Bituminous Macadam Plant With Dual Lines for RAP Clogging Control
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Solution Overview
Problem
Existing bituminous macadam production plants are complex, expensive, and prone to clogging due to heated recycled materials, limiting the processing of large quantities of recycled asphalt pavement (RAP).
Innovation Solution
A plant design with a dual supply line system, where one line handles inert lithic materials and another handles recycled materials, using a diverter to adjust between configurations, along with a sieving unit and heated hopper to manage material flow and prevent clogging, allowing up to 60% RAP processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single drier with counter-current configuration is used to process both virgin and recycled materials, then the plant can handle recycled materials, but the plant becomes complex and expensive with increased risk of clogging
Solution Approach 1:
The plant is divided into two independent processing lines: a first line for virgin materials and a second line for recycled materials. Each line has its own drier and supply system, allowing them to operate independently without interfering with each other. This segmentation reduces the complexity of the overall system while maintaining the ability to process both material types simultaneously.
Solution Approach 2:
The recycled material processing capability is extracted as a separate, dedicated line rather than being integrated into the existing virgin material processing system. This allows the recycled material line to be optimized specifically for handling heated bituminous materials without affecting the simplicity of the virgin material line.
2Productivity
If recycled materials are heated in the drier, then they can be processed, but clogging problems occur due to the heated bituminous material
Solution Approach 1:
By separating the processing of virgin and recycled materials into distinct lines, the heated recycled materials only travel through the second supply line, which is dedicated to handling hot bituminous materials. This prevents heated materials from contaminating or clogging the first supply line used for virgin materials.
Solution Approach 2:
The second supply line acts as an intermediary pathway specifically designed to handle heated recycled materials from the second drier to the mixing drum. This dedicated pathway prevents direct contact between heated bituminous materials and other plant components, reducing clogging risks.
3Adaptability or versatility
If the percentage of recycled material in macadams is increased, then environmental sustainability improves, but obstructions due to heated recycled material increase
Solution Approach 1:
The plant configuration allows independent operation of two processing lines, enabling high percentages of recycled material (up to 60% or more) to be processed through the second line without affecting the first line. This segmentation isolates the obstructions caused by heated recycled materials to only the second supply line.
Solution Approach 2:
The problematic heated recycled materials are extracted and routed through a dedicated second supply line that is specifically designed to handle them. This extraction prevents the heated materials from causing obstructions in the virgin material handling system.
4Reliability
If a dual supply line system with diverter is used, then material flow can be managed to prevent clogging, but the device complexity increases
Solution Approach 1:
The supply system is segmented into two independent lines with a diverter mechanism that routes materials based on their origin (virgin or recycled). This segmentation allows each line to be optimized for its specific material type while maintaining overall system simplicity through modular design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The plant effectively processes high quantities of recycled materials with reduced clogging, maintaining operational efficiency and simplicity while producing bituminous macadams.
Implementation Method 1
a drying drum (102) rotating about its own main axis of extension
Implementation Method 2
at least one burner (108) for generating a drying flow in the drying drum (102)
Implementation Method 3
the first and second supply lines can feed the by-product from the dryer to the mixer using gravity
Data Source
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AI summary
Described is an industrial plant for the production of bituminous macadams comprising: a dryer (101) equipped with a loading head (103) for introducing into the drying drum (102) a virgin inert lithic material, an unloading head (104), a supplying device (111) for introducing into the drying drum (102) a recycled bituminous material, a burner (108), a system (105) for supplying the inert virgin inert lithic material and the recycled bituminous material according to a first feed direction (V1); the industrial plant comprises a mixer (6) downstream of the dryer (101), a first supply line (7) between the unloading head (104) and the mixer (6), a second supply line (8) between the unloading head (104) and the mixer (6), a diverter (9) between the unloading head (104) and said first and second supply lines (7, 8) adjustable between a first operating configuration wherein the unloading head (104) is in communication with the first supply line (7) and a second operating configuration wherein the unloading head (104) is in communication with the second supply line (8).