Batch Type Asphalt Mixing Plant Comprehensive Analysis

Batch type asphalt mixing plant is a kind of equipment that produces asphalt mixture in batches. It forms high-quality asphalt mixture by accurately controlling the ratio and temperature of raw materials such as aggregate, asphalt, mineral powder, etc., and is widely used in road construction and maintenance projects. Its core features are batch metering and forced mixing. Each production cycle independently completes the drying, screening, metering, mixing and other links of aggregate to ensure the stability of the mixture gradation and uniform asphalt coating.
 

Working principle of batch type asphalt mixing plant:
1. Cold material supply and initial mixing
Cold aggregate (sand and gravel, etc.) is transported from an independent cold material bin to the aggregate belt according to a preset ratio through a belt conveyor to complete the primary ratio. The cold material bin adopts a modular design, and the gradation can be flexibly adjusted by adjusting the belt speed or the bin door opening.

2. Drying and heating
The aggregate enters the rotating drying drum and directly contacts the high-temperature hot air generated by the burner to remove moisture and heat it to 160-180℃. The drying drum adopts an inclined design, and a lifting plate is provided inside to improve the heat exchange efficiency between aggregate and hot air.

3. Screening and metering
The hot aggregate enters the vibrating screen through the elevator, and is stored in the hot aggregate bin after being graded according to particle size. Aggregates, mineral powder and asphalt of various specifications are accurately measured by electronic scales, and the error is controlled within ±0.5% (aggregates) and ±0.25% (asphalt).

4. Forced mixing and unloading
The measured materials are put into the double-shaft forced mixing tank in sequence and fully mixed with asphalt. The mixing time is usually 45-90 seconds to ensure that the surface of the aggregate is evenly coated with asphalt. The finished material is loaded and transported through the unloading door.

5. Environmental protection and waste heat recovery
The exhaust gas generated during the drying process is treated by cyclone dust removal and bag dust removal, and the dust emission meets environmental protection standards. Some equipment integrates waste heat recovery system for preheating asphalt or aggregate to reduce energy consumption.
 

Output range of batch type asphalt mixing plant
The capacity of asphalt batch mixing plants covers a wide range, and the main models include:
- Small: 40-80 tons/hour (such as LB-1000, mixing tank capacity 1000 kg), suitable for rural roads and small repair projects.
- Medium: 100-200 tons/hour (such as LB-2000, mixing tank capacity 2000 kg), commonly used in urban roads and general highway construction.
- Large: 240-320 tons/hour (such as LB-4000, mixing tank capacity 4000 kg), mainly serving large projects such as highways and airport runways.

Core advantages of batch type asphalt mixing plant:
1. High precision and quality stability
Batch metering and forced mixing process ensure small aggregate grading error, accurate asphalt dosage, and better mixture uniformity than continuous equipment, especially suitable for high-grade pavement and modified asphalt production.

2. Flexible adaptability
It can quickly switch different mix ratios to meet the production needs of various asphalt mixtures (such as ordinary asphalt, modified asphalt, and colored asphalt).

3. Environmental protection and energy saving
Integrated high-efficiency dust removal system (such as bag dust removal area of 1,350 square meters), dust emission is less than 30mg/m³. Some equipment uses oil-to-gas technology, combined with an intelligent temperature control system, which reduces energy consumption by 18%-22%.

4. Convenient maintenance
Key components (such as mixing blades and vibrating screens) are made of wear-resistant materials, and the modular design facilitates quick replacement. For example, the independent structure of the cold material bin and the hot aggregate bin reduces equipment downtime and maintenance time.

Market share of batch type asphalt mixing plant:
Asphalt batch mixing plants dominate the high-end market, with a global market share of about 60% in 2023. With their cost-effective advantages, Chinese asphalt mixing plant manufacturers account for 61% of global mobile equipment exports.

Application areas of batch type asphalt mixing plant:
1. Road engineering
- Expressways: Produce high-performance asphalt mixtures such as AC and SMA to ensure road durability.
- Urban roads: Flexibly adjust the mix ratio to meet different traffic flow requirements, such as the production of permeable asphalt and noise reduction asphalt.

2. Special projects
- Airport runways: High-stability mixtures ensure safe aircraft takeoff and landing.
- Bridge paving: Use high-viscosity modified asphalt mixtures to improve the anti-skid and crack resistance of bridge decks.

3. Environmental protection and recycling
- Recycling of old materials: Through thermal recycling technology, the utilization rate of old asphalt mixtures can reach more than 40%, reducing carbon emissions and resource consumption.
- Low-carbon production: Intelligent temperature control and new energy (electricity, biomass fuel) applications drive the industry towards the goal of carbon neutrality.

Batch type asphalt mixing plants occupy a core position in road construction with their high precision, flexibility and environmental protection advantages. With technological upgrades and policy promotion, their market share will continue to grow, especially in high-end fields such as high-grade highways and airports. In the future, intelligence, greening and high recycling ratio will become the key directions for the development of the industry.