Update Your Plant for Spring Startup

BY ASPHALTPRO STAFF

This month’s production-related product gallery focuses on the asphalt plant and production of asphalt pavement mixes. To produce hot-mix asphalt (HMA) and warm-mix asphalt (WMA) most efficiently today, an owner must take more than dollars into account. You’re also looking at the environmental impact of the operation. While you’re taking the winter season to perform routine and annual maintenance, use the ideas on the next few pages to plan upgrades and enhancements for your most efficient and sustainable operation at season startup and beyond.

The original equipment manufacturers (OEMs), service providers and consultants who provided information for this department are listed in alphabetical order. For easier connecting, look up this department on www.TheAsphatPro.com where those entities who are advertising partners—thus supporters of your industry—will have live links directly to their websites for you to click. When calling for more information, make sure you let folks know you saw them in AsphaltPro Magazine.

Adm

The EX Series asphalt plants from Asphalt Drum Mixers (ADM) are designed to meet production capacity demands from 120 to 425 TPH under strict environmental regulations. The EX Series’ single-drum counterflow system uses the latest in innovative technology, resulting in the longest aggregates drying and mixing times in the industry, according to the manufacturer. The EX Series comes in portable, skid-mounted and relocatable versions designed to meet all federal and state specifications to ensure consistent, quality asphalt.

The EX Series’ unique single-drum counterflow technology system uses separate drying and mixing zones to achieve the optimum heat transfer and fuel efficiency. EX plants are capable of processing high percentages of recycled asphalt pavement (RAP), producing hot mix containing up to 50 percent recycled material, according to the manufacturer. Visit ADM in their booth S5467 at CONEXPO-CON-AGG to learn more.

For more information, call (260) 637-5729 or visit https://www.admasphaltplants.com/ ex-series/.

Ahern Industries

With over 40 years of experience in the asphalt plant industry, Ahern Industries specializes in asphalt plant disassembly, relocation, complete fabrication and season startup.

For more information, call (210) 240-8395 or visit www.ahernindustries.com.

ficiently burn oil, natural gas or propane. Its compact flame makes it compatible with virtually all drum designs without complicated adjustments. Rapidly swirling high energy air is the key to its combustion. The swirling air and flame are created by the fixed internal spin vanes and the patented castellated nose, ring and nozzle design. True to its name, the Whisper Jet burner is designed and equipped to reduce burner noise.

Its nominal maximum aggregate drying capacity, at 5% moisture content, is rated at 140 TPH for the WJ-35 up to 600 TPH for the WJ-150. There are six models to choose from, ranging in integral blower horsepower from 40 to 150. Visit Astec in their booth C30235 at CONEXPO-CON/AGG to learn more.

For more information, visit https://www. astecindustries.com/products/details/whisperjet-burner

B&S LIGHT

Almix

At the center of each customizable UF Series asphalt plant from ALmix, you’ll find the UF Series drum mixer. These are counterflow drum mixers that include a bolt-in flight layout, that when coupled with VFD-controlled rotational speed are designed to allow for maximum drying and mixing efficiency, lower stack temperature and reduced fuel consumption. The UF Series drums are available in a variety of sizes, with countless features and options. Visit ALmix in their booth S6816 at CONEXPO-CON/AGG to learn more.

For more information, call (260) 672-3004 or visit https://almix.com/the-uf-series.

Astec

The Astec Whisper Jet® burner is designed with patented technology to cleanly and ef-

B&S Light Industries offers the EZ-Loader silo/truck loadout system for virtually unlimited capacity for tickets, customers, trucks, materials and more. Operators view, modify and/or reprint any previous ticket(s) as needed from logical, well organized and intuitive menu screens, according to the manufacturer.

While the operator manual—including scale manuals with illustrations—is contained in the “help” file for viewing or printing, B&S offers support to customers and stocks—ready for shipment—all replacement parts for the first system the company built nearly three decades ago as well as each of the 2,500+ systems since. Simulation for training is extensive and realistic, according to the manufacturer.

The system offers automatic daily backup of current plant data to inexpensive, removable flash disk. The operator can achieve

2.7M Square Feet of Exhibits

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1,800 Exhibitors

150 Education Sessions

REGISTER at conexpoconagg.com

Save 20% with promo code SHOW20 continuous real time data synchronization of multiple office computers and plants, numerous file transfer protocols to interface with most popular accounting packages, and have TCP/IP communication. safety, with other days devoted to mix quality, production, and electro-mechanical, depending on the track you sign up for.

For more information, contact (918) 3421160 or sales@bslight.com.

These courses run through March 17, with in-person information during the Rocky Mountain Asphalt Conference and Equipment Show (RMACES) in Denver Feb. 7-8, at booth 505.

For more information, contact (952) 9396000 or visit www.clarencerichard.com.

Command Alkon

Command Alkon offers the Apex Scale Ticketing Software to eliminate gaps in communication between dispatch and the back office, to reduce truck time at the plant, and to offer complete visibility. Combine Apex with simple site automation technology to get trucks in and out of the plant efficiently. Visit with Command Alkon and attend one of their live demonstrations in their booth N12315 at CONEXPO-CON/AGG to learn more.

For more information, visit commandalkon. com/getapex.

Brock

BROCK is pleased to announce Lance Clark as its new regional sales manager – Southwest. He takes over the states previously covered by Sales Representative Phil Hoffman who will be helping Clark as he transitions into the area. Clark’s territory includes the states of Texas, Oklahoma, Arkansas, Louisiana, Mississippi and Alabama. In his role he will be responsible for providing outstanding customer service while selling BROCK equipment, parts and on-site construction services in the territory.

Clark has over 16 years of successful engineering and sales experience in the hot-mix asphalt (HMA) equipment industry. He came to BROCK in 2021 after several years with Astec Industries to help develop the BROCK line-up of quality hot oil heaters and liquid asphalt storage tanks.

For more information, contact (423) 4769900 or visit www.brock.llc

Clarence Richard

The Clarence Richard Company offers more than hot-mix asphalt (HMA) components and service. The Plant Operation Workshop, taught in person and via intensive online courses, is designed to teach plant and production personnel improved safety, mix quality and production techniques as well as tips for improving operating costs. Weeklong courses include an entire day devoted to

Conveyor Components

The Model CT, manufactured by Conveyor Components Company, is comprised of a control unit and tilt probe, which senses the presence or absence of material. The control unit is enclosed in a rugged cast aluminum housing with external red and green LED status indicator lights and surface mount printed circuit boards. Weatherproof, dust-ignition proof and explosion proof models are available. Optional black epoxy powder coating is available for corrosive environments.

The Model CT is commonly used when other controls won’t work due to bin vibration, or actual bin walls aren’t available for mounting other controls. Typical applications include level detection in hoppers, silos, stackers, crushers and conveyor transfer points.

The CT tilt probes are available as a standard 9-inch tilt probe or a compact 6-inch tilt probe and have 25 feet of electrical cable. Stainless steel probe housings are available as an option. Float ball and paddle accessories are also available for fine-grain materials.

For more information, contact (800) 2333233 or visit the Conveyor Components website.

Cwmf

CWMF, Waite Park, Minnesota, now offers a fines metering system for its portable Dust-Eater® baghouses, allowing producers better control of fines and reducing set-up time. As mix designs evolve, controlling dust is imperative to producing a quality product that will meet specifications. This device is designed to consolidate a remotely located dust pod and additional augers. It works when baghouse fines are first conveyed to the discharge auger on the baghouse. The discharge auger has a drop-out point where the dust will be stored in a small pod. This pod will have a rotary vane feeder attached, which will meter the amount of fines returned to the drum. If you are producing more fines than you are returning, the auger will bypass the dust pod, discharging them to a wet auger. At this point, water will blend with the fines, and it can be rejected.

For more information, contact sales@ cwmfcorp.com.

Eagle Crusher

The team from Eagle Crusher, Galion, Ohio, offers the RapiDeploy® 1000, which includes the features of the original RapiDeploy 500®, plus the Eagle Crusher UltraMax 15 impactor. The RapiDeploy 1000 is designed to crush, screen, separate and stockpile—all in one pull. Look for the new UltraMax 1600XOC portable impactor plant and the 8x20 screen plant with integrated feed conveyor and blending gates at Eagle Crusher’s booth C30949 at CONEXPO-CON/AGG.

For more information, contact (800) 25-EAGLE or visit www.EagleCrusher.com.

Gencor

The heart of the Gencor Ultraplant® is built around the unique, patented, counterflow Ultradrum® technology. The Gencor Ultra II® burner is extended well inside the dryer for maximum efficiency and contact with the wet aggregates and uses compressed air to atomize each droplet of fuel for optimum fuel efficiency.

The isolated mixing section of the Ultradrum is located behind the burner so there is no chance of liquid asphalt encountering the burner flame. This means there is no oxidation of the asphalt, no degradation of the mix and no asphalt vapors entering the ex- haust gas stream. Vapors generated in the mixing section are pulled through the burner by a patented volatile reclaim system and consumed as fuel.

Recycle is added to the isolated mixing zone through a wide collar behind the burner flame. Gencor’s fines return system is designed to provide simple metering and easy transportability. The optional Ultradrum insulation package substantially reduces thermal heat loss by reducing fuel usage as much as 7%.

Standard features include:

• Patented adjustable 5-way veiling flights;

• Patented combustion T-flights;

• Sweeping material inlet flights for even drum loading;

• Self-cleaning RAP inlet to allow up to 50% RAP;

• Large drum diameter to reduce air velocity and dust carry-out;

• Friction driven trunnion rolls for lower noise, maintenance and energy; and

• Positive volatile reclaim system to capture and destroy hydrocarbons.

For more information, contact (407) 2906000 or visit www.gencor.com.

Homestead Valve

Homestead Valve division of Olson Technologies Inc. offers a full line of hot-jacketed, 2-way shutoff and 3-way diverter valves to meet flow requirements, including those made of cast iron (to 450°F), of ductile iron (to 650°F) and with high temperature seals. Actuator types include pneumatic, electric, open-close and modulating.

For more information, contact (610) 7701100 or sales@homesteadvalve.com.

Kenco

Kenco Engineering Inc. offers innovative products for the aggregates, road building and biomass industries to protect your investment in your production equipment. Within the past couple of years, the engineers have innovated new concepts, including one originally designed for the vertical construction industry: the foundation drilling auger protection concept from Kenco is designed to reduce downtime at the asphalt plant and at the paver by retaining auger diameter. Kenco’s unique tungsten carbide impregnated (TCI) process protects auger flights from abrasive wear. Crushed tungsten carbide (TC) is im- pregnated into the flight edges (and outer faces, if desired) by melting the flight metal to a depth between 0.25 and 0.375 inches and dropping crushed TC particles into the molten puddle. After cooling, the TC is solidified deep into the parent metal.

Kenco’s unique tungsten carbide impregnated (TCI) process protects auger flights from abrasive wear.

TC wear strips featuring the Kenco TCI process can be welded to flight edges and any other drill tooling that needs extra protection. It’s not an overlay or spray-on. The TC becomes a part of the steel. Kenco crushes and sizes the TC raw material in-house to maintain quality. TC has a hardness exceeding 90 Rockwell A.

For more information, contact (916) 7828494 or visit www.kencoengineering.com.

Are you exploring NAPA’s climate challenge, but unsure of your navigation? We can help you take at least one step forward — by replacing your tank heaters, hot oil heaters, fuel oil preheaters, and distributor truck heaters with our zero-emission, 100% efficient, Lo-Density® drywell-style electric heat. Check out our new operating cost calculator

Meeker

Meeker Equipment designed the Patriot hot oil heater for both reliability and efficiency. The 2-pass helical heater absorbs BTU energy out of the burner flame, which directly correlates to low stack temperatures. Using Meeker’s SABER STACK option drops stack temperatures even lower, sometimes as much as 100°F, according to the manufacturer.

All heaters come with a programmable logic controller (PLC). Once the heater starts up, the PLC tracks such things as:

• the hours the burner ran (some states require you to report this);

• number of times the burner cycles (for trouble shooting);

• stack limits;

• temperature limits; and

• flow limits, to name a few.

The removable expansion tank is mounted off center of the heater to allow it to keep cool. The tank comes with a magnetic shutoff switch and a visual expansion tank level indicator.

The heater uses a high flow SIHI centrifugal pump with mechanical seals for 12-foot per second flow through the coil. This turbulent flow through the heater keeps the oil from degrading.

The burner is a Webster JB1 burner, which features an adjustable combustion head assembly, allowing for unmatched fuel to air mixing, smooth lights-offs and quiet operation. The modulating burner operation creates a wide turn down ratio, allowing the burner to fire only at its demand. In other words, if less heat is required, then the burner fires only to that output.

All heaters from the OEM are prewired, pre-fired and pressure-tested before shipping. The OEM states that it normally has the heaters in stock for quick delivery. Visit Meeker at booth C32553 at CONEXPO-CON/AGG to learn more.

For more information, contact (888) 3330323 or visit www.meekerequipment.com.

Meyer Lab

The family owned and operator Meyer Lab offers specially formulated temporary and semi-permanent release agents and coatings, drag slat cleaners, and extraction solvents designed to work on all asphalt mix designs, including all performance-grade mix designs such as PG76-22. These are state-approved and NTPEP-listed products formulated and made in the United States with custom-built dispensing systems. Meyer is a full-service supplier with more than 75 service representatives and numerous warehouses located throughout the United States.

For more information, contact (800) 5807677 or sales@meyerlab.com.

ed, the Vulcan Burner opens completely to allow for easy access.

Vulcan burners come equipped with two safety switches in case of overheating or separation while in operation. The 75-horsepower motor is designed to move the same amount of air as other burners with larger motors, which offers energy efficiency and cost savings. The fan intake is sound-insulated for quieter operation. The flame shaper can be adjusted while the burner is in operation.

For more information, contact (866) 6471782 or visit www.reliableasphalt.com.

Stansteel

Pugmill Systems

Pugmill Systems designs and manufactures custom mixing solutions for the asphalt (and other) industries. The company builds stationary pugmills from 5 to 2,000 TPH capacities with coordinated feeder systems and site-specific plant arrangements. The team also builds portable pugmills with capacities from 5 to 1,500 TPH and options like asphalt pump plus meter, water pump meter, silo systems, feed hoppers, conveyors and the like. Their pugmill mixers include timed and untimed with models from 5 to 2,000 TPH customized to the customer’s needs.

For more information, contact (931) 3880626 or visit pugmillsystems.com.

Reliable

Reliable Asphalt Products offers the Vulcan burner. Vulcan burners are total air burners with a single motor and a coaxial blower, which provides a near-linear fan curve. They can be run on multiple fuels, simultaneously if required. There are optional blower mount configurations, and they can be converted from long to short nose.

Vulcan Burners are designed to be low maintenance—the direct driven fan has no belts or pulleys. When maintenance is need-

The Tank Manager System™ from Stansteel®, Louisville, Kentucky, allows plant operators and superintendents to monitor and regulate all their AC tanks and hot mix silos. Users can set individual tank high/low parameters for level and temperature to initiate a pump shutdown, thus preventing tank overflows. In addition, users can operate AC tank supply, return and fill valves with the push of a button. The Tank Manager System also allows users to send emails and texts to specific individuals notifying them during alarm events—such as “low hot oil temperature”— that action needs to be taken. The system is designed to be operated on a computer or any smart phone. Essentially, the Tank Manager System gives you the control to run your business while it runs your tanks:

• Preventing tank spills and overfills;

• Avoiding AC waste and contamination;

• Offering remote control of all valves and pumps;

• Knowing silo and tank levels 24/7 from anywhere; and

• Offering new non-contact accu-level technology.

For more information, contact (800) 8260223 or visit https://stansteel.com/tankmanager/.

Systems Equipment

Systems Equipment Corp offers The Peacekeeper drum mix process computer, which is an ADP-100 asphalt blending system with optional Windows-based graphics-enhanced user interface. The Peacekeeper system is designed to offer improved proportioning accuracy of aggregates and additives according to prescribed mix formulas while it measures and controls liquid asphalt mass flow rate so blends are accurately interlocked to the measured aggregate.

For more information, contact (563) 5686387 or visit www.systemsequipment.com.

Tarmac

Tarmac International Inc. launched the 30NOx burner with PLC controller in 2022. The burner features two fuel valves—a primary in the back and a secondary in the center. “We pre-mix the fuel and air early,” President Ron Heap said. The burner uses early mixing of fuel and air along with internal gas recirculation to reduce NOx down to 30 PPM. This 30 PPM NOx is a level that Tarmac’s customers are experiencing in the USA.

The new burner controller allows for improved fuel and air valve positioning (parallel positioning) with both manual and auto control. An Allen Bradley PLC with 10-inch touch screen controls the burner and interlocks. Manual operators are included for backup control should the PLC fail. There is a “dashboard” where management can see burner production, fuel per ton, position of the fuel and air valves, position of the ID fan, negative pressure of the burner faceplate. Over-the-phone service is available with the technician seeing the parameters of the burner controller.

For more information, contact (816) 2200700 or visit www.tarmacinc.com.

Wem

WEM Automation offers replacement controls for all makes and models of asphalt batch and drum plants, including silo loadout and data analytics. The company’s 24/7 service and support assists with easy-to-use, configurable automation and control systems, according to the manufacturer.

For more information, contact (262) 7822340 or visit www.WEMAutomation.com.