Overviews
The RLB-series Recycling Asphalt Mixing Plant (RAP) integrates an additional regeneration drying drum and metering device into the standard batch mixing system. This independent drum heats and measures recycled materials accurately and reliably. To prevent asphalt from overheating or aging, the system uses a specially designed short-flame burner. This burner, combined with a protective chamber, prevents direct contact between the flame and recycled materials.
This plant adopts cutting-edge international thermal regeneration technology. It recycles damaged asphalt pavement milled from road surfaces. After sieving (if needed), the recycled asphalt is heated, stored, and measured. Then, it’s mixed evenly with new aggregates, fresh asphalt, and—if necessary—recycling agents in the mixing cylinder. As a result, the final asphalt mixture is high-quality and consistent. This makes the plant ideal for base, intermediate, and surface layers of high-grade asphalt roads.
By using the RLB-series system, more than 30% of recycled aggregates can be reused. Additionally, it saves over 30% of asphalt resources, reducing production costs significantly. These benefits contribute to both economic efficiency and environmental protection, aligning with sustainability goals.
Our team has combined the latest European technology with practical local needs to develop this advanced solution. The RLB-series is stable, reliable, and built for safe thermal recycling. It ensures precise heating without burning loss, smoke emission, or added pollution. With a recycling rate of up to 60%, it delivers strong economic returns and meets international standards.
Key Features
- Heat Regeneration Technology: Our plant uses advanced heat regeneration to recycle asphalt waste and reduce raw material use.
- Eco-Friendly：Reusing asphalt lowers emissions and supports sustainable construction practices.
- High-Quality Output：Precise heating ensures strong, smooth, and long-lasting asphalt mixes.
- Cost Savings： Less need for new materials means lower production costs over time.
- Versatile Use： Compatible with various asphalt mixes for different road projects.
- Easy to Operate： A user-friendly interface simplifies control and boosts efficiency.
- Built to Last： Durable materials ensure reliable performance in tough conditions.
- Expert Support：From setup to maintenance, our team keeps your plant running strong.
Main Systems
Cold Aggregate Supply System
Feeding Belt Conveyor:
- The aggregate belt conveyor features a high-quality rubber belt, sealed bearings, and both inner and outer cleaning scrapers. At the tail end, a tension adjustment device and automatic side guide rollers ensure proper belt alignment.
- Safety chains are installed on both sides of the raised section to secure the connection with the inclined belt conveyor. Additionally, a safety pull cord switch is mounted on one side to protect operator safety during operation.
Cold Aggregate Hoppers:
- For recycling asphalt mixing plant (RAP), the cold aggregate bin features a split upper-lower design for easy transport and ample capacity. It includes a maintenance platform, protective plate, and anti-stick treatment for high temperatures.
- Each hopper has a belt feeder with Omron proximity switches and adjustable gates. Wall-mounted vibrators prevent arching, with multiple vibration modes selectable in the control room.
A dual-motor vibrating screen (1 m²) removes oversized asphalt, which can be crushed and reused if needed.
Belt Feeder:
- Both cold aggregate bins use belt feeders to ensure uniform material flow, helping maintain balanced burner output in the drying drum. The feeders use wear-resistant rubber belts, with material volume controlled by adjusting chute openings and belt speed.
- Operators can fine-tune the feeding rate in the control room by matching belt speed to gate openings. The system features sealed idlers and support rollers, eliminating the need for lubrication during extended use.
- To reduce material buildup, each feeder includes an external scraper and a belt tensioning device. Automatic side guide rollers help correct belt misalignment. The overall feeding rate can be adjusted via the control system without changing preset material proportions.
Drying System
Drying Drum:
Our engineers have designed a highly efficient regeneration drying drum with a specialized internal structure that maximizes thermal energy use. This design prevents hot materials from sticking to the drum wall and lifting blades, avoiding asphalt aging and burning. As a result, the drum delivers exceptional performance.
Regeneration Drying Drum Specifications:
- Type: Downflow type
- Transmission: Friction drive
- Transmission Mechanism: Shaft-mounted motor reducer, Friction wheel, Regeneration drying drum roller
The drum cylinder is made of welded boiler-grade steel. An H-beam frame, fixed to support legs, determines the drum’s inclination. Four friction wheels, driven by shaft-mounted motor reducers, rotate the drum. Inclined positioning wheels at the feed end prevent axial displacement, ensuring long-lasting operation.
For accurate temperature control, infrared sensors and thermocouples are installed in the transition hopper and flue. These signals are processed by a computer and synchronized with the burner and draft fan’s servo system. This closed-loop regulation keeps thermal efficiency at its peak, maintaining a discharge temperature deviation within ±5°C.
Burner:
The integrated burner in our Recycling Asphalt Mixing Plant (RAP) is a dual-fuel electromechanical unit (light and heavy oil). It uses compressed air atomization for efficient fuel-to-air ratio adjustment, improving efficiency and extending the lifespan of the fan and pump.
Operators can adjust air-to-oil ratios from the control room. The burner also features automatic ignition and flame monitoring for safe, reliable operation in asphalt recycling.
Main Tower(Dust Collector, Transition Hopper, Measuring Hopper, Hot Material Chute)
Main Structure:
The main tower in the recycling asphalt mixing plant plays a crucial role, supporting the regeneration drying, heating, storage, measuring, and exhaust gas treatment systems. Its stability is essential for smooth operation. The frame, made of sturdy H-shaped steel beams, ensures secure fastening. It is detachable for easy transport and cost reduction. Designed with ladder platforms, it simplifies installation and maintenance.
Transition Hopper:
The transition hopper temporarily stores recycled materials from the regeneration drying drum, ensuring continuous operation of the mixing equipment in the Recycling Asphalt Mixing Plant. Its exterior is thermally insulated, coated in stainless steel, and heated with thermal oil to prevent material adhesion. Additionally, an imported sensor monitors material levels in real-time, while an infrared device adjusts temperature through a computer.
Moreover, the hopper is equipped with a sliding door system powered by an imported cylinder, ensuring zero leakage and smooth operation.
Exhaust Gas Treatment System:
- The exhaust gas treatment system includes a flue and a regeneration-induced draft fan. Exhaust gases from the drying drum pass through the flue and fan for secondary combustion in the original drum. This process maximizes thermal efficiency, cuts costs, prevents pollution, and meets environmental standards.
- Additionally, the draft fan prevents oil fume buildup, simplifying cleaning and maintenance. Two thermocouples on the outlet flue ensure safe operation. One provides real-time control via the computer, while the other displays data on the instrument, offering dual protection for the regeneration system.
Measuring Hopper:
- The accuracy of the measuring hopper is crucial for machine-matching in regenerated asphalt production. Our hopper uses pressure sensors for precise and stable measurement. These sensor signals are processed by the PLC and displayed on the computer interface.
- To ensure clean and non-adhesive discharge, the hopper’s outer shell is insulated with rock wool and covered in stainless steel. A sliding door mechanism prevents material leakage, ensuring smooth discharge. The door’s operation is controlled by an imported cylinder, improving overall efficiency.
Hot Material Chute:
The hot material chute conveys regenerated asphalt from the measuring hopper to the asphalt mixer. To ensure smooth discharge, it features a large angle and cross-section. Additionally, the chute’s outer shell is heated with thermal oil, insulated with rock wool, and covered in stainless steel. Furthermore, observation windows are included for easy inspection and maintenance.
Asphalt Mixture Elevator
Asphalt Mixture Elevator:
The asphalt mixture elevator in the Recycling Asphalt Mixing Plant uses a strong, wear-resistant circular chain and an anti-reverse drive for safe and reliable operation. It also includes automatic tensioning and emergency safety features at the base.
To prevent leaks during assembly, sealant or asbestos strips are applied at all joints. The hopper opening is reinforced with wear-resistant steel, and both the inlet and outlet have durable lining plates.
Designed for high temperatures, the structure is easy to access and maintain.
Control System
Main Structure:
The regeneration control system seamlessly integrates with the asphalt mixing equipment through online coordination. The lower-level computer gathers input and output signals via the PLC’s I/O ports, allowing precise blending of recycled and new materials.
Meanwhile, the upper-level computer uses a dedicated PC with advanced control software to communicate directly with the PLC. With a built-in LCD monitor, it enables real-time control, operational monitoring, and report generation.
System Configuration:
- The upper-level computer uses an industrial or commercial PC equipped with an advanced software suite and a branded LCD monitor.
- The lower-level system relies on Siemens field data acquisition modules and I/O units for on-site control. Multiple temperature sensors monitor the heating of recycled materials, with data fed into the PLC for high-temperature protection and alarms.
- Our self-developed thermal regeneration control system ensures safe, stable, and reliable operation. It also provides a user-friendly interface for seamless integration with the main equipment, enabling equipment control, real-time monitoring, and report printing.
System Software:
The control interface is user-friendly and offers real-time updates on equipment status, alarms, and fault indicators. Moreover, users can easily set high-temperature protection, adjust alarm settings, and modify key parameters directly through the computer. In addition, the control system supports both automatic and manual modes, giving users complete control over the mixing equipment.
Electrical Components:
We use high-quality electrical components from top international brands such as Schneider, Omron, and Siemens. Additionally, we design and build each electrical cabinet to meet international standards. This approach blocks external interference, ensuring the regeneration control system operates safely, reliably, and consistently.