Key components

These are the components of counter-flow asphalt plants.

Feed bins

These are the components responsible for the temporary storage and weighing of the aggregates.

They have an opening that is large enough to be refilled by a front loader without one aggregate contaminating the other, making the operation process easier and ensuring quality.

The aggregate weighing is done individually by using dynamic weighing with load cells, rotation sensors, and variable speed gearboxes. The weighing system is fully automated and operates with self-monitoring logic ensuring perfect weighing control of each of the components.

The modular project concept allows adding on to the number of bins and/or to use accessory components (e.g. cold mix production system) at any time with assembling agility and ease.

Dryer

The rotating cylinder type dryer with internal fins attached to it operates with a counter-flow of external mixture that brings proven advantages in quality and production capacity. It is the most efficient drying process for heating and drying the aggregates with the best use of energy, productivity, and economy of fuel. The heat is gradually applied to the aggregates and results in highly efficient thermal exchange.

The drum has an exclusive function of drying and heating the aggregates while the mixing process is the mixer's responsibility.

The fact that the counter-flow mixing process is external ensures a long life to the mix since the binding properties of the PAC are preserved. Only the aggregates, during the drying and heating process, are in contact with the flow of hot gases. The PAC, however, is a component that is susceptible to radiation and gases at high temperatures and therefore is injected only in the mixer, which is a component that is sealed closed.

Burner

This is the component that is responsible for generating energy for drying and heating the aggregates by the combustion of fuel oils (light and/or heavy) and/or gases (LPG and/or Natural Gas).

It has an ignition that is controlled by the operator at the control panel. A pilot light is lit to start the combustion process, but afterwards it is stabilized on its own. The air and fuel metering are precise, ensuring total use and maximum savings on fuel.

Because of its modern design, the burner can be easily accessed for cleaning, maintenance and regulating.

Mixer

This component is responsible for the homogenization between the aggregates and the PAC, which is one of the main factors related to the quality of the mix produced. The Pugmill type external mixer is a large metal box with moveable lids and is heated by the circulation of thermal oil that maintains the temperature of the mix during the process. There are also two other parallel shafts that turn in the opposite way with arms, fins, and internal protection built out of high resistant steel. It is powered directly by two gear motors that are synchronized by two reduction gearboxes.

The most important factors of equipment designed with a Pugmill type mixer are the quality of the material produced due to the strong mechanical action applied directly on the mix and the preservation of the binder's long life since it is injected in a controlled environment and not exposed to agents that can damage it.

The Pugmill's external weighing and mixing system allows the incorporation of fillers, fibers, polymers, or other agglutinating materials to the asphalt mix by means of a simple process.

The quality of the mix in external mixture continuous plants can be compared to those prepared by batch plants

Pre-collector of particulates®

The Pre-collector of particulates® has the function of a pre-filter, effectively collecting 80% of the particles when considering all sizes and 100% for particles larger than 200 microns. This makes the filtering elements last longer since the larger particles are the most abrasive and have a higher temperature than the gases.

The material collected in the pre-collector of particulates® is sent back directly into the mixer.

Bag filter

Ciber has developed an exclusive pleated bag filtering system in order to purify the exhaust gases from its plants and comply with the high global standards for environmental protection. Designed in the shape of a cartridge, the pleated bags have a filtering area that is five times greater than the traditional smooth bags, which makes it possible to build a portable plant that is still highly efficient in retaining the particles, offering high operational stability even during high production levels.

CIBER's bags filter on the surface (not allowing the fabric to become contaminated), which makes them completely washable. It is an option to wash them if needed, such as in the case of using contaminated fuel. Along with all these advantages, the pleated surface filtering bags facilitate the self-cleaning operation, consuming a lower quantity of compressed air as well as generating a lower load loss in the filter.

The material collected in the bag filter is sent back directly into the mixer

Main accessories

Tanks

CIBER tanks are used together with the asphalt plant and can be fixed or portable, having various capacities and configurations. There are eight models with heaters attached (MT – Master Tank) and two auxiliary models (ST - Storage Tanks) that can be assembled depending on each need. The components offer an indirect heating system for preserving the chemical properties of the PAC, direct temperature reading, self-monitoring and active safety systems, as well as different configurations for using special asphalts.

Fine aggregates feed bin

This is an external bin used for weighing other substrates such as filler (lime/cement), fibers, and/or coloring.

STA 30 and STA 40 High Capacity Storage Silos

These external silos are used to store temporarily the asphalt mix in order to maximize the logistic capacity of the project. They can be portable or stationary.