipe. DOUBLE CHASSIS PLANT: Equipment divided into two different chassis Mobility which takes unity of drying, mixing and control into consideration; Another chassis, also mobile, with the dosing unit; Four feed bins in a row (with the ability to extend to up to six bins); Individual capacities of 7 m 3 ; Bins with 3.1 m top openings; Choice of setup in a line or at a 90. New floodgate on the feed bins - mechanical activation set easy access. High-precision, effortless adjustment; Steep Angle of the bin's side walls - facilitates the flow of materials; Only 1.5m high ramp - reduces the amount of preparation work (retaining walls); V-shaped feeding belts - ensure a greater sample of material going across the load cell and greater precision for the weighing system; Security rings - installed on the rollers to avoid misalignment of the feeder belt; Rollers with shielded bearings - positioned on the inside of the roller, these increase the unit's durability; Rollers assembled at a 2 degree angle - make the system self-centering. individual weighing system with a centered load cell 3

4 High-performance vibrators - in addition to vibrating, they also exert a strong mechanical action on the aggregates via a plate connected directly to the vibrator; Machine comes standard with two vibrators - positioned on the feed bins that operate with finer materials. Optional: Vibrators on the other bins; Flow sensors - automatically detect a lack of material in the bin, without intervention of the technician. Composed of a material feeler and an endstop key; Level sensors (optional) - extremely useful because they help the operator control the loading of the feed bins, always keeping them at an ideal level. Scraper - positioned on the internal part of the dryer, it makes sure that all heavy materials actually enter the dryer. COUNTERFLOW DRYER section 1 section 2 section 3 section 1: larger diameter leads to the Venturi effect, with greater drying volume section 2: maximum heat exchange between aggregates and flame section 3: prevents the material from falling on the fire Terex plants have a counterflow drying system that maximizes their drying efficiency and fuel economy. The initial section, designed with a bigger diameter than the rest of the dryer's body, produces the Venturi effect, decelerating the gases, which keeps a significant percentage of the larger particles from being sucked into the exhaust system. This in turn reduces the workload of the bag filter and the filtering area needed, thereby increasing the durability of the filtration elements. The dryer is driven by gear motors, which eliminates the use of belts. HIGH DRYING EFFICIENCY AND MAXIMUM FUEL SAVINGS: The dryer's size, 2.20 m in diameter at the largest section and 1.8 m at the smallest and with a 7.8 m length, give it a large drying volume; The different formats of internal fins, designed with the help of state-of-the-art computer tools, maximize heat exchange between the aggregates and the flame. Bolted fins in the dryer make it possible to obtain a better adjustment for any situation, ensuring superb drying performance and therefore greater fuel economy; Perfect distribution of the different fins on the dryer optimizes its efficiency. An example of this is the combustion zone where the fins are designed and distributed in such a way as to keep the material from reaching the flame. This increases the unit's thermal performance and reduces the emission of toxic gases and the contamination of the aggregates by unburned fuel; Fins made out of SS 400 AR steel - the use of hardened steel for the fins extends their working life, reducing maintenance costs and increasing the equipment's productivity. 4

5 BURNER Hauck, recognized worldwide as one of the biggest and best burner manufacturers in the world, supplies the Starjet 4260 burners for Terex's E100P plants. The flame on the burners can be adjusted perfectly, allowing them to adapt to all working conditions, reducing fuel consumption, and improving the plant's drying performance. The Starjet 4260 can work with a low flame and this avoids wasting material in the beginning of production, which is very common with plants equipped with other burners. The Hauck burner can burn different types of fuel such as: diesel, heavy oil, and ethanol: The E 100P comes standard with a video camera for real-time viewing of the flame, in addition to an ultra-violet sensor flame control system. An optional kit for burning gas in the burner is available. Hauck burner FUEL AND ASPHALT TEMPERATURE REGULATOR (RECTIFIER) Fuel Temperature Regulator (Rectifier): By making sure that the fuel is at an ideal temperature for combustion, the regulator therefore decreases waste, in so far as it improves use of the thermal energy yield. The temperature regulator also makes it possible to store the fuel at lower temperatures, in this way making better administration possible while it is in the holding tank. Optional Asphalt Temperature Regulator (Rectifier): The use of this accessory makes it possible for the binding agent to be sprayed on the aggregates at an ideal temperature, controlled by the plant's PLC, which in turn ensures that it has the ideal viscosity for ease of mixing with the aggregates. The binding agent can be stored at a lower temperature in the storage tanks, significantly reducing the evaporation of its lighter portions and even more importantly: it greatly reduces the effects of oxidation and aging of the asphalt. Additionally, the use of fuel and asphalt temperature regulators makes it possible to store heavy fuels and HMAC at lower temperatures, resulting in significant increases in fuel economy for the thermal fluid heater. Visual representation of the asphalt and fuel regulators asphalt regulator fuel regulator 5

6 EXTERNAL ROTATIONAL MIXER mixing chamber The biggest advantages of using Terex asphalt plants are the results of the exchange of experiences between Terex Roadbuilding Latin America and Terex Roadbuilding's main offices in the United States. All factors which have an influence on the end quality of the asphalt mix have been exhaustively taken into account. This is why the external rotational mixer was designed with a toothed fin system that has a strong mechanical mixing action and a unique system for adding the fine aggregates. Toothed fins - our exclusive toothed fin system keeps the material in the lower part of the external rotational mixer where it receives an elevated number of strong paddle strokes, lending greater mechanical energy to the mixing process and, consequentially, a homogeneous asphalt mixture of excellent quality; Bolted fins in the dryer - possibility of adjusting the fins, allowing the customer to perfectly control the variables of mix time and mechanical energy, resulting in a better mix quality and a higher level of homogeneity under any situation; The components, with their high durability and strength (covering of the mixer bottom and fins in SS 400 AR steel), have been designed to achieve a longer working life, reducing maintenance costs and increasing the equipment's productivity; mixer's coating Dosing System for the fine aggregates: The mixing zone is divided into two parts. The first is used to mix the binding agent mixture with the larger size aggregates and the end section is used to dose the finer aggregates. The dosage of the fine aggregates is done all along the entire final section so that it is not concentrated on a single mixing area. This dosing system makes it possible to treat the different materials used in the mixing process according to their properties. This ensures that the larger-sized aggregates are perfectly coated by the binding agent in the right thickness. Only after this are the fine aggregates added and mixed in with greater ease with the asphalt binding agent. All these factors combined contribute to an effective production of a top quality asphalt mixture. external rotational mixer - mixing zone divided into two parts Because of the way the external rotational mixer was designed together with its process, it has the following advantages: Low maintenance; Energy-saving; Self-cleaning mixing zone. MIXTURE CONVEYOR (DRAG MIXER) 6 internal view The Terex E 100P has a large scale retractable conveyor (at a height of 3.9 m off the ground) for working with large scale trucks and has a Drag Mixer system that prevents the asphalt mixture from segregating during the loading process. The Drag Mixer system has heavy-duty steel toothed fins distributed in such a way (for every two toothed fins, there is one dull fin) that they cause a non-linear movement of the mix, while still keeping its superb level of homogeneity; Driven by a gearmotor; Connected to the mobile, retractable chassis, facilitating the plant's transport. Preparing its placement for carrying out tasks is fast and easy to adjust; Heavy-duty belts and fins; Bottom and sides of the conveyor made out of SS 400 AR steel - the utilization of hardened steel for the bottom of the conveyor extends its durability, reducing maintenance costs and increasing the equipment's productivity; Storage bin for 1 m 3 of ready mix; The bin floodgate's pneumatic opening is controlled by a PLC; Optional asphalt mix weighing hopper.

7 ENVIRONMENTALLY AWARE PRODUCTIVITY - HOT RECLAIMING Terex Roadbuilding is a pioneer in Latin America in hot reclaiming for asphalt plants. Material recycling is becoming increasingly important, especially due to its economic and ecological aspects. It helps to conserve the environment by using less virgin mineral aggregates and it is extremely economical because it reuses the old material already on the road. Equipped with a floodgate for the addition of reclaimed materials and with an exclusive external heating ring, the E 100P asphalt plants are designed to process up to 40% reclaimed materials while still maintaining the same asphalt mixture quality. Ask about the optional mobile recycling unit. BAG FILTER The E100P's automatic damper system The Terex E 100P has an ample filtering area, equipped with 480 Nomex bags, which ensures the minimization of recirculation and high-speed points. In this way, the plant is able to ensure efficiency rates greater than 99.9%, with particulate emissions of less than 50 mg/nm 3, in full compliance with the strictest environmental legislation. The use of Nomex filters makes it possible to work with a much wider range of temperatures, between 110 C and 210 C, without reducing the filtration elements' working life. The bag filters' safety system automatically and simultaneously blocks the asphalt and fuel pumps if the temperature of the filters becomes too high. Our exclusive automatically activated damping system makes absolute control of fume temperature possible, keeping it stable at the bag filters, thereby ensuring the system's efficiency and long life. Low ascending speed: ensures the effective cleaning of the bags by the air jet pulse, which prevents the bag filter from bottlenecking production. Uniform distribution of the filtering load throughout all of the bags: - longer working life for the units (bag filters) - more effective filtration process Automatic control of the burner. 7

8 CONTROL CABIN Spacious and comfortable control cabin, ideally located and with excellent view. The location of the cabin not only gives a complete view of the truck loading, it is also far away from the aggregate feed bins, in this way avoiding a dust-filled area and possible spills of material due to loading tractor operating errors. It also provides contact between the plant's operator and the driver of the truck being loaded. The electric power switch panel is located outside the control cabin, thus leaving more free space and facilitating maintenance. Air-conditioned control cabin; Plenty of space for the operator; Comfortable operating post and environment; Excellent sealing system; 17" LCD monitor; DELL Computer; Ample view of the entire process; Panel for complete manual control in parallel control via PLC. Access window for delivering weighing ticket. AUTOMATION AND CONTROL State of the art control system via PLC with Ethernet interface; Real time communication and operation; Monitoring software in English, Spanish and Portuguese; System for automatically diagnosing failures via PLC; Parts catalog and operating manual on CD; Backup of the hard drive on CD-ROM; Full control of the plant's operation via monitoring software; Complete control of the process and variables; Generates a wide variety of reports: - production - temperatures - truck loads (issues tickets) - alarms and events manual control panel The motors can be started up manually or automatically, which makes it possible to operate even if the PLC fails; Control over all motors and devices via monitoring software; Monitoring of the temperatures of the fumes, filter, binding agent and mixture through 06 temperature sensors: fumes (02), filter (02), binding agent (1) and mixture (1); Material flow sensors in order to detect the lack of material in the feed bins; Level sensors in the feed bins (optional); Automatic activation of the vibrators; Burner control - flame modulation via PLC; Automatic control of the fuel temperature regulator and optional asphalt temperature regulator; Automatic control of the opening time of the floodgate for the storage bin; Monitoring of the process' electrical variables. 8

9 OPTIONAL EQUIPMENT FILLER FEED BIN Terex Roadbuilding is constantly paying attention to and responding to client needs, and that is why we have developed a 1 m 3 capacity filler feed bin for two applications: filling in voids in the mixture or adhesiveness. Easy to install with an additional assembly kit, it serves a wide variety of asphalt mixture traits. FIBER FEED BIN The 2 m 3 fiber feed bin was designed to add any type of fiber to special asphalt mixes in a controlled way. Attached to the asphalt plant, it precisely measures the desired percentage of fibers by way of a screw conveyor, activated by a gearmotor, which is controlled by a frequency inverter connected to the Sistex control system. In order to meet the needs of a wide variety of special mixes, like SMA (Stone Matrix Asphalt) and PFL (Porous Friction Layer), the manner in which the fibers are processed is just as important as how they are dosed: - The fibers are usually supplied in the form of pallets that "open up" by way of the mechanical energy of the mix with the virgin aggregates and the heat (without contact with the flame); - Only after this quick mixing process, called the "dry mix", the asphalt binding agent is added and the moist mixture is processed; - The efficient injection of the fibers will make it possible to add greater asphalt content without exudation, as well as making higher quality binding agent film possible over the aggregates in these high performance asphalt mixtures. This is why Terex asphalt plants have an important competitive advantage: the fibers can be incorporated into the mix - through the reclaiming ring inflow (where they will go through heating), and first mixed with the virgin aggregates (mixing zone 3), meeting international requirements for special mixtures. SYSTEMS FOR COLLECTION AND CONTROL OF FINE AGGREGATE DOSING Consists in the extraction of fine aggregates from the bag filter filtration and depositing them in a 1 m 3 or 20 m 3 feed bin. The percentage of fine aggregates to be added to the process is determined by the traits of the mixture to be used. The injection of fine aggregates takes place by way of a screw conveyor, which is activated by a gearmotor controlled by a frequency inverter connected to the Sistex control system. The excess material goes through an overflow chute or screw conveyor for loading onto a specialized vehicle or discarding area. fine aggregate collection system with 20 m 3 feed bin fine aggregate collection system with 1 m 3 feed bin 9

10 OPTIONAL EQUIPMENT ASPHALT MIX WEIGHING HOPPER Bin placed after the basic mixture bins and connected to four load cells that weigh the product once it is ready and before it is loaded on to the dump trucks. This optional feature also allows for the printing of a loaded mixture ticket if the customer purchases a printer for this purpose. It can be adapted to any of the different bin models. Available for the 1 m 3, 10 m 3 and 25 m 3 bins. READY MIX STORAGE BINS CONVEYOR WITH 10 m 3 FIXED AND MOBILE SELF-ERECTING BIN CONVEYOR WITH 25 m 3 FIXED AND MOBILE SELF-ERECTING BIN - Bins built out of heavy duty steel. The discharge floodgates are pneumatically activated by two cylinders. Their framework is designed with an I-beam support which makes it possible for trucks to go under it without the need to lower the flooring. The access stairs have guardrails. ELEVATOR WITH 50 m 3 FIXED BIN - Made with heavy duty steel and thermally coated. The discharge floodgates are pneumatically activated by two cylinders and are thermally coated. Assembled on an I-Beam framework with four support feet makes it possible for trucks to go under it without the need to lower the flooring. The access stairs have guardrails. 25 m 3 mobile self-erecting bin All of the bins are integrated with the Drag Mixer-type hot mix elevator, are completely closed, and their bottoms are covered with wear plates. They have overflow chutes activated by two pneumatic cylinders with by-pass ducts. The anti-segregation pre-bin has an automatic unloading system and is pneumatically activated, coming with a lubricator and drain valve on the compressed-air line. fixed bin 25 m 3 Fixed bin 10 m 3 Mobile 10 m 3 bin Fixed bin 25 m 3 Mobile 25 m 3 bin Fixed 50 m 3 bin Capacity 10 m 3 10 m 3 25 m 3 25 m 3 50 m 3 Truck passage Height 4,450 mm 4,450 mm 3,510 mm 3,510 mm 3,020 mm Width 3,650 mm 3,650 mm 4,000 mm 4,000 mm 3,450 mm Weight 9,000 kg 15,000 kg 18,500 kg 21,800 kg 20,000 kg SEMITRAILER WITH CABIN Cabin assembled on a semitrailer, with room for coupling a generator and 5,000 liter fuel tank (optional): makes it easier to install the equipment where electricity is not available. semitrailer with cabin VIDEO CAMERAS Three video cameras control the plant's operations from the control cabin. Example of configuration: - 01 for controlling the feed bins - 01 for controlling the loading of the trucks - 01 for the tank area All visualization is done remotely, by telephone line. 10

11 OPTIONAL EQUIPMENT MOBILE RECLAIMING UNIT The recycling of asphalt pavement, commonly known as RAP (Recycled Asphalt Pavement), consists in reusing the material from pavement milling. Use of reclaimed asphalt pavement can replace the use of some kinds of virgin aggregates in a new asphalt mixture. The purpose of the reclaiming system is to reincorporate materials from milling processes into the asphalt mixing process. These are introduced by way of the reclaiming cover (recycling ring), allowing for the use of RAP, leading to savings, environmental awareness and high quality for the end product. Recycling cover HEATING AND STORAGE SYSTEM FUEL - TANKS Terex Roadbuilding has a variety of horizontal tanks for asphalt and fuel, in fixed or mobile versions (with a framework assembled over the chassis and their own axles for highway transport). The tanks have: Complete thermal insulation with external protection; Indirect heating via coil; Thermal fluid heating system (300,000, 400,000 or kcal/h); Interconnecting flexible piping between the tanks and plant (optional); Asphalt/fuel loading and circulation system (optional); System of agitators for modified asphalt - polymers and asphalt-rubber, among others (optional); Intelligent tank system - with temperature sensors (optional). 50,000-liter heat insulated tank Configurations available with 15,000 L for fuel and 35,000 L for asphalt or 50,000 L for asphalt 60,000-liter heat insulated tank Configurations available with 20,000 L for fuel and 40,000 L for asphalt or 60,000 L for asphalt 80,000-liter heat insulated tank Configurations available with 20,000 L for fuel and 60,000 L for asphalt or 80,000 L for asphalt 100,000-liter heat insulated tank Configurations available with 20,000 L for fuel and 80,000 L for asphalt or 100,000 L for asphalt * Other tanks available: 5,000 L, 20,000 L and 30,000 L. OTHER OPTIONAL ITEMS FOR THE TEREX E 100P: Fuel flow gauge Asphalt flow gauge Capacitor bank Impulse System control 11

12 TECHNICAL SPECIFICATIONS TEREX E 100P PLANT Single chassis Double chassis Production (ton/h) Number of chassis Number of axles/tiress Feed bins Capacity (m 3 ) 1 4 axles / 16 tires 4 (side by side) ( * ) (aggregates moisture up to 5%) 2 Chassis 1: 4 axles/16 tires Chassis 2: 1 axle/4 tires or 2 axles/8 tires 4 (std)/5 or 6 (optional) 7 Dosing system Dryer Individual weighing system with a centered load cell Counterflow type 2.2 m at the largest section Dimensions 1.8 m at the smallest section 7.8 m long Burner Thermal output (kcal/h) Mixer Filtration system Hauck Starjet ,425,000 External rotational Bag filter: 480 units (Nomex treated) Greater than 99.9% Efficiency Conveyor Ready mix bin Ring for the inflow of reclaimed material Particle emissions less than 50 mg/nm 3 Drag Mixer type with antisegregation toothed fins 1 m 3 (std) - options for 10, 25 or 50 m 3 Standard ( * ) The plant's production rate can vary depending on the following factors: aggregate moisture, altitude where equipment is installed, percentage of fine aggregates in mixture, mixture temperature, fuel's calorific power and the specific weight of the aggregates. Travel dimensions: Height: 4.4 m Length: 22.5 m Weight: 56,000 kg Width: 3.2 m All of the pictures, illustrations, and specifications are based on current information on the date this publication was approved. Terex Roadbuilding Latin America reserves the right to change specifications and designs and eliminate components without prior notice. The performance data depends on plant site conditions. Some of the components mentioned are optional though not explicitly indicated as such in the text. May/2009 TEREX ROADBUILDING LATIN AMERICA Rua Comendador Clemente Cifali, 530 Distrito Industrial Ritter Cachoeirinha/RS Brasil Fone: +55 (51) Fax: +55 (51)