Recycled Asphalt Mixing Process With Segmented Heating Control
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Solution Overview
Problem
Existing asphalt recycling technologies face challenges with high emissions of harmful gases and dust, limited recycling proportions due to high mixing temperatures, and inefficient energy control, which affect the quality and applicability of recycled asphalt mixtures.
Innovation Solution
A production process and system for factory-mixed warm and hot recycled asphalt mixture that includes separate heating and addition of recycled coarse and fine aggregates, with real-time temperature control and dynamic adjustment of heating units, allowing for a high proportion of recycled materials up to 80% and improved energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the proportion of recycled materials is increased, then the recycling efficiency is improved, but the dosage of rejuvenator and heating time increase, leading to higher emissions of harmful gases and dust
Solution Approach 1:
The patent segments the recycling process into separate heating zones and mixing stages, allowing different proportions of recycled materials to be processed differently. This enables optimized heating time and temperature for each segment, reducing overall emissions while maintaining high recycling efficiency.
Solution Approach 2:
The patent changes the heating parameters (temperature, time) based on the proportion of recycled materials used. By dynamically adjusting these parameters, the system achieves high recycling efficiency while controlling emissions of harmful gases and dust to acceptable levels.
2Productivity
If the mixing temperature is increased, then the mixing efficiency is improved, but the proportion of recycled materials that can be used is limited
Solution Approach 1:
The patent employs dynamic temperature control during the mixing process, adjusting the temperature based on the proportion of recycled materials being used. This dynamic approach allows high mixing efficiency to be maintained while accommodating a wider range of recycled material proportions in the mixture.
Solution Approach 2:
The patent changes the mixing temperature parameter according to the recycled material proportion. By optimizing this parameter for different scenarios, the system achieves both high mixing efficiency and high adaptability to various recycled material contents.
3Manufacturing precision
If the heating time is extended, then the quality of recycled materials is improved, but the energy consumption increases
Solution Approach 1:
The patent implements feedback control in the heating process, monitoring the quality of recycled materials in real-time and adjusting heating time accordingly. This feedback mechanism ensures optimal quality is achieved while minimizing unnecessary energy consumption from extended heating.
Solution Approach 2:
The patent performs preliminary heating and preparation of recycled materials before the main mixing process. This preliminary action pre-treats the materials to reduce the total heating time required later, thereby improving quality while reducing overall energy consumption.
4Reliability
If the dosage of rejuvenator is increased, then the performance of recycled asphalt mixture is improved, but the cost and complexity of the process increase
Solution Approach 1:
The patent optimizes the rejuvenator dosage parameter based on the specific composition and condition of recycled materials. By precisely controlling this parameter rather than using excessive amounts, the system achieves high performance while maintaining process simplicity and cost-effectiveness.
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
Enhances the performance and quality of recycled asphalt mixtures by increasing the recycling proportion while reducing emissions and energy waste, ensuring optimal heating conditions, and improving the durability and stability of the final product.
Implementation Method 1
a heating unit is configured to heat the recycled aggregate in the recycling drum to a preset temperature
Implementation Method 2
the recycling drum is configured to rotate, and the heating unit is configured to heat the recycled aggregate in the recycling drum to a preset temperature
Implementation Method 3
a vibration motor is mounted on the frame, and the vibration motor is configured to drive the vibrating screen to vibrate
Implementation Method 4
the heating unit is configured to heat the recycled aggregate in the recycling drum to a preset temperature
Data Source
AI summary
A production process includes: feeding the recycled coarse aggregates and new aggregates into the hot recycled material drying drum simultaneously through the cold material bin for heating; adding the recycled fine aggregates to the mixing cylinder of the cold recycled material mixer through the existing cold addition system for recycled materials, and then being mixed and stirred with the recycling agent after dry mixing for a certain period of time, and placing the oil-rich fine aggregates in the cold recycled material batching machine and conveyed to the cold recycled material hoist through a conveyor belt.