Counterflow Asphalt Drum Mix Plant

GAJJAR make asphalt plant with two drums and one simple design. You can be assured with our proven technology and time-tested engineering principles. They combine the simplicity of existing continuous drum-mix plants with the added efficiency achieved through counterflow technology. The plants produce mix at a lower cost than traditional parallel-flow drum-mix plants. They require less energy to heat materials, and therefore reduce emissions as well. In counter flow drum mix plants, aggregates and air flow in opposite directions through the drum, enabling more efficient heating of the aggregates and better control over the mixing process. This design enhances asphalt quality, making it ideal for applications where superior durability and performance are required. Counter flow plants are often preferred for producing high-performance asphalt mixes for highways, airports, heavy-duty pavements, and other critical infrastructure projects. They offer excellent temperature control, ensuring thorough mixing and uniform distribution of asphalt binder throughout the mixture.

STATIONARY

Counterflow Asphalt Drum Mix Plant

CONTINUOUS DUAL DRUM ASPHALT MIXING

Capacity Range:
90 TPH to 160 TPH

Exceptional
Pavement Mix Output

HIGHLIGHTS

Efficient counterflow dryer drum
Fuel savings through counterflow technology
Use of RAP
Reduced bitumen aging
High quality mix
Optional bag filter and pre-separator which is environment-friendly

Advantages of Counterflow Drum Mix Plant

Improved Heat Efficiency: The counterflow design ensures better heat transfer, reducing fuel consumption.

Reduced Emissions: The efficient dust collection system minimizes the release of pollutants.

High-Quality Mix: Uniform heating and mixing result in a consistent and high-quality asphalt mix.

Continuous Operation: The plant can operate continuously, making it suitable for large-scale projects.

Working Principles

1. Weighing Virgin Aggregates

The virgin aggregates (such as sand, gravel, and crushed stone) are individually weighed from the cold feed bins using a variable, continuous, and automatic belt speed. The proportions are determined by the control systems. Once weighed, the aggregates are transferred to the dryer via a charging conveyor.

2. Drying and Heating

As the drum rotates, aggregates move towards the burner located at the opposite end. The burner heats the aggregates as they move through the drum. The hot air generated by the burner flows in the opposite direction to the aggregates, ensuring efficient heat transfer and drying.

3. Hot Aggregate Flow and Mixing

Once the aggregates are heated and dried, they move into the mixing zone of the drum. In this mixing drum, the hot aggregates are mixed with bitumen (asphalt binder). The bitumen is stored in a heated tank and pumped into the drum at a controlled rate. The mixing process ensures that the bitumen coats the aggregates uniformly, creating a homogenous asphalt mix.

4. Discharge

Key Components of Counterflow Asphalt Drum Mix Plant

The aggregate feeding bins in Gajjar Asphalt Mixing plants are equipped with variable speed drive motors and gearboxes for each bin. These motors allow precise control and regulation of the aggregate flow individually, enabling the addition of the required proportions of individual aggregates according to the mix design.

In this technology the burner is positioned at the lower end of the drum, generates hot air. This hot air flows in the opposite direction (counterflow) to the movement of the aggregates. The drum rotates, moving aggregates towards the burner while hot air flows in the opposite direction for efficient heat transfer.

Gajjar makes asphalt drum mix plant features an efficient, low-noise burner that can operate using diesel, LDO (Light Diesel Oil), and furnace oil (optional). This maintenance-free burner produces a strong flame, effectively heating the aggregates to their maximum temperature. By continuously reducing the aggregate moisture content, the burner ensures optimal production. The burner uses a two/three nozzle type pressure jet system with high- low intensity. This design enhances fuel efficiency.

After being heated and dried in the drying drum, the aggregates move into the mixing drum. The transition is seamless, ensuring that the aggregates retain their heat. Bitumen (asphalt binder) is stored in heated tanks and pumped into the mixing drum at a controlled rate. The bitumen is injected through a series of nozzles, ensuring even distribution. Inside the mixing drum, the aggregates and bitumen are thoroughly mixed. The drum is equipped with mixing paddles or flights that lift and tumble the aggregates, ensuring they are uniformly coated with bitumen. This process creates a homogenous asphalt mix. If required, mineral fillers and other additives can be introduced into the mixing drum. The mixing drum maintains the temperature of the mix to ensure proper coating and binding of the bitumen with the aggregates.

The load-out conveyor serves to discharge the hot mix material into a truck. At the other end, it is equipped with a GOB (Gate-Operated Bin) hopper. The GOB hopper helps control the segregation of the mixed asphalt. It is beneficial to have hydraulically operated gates for efficient operation.

Asphalt storage tanks come in cylindrical O-shaped or U-shaped designs. These tanks are insulated with 50 mm thick rock wool to prevent heat loss and reduce burner fuel consumption. They are mounted on a sturdy full chassis. The standard package includes an automatic pressure jet oil burner, a bitumen pump with a jacketed oil body, and a bitumen metering system with a variable speed motor and hot oil circulation motor.

Available Models

MODEL		CDMX-60	CDMX-65
RATED OUTPUT @3% Moisture Content	TPH	90 - 120	120 - 160

NOTE: The plant’s production rate can vary depending on the following factors: aggregate moisture, the altitude where equipment is installed, the percentage of fine aggregates in the mixture, mixture temperature, fuel’s calorific power, and the specific weight of the aggregates.

Per GAJJAR’s policy of constant upgradation of products, specifications are subject to change without prior notice.

STATIONARY