Microwave Heated Batcher for Batch Asphalt Mix Plant
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Solution Overview
Problem
Asphalt mix plants require substantial infrastructure and are often idle due to seasonal demand, making them economically unfeasible for sporadic or small-scale asphalt production, especially in colder climates and remote areas, where the high cost and complexity of setting up and maintaining these plants are not justified by infrequent demand.
Innovation Solution
A stationary batch asphalt mix plant utilizing a microwave heated batcher, which reduces the need for large heaters and infrastructure by moving the heating process to the point of storage, allowing for smaller, more cost-effective mobile plants that can produce hot mix asphalt on demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a drum dryer heater with open flame burner is used to heat and mix aggregate and asphalt binder, then the asphalt mix can be produced, but the infrastructure requirement and device complexity increase significantly
Solution Approach 1:
The patent replaces the mechanical drum dryer heater system with a microwave heating system. The microwave generator produces electromagnetic radiation that directly heats the aggregate and asphalt binder in a mixing chamber, eliminating the need for complex mechanical drum heating mechanisms, open flame burners, and associated infrastructure while maintaining the capability to produce asphalt mix.
2Productivity
If a permanent asphalt mix plant is established to meet seasonal demand, then large volumes of asphalt can be produced, but the plant remains idle for significant portions of the year due to seasonal and sporadic demand patterns
Solution Approach 1:
The patent transforms the static, fixed-capacity permanent plant into a dynamic system where a portable microwave-heated batch plant can be deployed only when demand exists. The plant configuration and operational capacity can be adjusted dynamically based on seasonal and project-specific requirements, allowing the system to be active during demand periods and dormant during low-demand periods without significant idle time losses.
3Adaptability or versatility
If a portable asphalt mix plant is used for specific projects, then the plant can be positioned near job sites, but the cost and time required to move, setup, and take down the plant remain substantial
Solution Approach 1:
The patent divides the asphalt mix plant into modular, portable components that can be easily transported and assembled. The microwave generator, mixing chamber, aggregate storage, and asphalt binder storage are configured as separate but integrable modules, allowing rapid setup and teardown for different projects without the substantial time and cost burdens of moving traditional portable plants.
4Device complexity
If raw materials are stored in bulk quantity or super sacks at the mix site, then the plant can operate with limited infrastructure, but substantial infrastructure is still needed for material handling and storage
Solution Approach 1:
The patent enables raw materials (aggregate and asphalt binder) to be delivered and stored in bulk quantity or super sacks at the mix site before the plant is activated. This preliminary storage action allows the portable plant to operate with minimal infrastructure during production, as materials are already prepared and positioned for immediate processing when demand arises.
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
This solution simplifies the plant components, reduces infrastructure and operational costs, and enables the use of mobile plants in environments where it was previously not cost-effective, allowing for timely and efficient production of asphalt even in areas with low demand, such as small municipalities.
Implementation Method 1
A stationary batch asphalt mix plant utilizing a microwave heated batcher
Data Source
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AI summary
The present disclosure relates to a plant for manufacturing heated asphalt mix. In particular, the disclosure relates to a batch asphalt mix plant for using a microwave heating vessel located in close proximity to a storage silo to heat asphalt mix at the point of storage using a batch production method.