Elevated Batch Mixer Asphalt Plant Layout
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Solution Overview
Problem
Existing asphalt plants are not easily installable, maintainable, and have a high height, which complicates their deployment and upkeep, especially for road surface production.
Innovation Solution
A discontinuous asphalt plant design featuring an elevated batch mixer relative to the metering device, with a metered aggregate elevator and multiple weighing hoppers for efficient aggregate dosing, and a vertically compact layout with separate towers for aggregate and asphalt storage, facilitating easier installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the batch mixer is located below the metering device, then the plant structure is simplified, but the plant height increases and maintenance becomes difficult
Solution Approach 1:
The patent transitions from a horizontal layout to a vertical stacking arrangement, placing the batch mixer above the metering device in the vertical dimension. This dimensional change reduces the horizontal footprint while maintaining functional connectivity through vertical aggregate elevators, effectively solving the contradiction between structural simplicity and plant height.
Solution Approach 2:
The patent implements a nested tower structure where multiple functional units (drying device, storage devices, metering device, batch mixer) are vertically stacked within compact towers. This nesting approach consolidates the plant into a space-efficient vertical configuration that reduces overall footprint while maintaining all necessary functions.
2Ease of manufacture
If the batch mixer is located below the metering device, then installation is easier, but maintenance accessibility is reduced
Solution Approach 1:
By relocating the batch mixer to an elevated position above the metering device, the patent improves maintenance accessibility. Technicians can access the batch mixer from above and the sides without needing to work in confined spaces below ground level, while the vertical compactness is achieved through tower stacking rather than horizontal spreading.
3Ease of operation
If traditional horizontal layout is used, then component access is easy, but plant height increases and space is wasted
Solution Approach 1:
The patent consolidates multiple horizontal components into vertical stacks within towers, transitioning from a horizontal spread-out layout to a vertical compact arrangement. This maintains operational accessibility while dramatically reducing the horizontal footprint of the plant.
Solution Approach 2:
Functional units are nested vertically within towers, with the drying device, storage devices, metering device, and batch mixer stacked in a compact vertical arrangement. This nesting maximizes space utilization and reduces the overall plant footprint while maintaining all necessary access points.
4Device complexity
If single weighing hopper is used, then device complexity is reduced, but dosing time increases and productivity decreases
Solution Approach 1:
The patent divides the aggregate dosing function into multiple parallel weighing hoppers (first and second weighing hoppers), each capable of independently weighing and discharging aggregates. This segmentation allows simultaneous operation of multiple hoppers, significantly increasing dosing capacity and productivity while maintaining manageable system complexity through modular design.
Solution Approach 2:
With multiple weighing hoppers operating in parallel, the system achieves continuous aggregate supply to the batch mixer. While one hopper is being filled, another can be discharging, eliminating idle time and maintaining continuous productive action throughout the dosing cycle.
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 design enhances ease of installation and maintenance while reducing height, improving production efficiency by allowing simultaneous dosing and reducing cycle times, thus increasing the production rate and reducing the risk of clogging during hot aggregate transfer.
Implementation Method 1
an aggregate drying device for drying wet and cold aggregates and producing dry and hot aggregates
Implementation Method 2
a metered aggregate elevator to raise the aggregates between the metering device and the batch mixer, the metered aggregate elevator being a bucket elevator
Data Source
Figure 1
Figure 2
AI summary
The coating station (2) has a rotary dryer (4) for producing hot and dry aggregates. An aggregate storage device (6) stores the dry and hot aggregates, and a metering device (8) delivers the aggregates stored in the aggregate storage device. A batch mixer (10) mixes the aggregates delivered by the metering device with a bitumen binder, so as to produce a bituminous mix. A bituminous mix storage device (12) stores the produced bituminous mix, where the batch mixer is raised relative to the metering device. A bucket lift (34) raises the aggregates between the metering device and the mixer.