APOLLO ASPHALT BATCH MIX PLANT MODEL ANP 1500

Asphalt Batch mix plant with Computerized panel and Bag House Type Pollution Control Unit.- Capacity 120 Tph Model ANP-1500

One Unit Apollo Asphalt Batch Mix Plant, Model ANP-1500 ( Manufactured under Technical Collaboration with NIIGATA ENGINEERING Co., Ltd. Japan ), generally summarized in the commercial offer and as technically illustrated in the technical offer and documents attached.

General Description :

Stationery, batch type, fully automatic asphalt mixing plant - Model ANP 1500

The plant is designed with electrical components to suit a 380V (+/- 4%)/3ph+neutral 50Hz supply and comprises of the following units.

Comprising of :

1. Cold Aggregates Bin Feeder :

An Easily transportable Four bin cold aggregates feeder unit with a storage capacity of 25.12 m3 / 40 T. Feeder bins with adjustable radial gate discharge and a variable speed drive to adjust the feed of the individual bins. The individual bins are provided with feeding units comprising of head and tail pulleys, single roll idlers, endless rubber conveyor, screw type belt tensioners, replaceable rubber skirting, no flow indicators, vibrator on sand bin, and a 1.5 kW squirrel cage electric motor supplied through a static invertor variable speed controls with transmission through gear reduction unit. Oversize protection safety grids on the hopper feeding opening.

Gathering conveyor with feeding capacity of 150 Tph. - Gathering conveyor and slinger conveyors provided with trough idlers, roller guides and return rollers.

Slinger conveyor (Throwing Conveyor) with a feeding capacity of 150 TpH, powered by a 3.75 kW squirrel cage electric motor and speed reduction unit is provided with trough idlers, roller guides and return rollers, mounted on a rigid structural frame.

Complete aggregates feeding system comprising of structural assembly with mechanical and electrical drives, necessary controls and wiring up to the control cabin.

2. Dryer Drum :

- Cylindrical (2.1m Dia.x 8m long), Inclined type Dryer drum unit with field proven internal flights designed to give bonus drying capacity with change in moisture content. Dryer drum supports comprising of four drum rollers and two thrust rollers on a rigid frame, and equipped with two steel tires.

- Hot aggregates temperature measurement device comprising of thermocouple type temperature probe located in the dryer drum discharge chute.

- Rigid structural frame, Dryer drum breaching boxes, drives, necessary controls and wiring.

3. Burner :

Complete Burner unit (300 - 1150 Ltrs/hr) Fully Automatic, Proportioning, High Pressure, Fuel atomising type low noise burner suitable for Light diesel fuel oil (or ASTM D396 No.4 fuel oil). Fully integrated low noise turbo blower powered by a 18. 5 kW , 4 pole motor.

Remote operating control station, high pressure fuel oil pump together with flame monitoring system, and with an electric ingniter, interconnections, controls, safety devices and interlocks, fuel line piping with necessary control valves, filters, structural base, supports and complete internal wiring and connections into the control cabin. Unique Air pre-heating system.

4. Two stage Dry Dust collecting type Pollution control system comprising of :

4.1. Primary Dust Collecting Unit

Primary dust collection system in form of a Double Cyclone ( 1.750 Dia. X 3.850 mm ) is provided to entrap larger dust particle from the dryer drum exhaust and for scavenging for the batching tower. Reclaimed dust recycling conveying system comprising of a material seal damper at the bottom of the cyclones, feeding the reclaimed dust at the foot of the hot elevator.
High capacity Exhaust fan powered by 90 kW, with automatic damper controls.

4.2 Bag House Filter Unit

- The two stage dry dust collection system has a bag house filter, with a maximum emission of 0.1- 0.2 gm/m3. Pulse jet type operating mechanism provided with "Connex / Nomex" felt as filtering media. The 400 Nos. of bags provide for approx. 433.6 m2 of filtering area. Bag filter Housing internally painted, with Heat resistant anti-acid paint.

- A Fully automatic De-dusting system incorporating air compressors, solenoid valves, etc.

- Air cooled, reciprocating type with built in pressure switch , 60 CFM air compressor with a 350 Ltrs air reservoir, powered by 15 kW 4 pole motor unit.

4.3 Fines re-cycling system

- Fines recycling system comprising of a screw conveyor for conveying the entrapped fines in the bag house to the filler elevator, which in turn feeds the filler weigh hopper atop the mixing tower.

- Structural assembly with supports, bags, cages, pressure and temperature controls, Electrical / mechanical drives, chimney (970mm dia. X 12 m long) with base supports, Exhaust duct piping and interconnections between different units and complete interconnecting wiring.

5. Batching Tower comprising of :

5.1 Hot Aggregates Bucket Elevator

Totally enclosed, vertically mounted, centrifugal discharge type bucket elevator conveys the hot aggregates from the Dryer drum dis charge to the top of the batching tower. The 140 TpH hot elevator is powered by an 11 kW, 4 pole motor and is supplied complete with wear plates, electrical / mechanical drives and wiring.

5.2 Four Deck Vibrating Screen

- Completely enclosed Four Deck vibrating screen (1200mm wide x 3600mm long), sieves and stores four different aggregate sizes. The Inclined circulating, vibrating type screen is provided with duplex spring absorbers, and is powered by a 7.5 kW four-pole motor.

- Supplied alongwith One set of Sieves with the following sieve sizes:
3 x 4 mm, 7 mm , 16 mm , 24 mm, 30 mm, 40 mm.

5.3 Hot Aggregates Bin

- Four compartment hot aggregates bin with 12 m3 storage capacity, over flow and over size rejection chute, bin level indicators, pneumatic controlled cut off gates and a sampling device on each compartment.

- Temperature measuring point on bin no.1.

5.4 Weighing System

- Automatic accumulating, weighing type Aggregate weigh hopper, with four point suspension hopper and load cell transducer.

- Automatic individual weighing type Asphalt and Filler weigh hopper with four points suspension hopper and load cell transducer.

- All weighing hoppers are fitted with proper shock isolation device.

5.5 Pug Mill type Mixer Unit

- Twin shaft, 1600 kg mixing capacity, jacketed pug mill with welded steel shell, lined with replaceable wear resistant spiral liners. Provided with a wide opening slide gate for quick discharge of hot mix.

- 37 kW, Four-pole motor Mixer drive, with roller chain arrangement.

- Complete Batching Tower structural unit with drives, controls, pneumatic piping and total wiring.

5.6 Pneumatic Control System

30 CFM Air compressor - air cooled type, powered by a 7.5 kW, Four pole motor, with built in pressure switch and air reservoir together with necessary valves, fittings Pneumatic piping and with complete wiring.

6. Filler Feeding system comprising of :

Completely enclosed Vertically mounted Filler elevator with induction discharge type bucket elevator for feeding filler into filler storage bin on the mixing tower. The 0.6 m3 filler and dust storage bin is provided with a level indicator to control the filler supply from filler elevator automatically. A Rotary type 1.5 kW filler feeder with pneumatically operated seal gate, feeds filler from filler storage bin into filler weigh hopper.

7. Asphalt pumping system comprising of :

- 5.5 kW, 450 Lpm, Jacketed, gear type Asphalt transfer pump for feeding asphalt from the storage tank to the asphalt weigh hopper complete with skid and wiring.

- 7.5 kW, 800 Lpm, hot oil jacketed asphalt gear type Spray pump for spraying asphalt into the pug mill mixer via spray bars. Complete unit with controls and wiring.

8. Indirectly heated Bitumen storage and Heating system comprising of :

2 nos. Cylindrical, horizontal Asphalt storage tank, capacity 25 000 Ltrs. each. Fully insulated and cladded with internal heat transfer coils and temperature indicator.

Thermic oil heating system with fully automatic light oil burner, hot oil transfer pump, necessary controls and safety interlocks. Total hot oil transfer piping with necessary control valves.

Bitumen jacketed piping with process valves and fittings for manual tank selection and single bitumen delivery pipeline.

Necessary wiring and process control devices.

9. Fuel Storage tank :

20 000 Ltrs capacity, vertical, cylindrical tank with fuel transfer pump, piping and necessary control valves, fittings and wiring.

10. Foreign Filler Silo :

Vertical, cylindrical filler silo, capacity 25 T (d=1.3) with manual (bagged filler) filler feeding arrangement comprising of a vertical fines elevator.

Completely enclosed Vertically mounted Filler elevator with induction discharge type bucket elevator for feeding filler into filler storage bin on the mixing tower.

21 Tph filler elevator, powered by 2.2 kW Four pole motor.

11. Computerized Control Cabin comprising of :

11.1 Operator's Control Cabin

- 2300 mm wide x 4300 mm long, Fully Air Conditioned operator's control cabin complete with weather proof exterior and fitted with tinted toughened glass windows and flush entrance door with lock.

- Interconnecting wiring (related to all the above sections) designed to suit the positioning of the unit within 10 m radius of the mixing unit.

11.2 Electrical Power control console

- Complete Motor control console for direct online starting and for star delta starting on necessary devices.

11.3 Distribution switch board

- Completely enclosed steel cubicle with push buttons starting of motors on star delta starters.
- Magnetic switches with overload thermal relay for each individual motor.
- Safety Interlocks and protection devices.
- Meters for online current voltage measurements for high capacity motors.
- Emergency stop button.
- Short circuit protection with switch fuse unit.
- Inverter Drives for control of cold aggregates bin feeders.

11.4 Temperature Indication

0 -300 Deg C, Electronic multi point scanner for measuring :
- Aggregates temperature measuring in Hot Bin no. 1.
- Asphalt feeding temperature.
- Bag filter inlet gas temperature.
- Bitumen tank temperature (Tank # - 1 & 2)

11.5 Sequence Control panel

- Programmable Logic Control (PLC) with man machine interface.
- Fully automatic electronic solid state sequence control.
- Operator override for manual or semi automatic control.
- Timer controls for both wet and dry cycle.
- Pilot lamps for indication of sequence currently operated.
- Signals and alarms.
- Storage of Fifty different type of mix proportions.
- Automatic free-fall compensation.
- Direct dialing of mix design by percentage.
- Preset batch counter controls the number of batches for a truck-full load.
- Provision for printing operating data like - Mix proportions, Batch weight, Total no. of batches, Sub total, gross total etc..

11.6 Dryer & Burner control

- Hot aggregates temperature at dryer discharge end.
- Remote Burner flame synchronization with hot aggregates temperature.
- Safety interlock, in case of high temperature.