BENNINGHOVEN 160 T/H CAPACITY
MOBILE ASPHALT MIXING PLANT “MBA-2000”
STANDARD CONDITIONS
The plant is designed for a production of, 160 t/h of road mix with a finished product at initial
moisture 4% and of 160° C, under the following standard conditions:
· Aggregates temperature at dryer inlet 10° C
· Altitude sea level
· Average feed aggregates density 1.650 kg/m3
· Heavy-oil No: 6 calorific value ³ 9.200 Kcal/kg
· Heavy-oil No: 4 calorific value ³ 9.700 Kcal/kg
· Diesel oil calorific value ≥ 10.200 Kcal/kg
· Hot aggregates temperature increase 160 K
· Mixture residual moisture content £ 0,3 %
· Max. aggregates size 40 mm
· Material passing screen 3 mm £ 35 %
· Material passing screen 80 mm £ 8 %
· Production rate is inclusive of all recovered filler and average value of 5 % in weight added
bitumen
· Material not porous and hygroscopic with normal shape
· Production tolerance rate according to ambient and parameter conditions ± 10 %
· Crude Gas Strain of max. 250 mg/Nm3
1.0 MOBILE COLD FEED SYSTEM
The unit is mounted onto a single axle articulated trailer unit.
1.1 Qty. 4 Aggregate Hoppers
Capacity : 15 m3 each
Loading width : 3.500 mm
1.2. Qty. 4 Grids
These grids which are dimensioned 50 x 100 mm are put on aggregate hoppers because of
preventing the nonstandart aggregates and foreign materials falling on the belt. So they can’t go to
the plant units.
1.3 Qty. 4 Belt Feeders
Each belt feeder is driven by a geared motor, which is
regulated by a frequency system. Support rollers and
guide idlers ensure smooth running of the belt. A
starvation switch will inform the plant operator in the
case of no material flow.
Belt length : 1.500 mm
Belt width : 650 mm
Drive : 2,2 kW
Capacity : 130 t/h each
1.4 Qty. 4 Belt Feeder Controls
All power elements, frequency control units and control units are fitted in a group control cabinet
mounted on the cold feed system.
1.5 Qty. 1 Vibrator Unit for Sand Hopper
Drive : 0,26 kW
1.6 Qty. 1 Collecting / Inclined Conveyor
Located under the belt feeders, with direct feed into the dryer drum. The belt is specially designed
to be transported with the unit and therefore can be easily folded by a winch arrangement.
Belt length : 22.000 mm
Belt width : 650 mm
Drive : 7,5 Kw
1.7 Running Gear
Overall length : 17.100 mm
Overall width : 2.500 mm
Overall height : 4.200 mm
Total weight : 20.500 kg
Axle load : 11.000 kg
King pin : 2 inches diameter
King pin load : 7.500 kg
Tyres : Double wheel 425/65 R 22,5
2.0 MOBILE DRYER AND BURNER
The fully mobile dryer cylinder and burner arrangement is fitted onto a double axle chassis. Rapid
installation is ensured through its special design.
2.1 Slinger Conveyor - reversible
Axis-centre distance : 3.500 mm
Belt width : 650 mm
Drive : 4 kW
2.2 Dryer Drum (TT. 8.22)
The dryer is of solid steel construction. A special lifter design achieves the highest efficiency in the
heating process and low exhaust gas temperature. The lifters are secured with a special clamp and
bolt arrangement in order to allow easy replacement of the lifter patterns. An aluminium cladding
with air insulation prevents heat loss and reduces the noise emission level. The dryer ends are
sealed with a special labyrinth arrangement.
The dryer is equipped with two (2) trunnion rings fabricated in wear resistant material. These are
fitted with spring steel plates to allow a smooth operation. The dryer is driven by chain via a geared
motor and mounted on four (4) support rollers with two (2) thrust rollers to prevent excess
longitudinal movement.
The dryer chassis is fabricated in heavy steel construction to ensure a long life.
Length : 8.000 mm
Diameter : 2.200 mm
Drum thickness : 12 mm
Drive motor : 37 kW
Insulation : Air insulation
2.3 BENNINGHOVEN TYPE RAX-JET 3 TURBO G-O “S” OIL AND NATURAL GAS COMBI
BURNER
2.3.1 Main Explanations
The burner is a compact unit of mono bloc design. The burner unit is mounted on steel rails which
allows the whole unit to slide back for inspection of the burner and dryer drum. In line with the
dryer, the air flow is generated by an internal radial-axial fan to ensure best combustion.
2.3.2 Main Technical Details
Exact proportions of fuel and combustion air are achieved by a servo motor arrangement. The servo
motor activates, via control levers, the oil metering valve and a multi wing air intake arrangement.
The oil is injected by pump pressure into smallest particles to give efficient and complete
combustion.
Burner head is fabricated out of heat resistant steel.The control panel incorporates all monitoring
and control equipment together with indicators for control of burner capacity. The temperature is
measured in the dryer discharge chute by a quick reacting FE-Constantan temperature sensor.
Optimum noise level reduction is achieved by a silencer arrangement fitted to the rear end of the
burner.
Burner Type : RAX-JET 3 G-O “S”
Burner Capacity : 350 – 1.400 kg/h Heavy-Oil
315 – 1.880 m³/h Naturel Gas
Turndown Range : 1 : 4 Heavy-Oil
1 : 6 Naturel Gas
Nominal heat output : 16.600 kW (=14.310.000 kCal/h)
Blower capacity : 21.000 m3/h
Blower pressure : 350 mm WS
Blower motor : 33 kW
Oil pump capacity : 36 l/min.
Oil pump pressure : 30 bar
Oil pump motor : 4 Kw
Gas line pressure : 300mBar
Energy Table for The Design of The Burner
Heavy-oil (No: 4) : Hu = 9.700 kcal/kg (40.600 kJ/kg)
Heavy-oil (No: 6) : Hu = 9.200 kcal/kg (38.500 kJ/kg)
Diesel oil : Hu = 10.200 kcal/kg (42.700 kJ/kg)
Naturel gas : Hu= 7.600 kcal/m³ (31.800 kJ/m³)
2.3.3 Burner Head
The burner head is made of heat resistant material and not only influences the flame shape but also
effects intensive mixing of natural gas and combustion air. The natural gas is ignited in the burner
head. This ensures a clean, soot free flame of high efficiency.
2.3.4 Burner Blower
The burner blower is an axial fan fitted with an internal hub-motor of a special enclosed, watertight,
and dust-proof design. In accordance with the characteristic of the axial fan, the air flow is highly
turbulent ensuring optimum mixing with the natural gas atomized by jet system and thus ensures
maximum combustion economy.
2.3.5 Fuel Feed System
There is an equipment for using diesel-oil and natural gas. And also it is prepared for using
heavy-oil. If there is need to use preheater in the future it can be bought by paying its money.
Gas Supply Manifold
The manifold consists of all necessary safety and control valves eccluding gas pressure regulator
after the main shutoff cock of the gas main.
2.3.6 Electronic Output Control
A thermostat senses the temperature of the material at the dryer discharge and passes the value to
the controller which compares the required temperature with the actual temperature at the drum
discharge chute and regulates the burner fuel/air setting. The controller incorporates adjustable
sense and pause functions and achieves constant output control with adequate accuracy.
2.3.7 Silencer
The silencer is a separate unit which is connected to the burner end. This special designed
construction reduces the noise level to a certain minimum. The silencer, like the burner, is
positioned on a track to allow the unit to slide backwards.
2.4 Running Gear
Twin axle construction articulated trailer, equipped with twin line brake system, parking brake and
king pin, complete with landing and support legs. Complete light facility with position, brake and
indication lights.
Overall length : 12.900 mm
Overall width : 2.900 mm
Overall height : 4.200 mm
Total weight : 28.000 kg
Axle load : 17.500 kg
King pin : 2 inches diameter
King pin load : 10.500 kg
Tyres : 365/80 R 20
2.0 MOBILE BAG HOUSE FILTER UNIT
Fully mobile unit fitted onto a single axle chassis complete with landing and support legs to ensure
easy installation and rapid relocation.
3.1 Dust Collecting Assembly
Filter capacity designed to match the plant capacity.
The filter is a cassette type filter in which the cloth filter bags are installed horizontally in order to
have easiest access. Cleaning mechanisms ensure effective cleaning of the bags. An integrated preseparator
separates the coarse from the fine material. Discharge of the collected filler is by rotary
valve. The coarse filler is conveyed via Qty 2 Screw conveyors into the Hot Elevator. The fines are
blown into the filler silo.
The exhaust fan is situated at the rear end of the unit with the chimney mounted on top. Paint finish
is in heat resistant paint on the external surfaces. The control panel is fixed to the chassis frame.
Air volume : 42.000 Nm3/h
Filter area : 630/590 m2
Stack diameter : 850 mm, braced
Stack height : 12.000 mm from ground level
Exhaust fan : 90 kW
Discharge fine filler : Qty. 2 Screw conveyors, 5.000 mm length each
Discharge coarse filler : Qty. 2 Screw conveyors, 5.000 mm length each
Screw conveyor drive : 4 kW
3.2 Running Gear
Single axle construction articulated trailer, equipped with twin line brake system, parking brake and
king pin, complete with landing and support legs. Complete light facility with position, brake and
indication lights.
Overall length : 10.000 mm
Overall width : 2.980 mm
Overall height : 4.300 mm
Total weight : 16.000 kg
3.0 MOBILE SCREEN AND MIXING UNIT INCLUDING CONTROL CABIN
The complete mobile mixing and screening unit is fitted with a twin axle arrangement. Features of
the unit are its high output, flexibility and mobility.
4.1 Hot Elevator
Head section with discharge chute, complete head shaft, geared drive motor with built in reverse
stop. Solid elevator chain with bolt on bucket attachments. The elevator tail section comes complete
with shaft and tensioning device.
The elevator has to be transported separately.
Capacity :160 t/h
Drive :15 Kw
4.2 Screen Assembly - 4 Fractions
Vibrating screen assembly. Longitudinal tensioned screen cloths.
Screen assembly is mounted onto coiled springs to isolate vibration.
Screen capacity: by regular feeding of all screen decks:
160 t/h with sand content (0-4 mm) of 35% aggregate
Screen has to be transported separately.
4.3 Hot Bins
Dried aggregates are stored in 4 bins with a total Capacity of approx. 20 t
Bin Capacities:
Sand/Bypass 0-5 mm approx. 8,3 t
Stone 5-12mm approx. 4,0 t
Stone 12-19 mm approx. 4,0 t
Stone 19-38 mm approx. 3,7 t
Total 0-38 mm approx. 20,0 t
The discharge doors are operated by air cylinders which are fitted with solenoid valves to ensure
exact weighing-off. A temperature sensor PT 100 is fitted in the sand bin. Qty. 4 level indicators at
mid point in bins. Oversize and overflow material is conveyed collectively to the outside.
4.4 Weighing System by Load Cells
For the weighing of aggregate, filler and bitumen, three individual systems are provided:
Aggregate Weighing
2.000 kg weigh hopper with two air cylinders operated discharge door, mounted onto Qty. three (3)
electronic load cells.
Bitumen Weighing
200 kg heated weigh bucket, mounted onto Qty. three (3) electronic load cells.
Filler Weighing
For two (2) filler types, 300 kg weigh hopper mounted onto Qty. one (1) electronic load cell.
Twin shaft paddle mixer achieving a homogeneous mixing process. The liner plates are bolted and
fastened to the outside to allow easy replacement of any wear parts. The mixer shaft is driven by
direct mounted geared motors complete with flexible coupling.
Discharge through a semi-rotary mixer door operated by two air cylinders and additionally an anti
drip door to avoid spillage operated by one air cylinder.
The mixer is fitted with a pivot point to allow swinging down of the complete mixer unit to ensure
easy maintenance. For temperature measurement an infrared radiation pyrometer is installed
underneath the mixer.
Drive motor : 2 x 22 kW, 56 rpm
Capacity : 2.250 kg
4.6 Platforms and stairways
Access to all levels.
4.7 Pneumatic system with compressor
Compressor including compressed air receiver tank as well as pneumatic air supply on mixer tower.
Type : KAESER
Capacity : 1.53 m³/min. at 10 bar
Drive : 11 kW
Air receiver tank capacity : 1.000 lt
4.8 Mixer Tower Scavenging
Dust extraction by fan feeding into the dust collection system by easy clamping type duct work.
Drive : 2,2 kW
Capacity : 2.400 m³/h
4.9 Control Cabin with Switch Gear and Starters
Control cabin mounted on mixer chassis. Complete with heating, air conditioning and fluorescent
lights. Benninghoven computer controls incorporating microprocessor plus manual switching for
weighing, mixing, mixer discharging.
All necessary switches for cold feed, drying, mixing and emergency "Stop" switch.
4.10 "Online Batcher 3000" Computer Control System
The Online Batcher replaces the once standard control panel complete with keys, lights and
indicators, in that all operating elements are represented visually on the screen.
All functions are controlled by touching the screen, whereby additional security of the computer
lock largely prevents operating errors.
Likewise, the cold feed is controlled by the Online Batcher. After entry of the recipe and preselection
of quantity, the drying process is initiated. All components that are involved in the drying
process are started automatically, the order is processed and finally the drying process is properly
completed.
The Online Batcher also provides the option of manual operation. Each group of components can be
operated automatically or manually. Each drive or door is assigned a button for manual operation.
The computer system for the mixing process controls (according to recipe and order) the weighing,
the mixing process and the charging of the mixed material storage silo. Statistics of mixing process
are maintained.
System modules
Real time orientated module system, open-ended.
Digital modules
· Aggregate weigher to 16 of 16 components
· Filler weigher to 6 of 6 components
· Bitumen weigher to 4 of 4 components
· Recipe storage for 500 recipes
· Pre-selection of target tonnage in 0.1 t steps
Analogue modules
Temperature input for control and for balancing of the mixture temperature.
System modules
· Real time representation of mixing process with graphical and alphanumerical controls of
the target and actual values on the colour screen.
· Recipe creation and selection, balancing with daily, monthly and annual logs and parametric
representation are carried out using the monochrome text monitor.
· Recipe input, alteration of basic parameters and advance entry of up to
9 customer orders, which can be entered and changed during the mixing process.
· Customer orders may be interrupted and others given priority, whereby the remaining
amount is stored and can be called up again if required.
· Free selection of mixing process; i.e. the filling of the weighers and the transfer of
aggregates, filler, bitumen and recycled material into the mixer can be selected in any order.
· Corrections can be made subsequently on the basis of previous mixtures.
· Continuous tare compensation.
· Statistical long term summing up of individual components.
· Documentation by printer or to hard drive with back-up to diskette.
· Batch-log-printer
· Modem connection for remote data transfer, for programme update and service