Go to Home Page

1Asphalt Plants Batching & Process Controls

A modern asphalt batching plant automation system should not only automate weighing and mixing of raw materials. It should provide solutions to the rest of the hard problems every operator faces daily, taking into consideration that asphalt production is a more complex procedure than concrete production. PROTEM’s automation systems provide holistic solutions to the problem of centralized production control guaranteeing the production of a homogenous mixture according to the mix design and legislative requirements. They minimize rejections and production waste, resulting in resource savings.

Factory automation is a necessary step towards achieving total control of all factory processes. Such an automation should provide the operator with the ability to easily monitor the production process and alert him in time about all errors or malfunctions that cannot be resolved automatically. The purpose of automation is to keep mix quality high while depending as little as possible on human factors and operator experience. This is exactly the scope of PROTEM asphalt batching plant automation, starting from the first commissioned plant in 1998 up to the present day.

1The automation can be successfully installed regardless of existing equipment state, regardless of whether it is old or used. The automation shall significantly upgrade your production capabilities. You shall be able to execute and monitor all functions such as weighing and mixing, drying and temperature control, feeding and silo levels, energy consumption and production errors all through the screen of a common PC.

Our automation can also support all other factory management processes. Connecting the automation to the weighbridge, issuing Delivery Notes through a unified system, associating results to laboratory tests are only some of the services we can provide either from the beginning, or at a later stage.

 

Main advantages:

  • Automated continuous control of aggregate feeder separately for each aggregate according to the mix design percentages.
  • Control of a scale conveyor belt in order to verify aggregate inflow from the feeder to the drier. Use of a scale conveyor belt allows for plant productivity measurement independently from the scales.
  • Automatic control of aggregate temperature at drier output, by controlling the burner with advanced PID algorithms. Maximum deviation of ± 8º C. The deviation can be lowered to ± 3º C when a moisture meter is available.
  • Aggregates for the 1st batch (cold mixer) and the last batch (mixer cleaning) are controlled by the automation in order to eliminate waste.
  • Exhaust gas measurement using specialized sensors in order to optimize fuel to air ratio. This results in lower fuel consumption and less pollution.
  • Filter monitoring and protection through exhaust gas temperature monitoring and automatic control of drier underpressure.
  • Accurate asphalt and admixtures weighing so that each mixture is within acceptable tolerances. Asphalt production differs from concrete production at this point because each asphalt batch mix is not stirred inside the transport truck and as a result it is not homogenized further after exiting the mixer.
  • Mix temperature and control at mixer exit. Alarm if it is outside the mix design limits.
  • Automatic quantity monitoring of finished product storage silos and automatic truck loading from storage silos.
  • Asphalt tanks’ pre-heating scheduling and control if the plant does not operate on a daily basis.
  • Communication with the weighbridge and truck weighing through the automation.
  • Raw material warehouse stock control based on actual incoming quantities from weighbridge data and actual raw material consumption as measured by the automation scales.
  • Delivery Note issuing including a production log or a weighing note (depending on company policy). Link to existing software or PROTEM’s Business Administration & Accounting Management Software.
  • Record keeping of historical production data, alerts, errors, mix design modification history.
  • Custom built plant mimic diagram, accurately representing the customer’s equipment.

 

 

1 All PROTEM systems are designed to provide a stable platform utilizing a powerful, flexible and reliable automation architecture. This means that in effect our clients do not have to implement all modernization steps in one step. Modules can be integrated to the system with no worries about future compatibility problems. Our system design philosophy is to grow the system along with the customer’s needs without having at any time to replace what we have delivered in the past in part or in whole. We shall always only talk about upgrades and expansions.