ROADBUILDING

ROADBUILDING
Asphalt Plant | Specifications
Production of up to 140 ton/h
Counter-Flow Drying
Rotational External Mixer
MAGNUM
Asphalt Plant
Series
MAGNUM
Asphalt Plant
Series
TEREX Roadbuilding Latin America, committed to quality and innovation,
has been in the market for 45 years. The company is allied with TEREX
Roadbuilding, one of the world’s largest manufacturers of paving and
roadbuilding equipment, and with TEREX, one of the top three largest
manufacturers of construction equipment in the world. Forming part of
this international structure, which brings together no less than 38
companies in various countries, TEREX Roadbuilding Latin America
stands out as a solid, dynamic firm with a tradition in the market.
Therefore, the support from the TEREX Group head office is fundamental.
After all, the vast experience and the fantastic interaction among the
members of the conglomerate are essential to the greater capability of
the group, the development of increasingly more creative, intelligent and
efficient solutions as well as the progressive increase of profitability in
the roadbuilding field.
COUNTER-FLOW DRYING SYSTEM WITH
EXCLUSIVE VENTURI FILTER:
perfect and economical drying
ROTATIONAL EXTERNAL MIXER:
superb mechanical energy for mixing
INTELLIGENT TANK USAGE:
highest quality asphalt mixture
STATE-OF-THE-ART DESIGNING
RESOURCES:
exceeding expectations and reaching better
results
AUTOMATION:
full control of processes
PORTABILITY:
agility and practicality
To sum up, the integration of the TEREX Corporation is complete, in the
administrative and financial areas as well as in the strategic aspects, and
makes part of the objectives set by the group for the coming years. What
does this mean? Significant investments and sustained growth focused
on the clients and their satisfaction. Thus, the goal of TEREX Roadbuilding
Latin America is to guarantee excellence in products and services with
quick and efficient responses to the needs of the clients.
Always anticipating market needs, TEREX Roadbuilding revolutionizes
what was already considered to be the most advanced in its category.
The Magnum Series Asphalt Plant is even more complete, modern, and
efficient. Innovative and deep changes have been implemented in order
to better meet the needs of new customers and expand the equipment's
use in the field. This demonstrates once again TEREX's commitment to
excellence in the products and services it offers.
The Magnum Series Counter-flow Plant was developed with the most
modern computer-assisted tools and mathematical modeling of turbulent
flows in order to offer real and significant differences in the preparation
of asphalt mixtures and to increase its production capacity to up to 140
tons per hour.
Completely mobile, it saves enormously on setup time because it only
needs 2 days to be ready for startup. This makes it more practical and
streamlined where it matters—at the job site. Its operation has been
completely automated, which gives the operator absolute control over
all of the processes and ensures that the production of asphalt mix will
be of extremely high quality.
In order to continue presenting the best product and to keep up a longlasting relationship with the consumer, each component on the Magnum
Series was analyzed in every minute detail so that it would boost the
productivity rate, make it more practical, as well as make the entire plant
and its final product more effective. The intelligent combination of new
features with proven items is what gave the conditions for the creation
of its exclusive system, whether mixing, drying, filtering, or recycling...and
many other resources. So, by improving the performance of the processes,
the quality of the mixture, the travel system, and saving on fuel, it is
possible to boost the profitability of your road building projects.
Take a closer look at the details and main new characteristics of the
Magnum Series Asphalt Plant components.
3
Magnum Series | Specifications
AGGREGATES FEED BIN
Spacious top openings - makes it possible to use large loaders to fill the bins.
Strong inclination of the bin walls - facilitates the flow of materials.
• Individual capacity of the feed bins - 5.5 m3.
• Side-by-side quadruple feed bin.
• Loading is only from one side.
• Only 1.5 m-high ramp - reduces the amount of preparation work to do (retaining walls).
• Safety rings - installed on the rollers, they keep the belt
from getting misaligned.
• New floodgate on the feed bins - mechanical actuation
set. Easy access. Adjustment without effort but with great
precision.
•
•
2900
3435
3795
4275
1500
V-shaped feeding belts - ensure a greater sample of material
going across the load cell and greater precision for the
weighing system.
• Rollers with shielded bearings - positioned on the inside
of the roller, they give greater durability to the unit.
• Feed bins with a loading height of only 3.8 meters on
the highest side and extensions located on the other feed
bins. Not only does this increase the volume of these feed
bins, but this also makes them easier to load because they
serve as an excellent referential for the operator. It is also
possible to support the scoop on the extensions because
they were built with a highly resistant material. All of these
factors together result in a perfect loading process that is
free from contaminants from the other bins.
• Rollers assembled with a 2-degree inclination - causes
the system to self-center itself.
•
2º
vibrating sieve
High-performance vibrators - other than vibration, they also
exert a strong mechanical action on the aggregates by means of
a plate connected directly to the vibrator.
• The basic machine is equipped with two vibrators - positioned
on the feed bins that operate with more fine materials.
• New vibrating sieve - has two vibrators. The set is mounted
on shock absorbers. Effective separation of materials of a size
that is not within the range for the recipe specified.
•
4
Magnum Series | Specifications
Simple maintenance - the design of the feed bins makes it possible to change their pads without
the need to take apart the feed bin frame.
• Flow sensors - instantly detect the lack of any material.
• Level sensors (optional) - extremely functional because they help the operator control the loading
of the feed bins, always keeping them at an ideal level.
• Humidity sensors (optional) - instantaneously check the humidity of the aggregates, which ensures
greater precision to the individual weighing system and higher quality to the asphalt mix.
• Conveyor belt - dumps the aggregates directly on the internal part of the dryer drum.
• Scrapper - positioned on the internal part of the dryer, it makes sure that all heavy materials actually
enter the dryer.
•
COUNTER-FLOW DRYER
The drying systems are fundamental for the perfect operation of an asphalt plant.
For this reason, the drying system of the Magnum Series Counter-flow Plant was
designed together with TEREX Roadbuilding, a worldwide leader in the
manufacturing of asphalt plants. The most sophisticated resources were used
in computer technology and mathematical modeling of turbulent flows and of
heat and mass transference in order to maximize the efficiency of the drying
process and save on fuel.
The initial section, designed with a bigger diameter than the rest of the dryer's
body, reproduces the Venturi effect, decelerating the gases, which keeps a
significant percentage of the larger particles from being sucked into the exhaust
system. This in turn reduces the workload of the bag filter and the filtering area
needed and thus increasing the durability of the filtering elements.
The dryer is driven by gear motors, which eliminates using chains.
drive system with gear motor
High drying efficiency and maximum fuel savings:
The dryer's dimension, 2.3 m in diameter at the largest section and 1.8 m in the smallest and a
length of 6600 mm, give it a superb drying volume.
• The different formats of internal fins, designed with the help of state-of-the-art computer tools,
maximize the heat exchanged between the aggregates and the flame.
• The perfect distribution of the different fins on the dryer optimizes its efficiency. An example of
this is the combustion zone where the fins are designed and distributed in such a way as to keep
the material from reaching the flame. This increases the thermal performance of the unit and reduces
the emission of toxic gases and the contamination of the aggregates with fuel that is not burned.
• Bolted fins in the dryer (optional) - makes it possible to obtain a better adjustment for any situation.
Superb drying performance and therefore greater fuel savings.
• Fins made out of USI AR 400 steel (optional) - the utilization of very hard steel to make the fins
has the purpose of extending their durability, reducing maintenance costs, and increasing the
equipment's productivity.
•
5
Magnum Series | Specifications
BURNER
The CF 04 burner has a dual spraying system designed with a gear pump and compressed air. This
ensures a perfect spraying of the fuel and consequently a better combustion performance.
Fuel temperature regulator: TEREX Roadbuilding offers the temperature regulator as a standard item
in its plants in order to always have an effective combustion in the preparation of the asphalt mix. This
regulator makes sure that the fuel is at an ideal temperature for combustion and therefore lowers waste
and improves the thermal energy yield. The temperature regulator also makes it possible to store the
fuel at a lower temperature and this way manage it better while it is in the holding tank. Significant energy
is saved when storing the fuel at a lower temperature.
• Hauck Burner (optional): Known worldwide as one of the largest
and best manufacturers of burners, Hauck is now one more
option of quality offered in the Magnum Series. The flame on
the Hauck burners can be adjusted perfectly, allowing the burner
to adapt to all working conditions, reducing fuel consumption,
and improving the plant's drying performance. Work can be
done on low flame and this avoids wasting material in the
beginning of production, which is very common with plants
equipped with other burners.
•
Hauck burner
CF 04 burner
TEREX Roadbuilding has given much thought to all of the factors that influence the final quality of the
asphalt mixture. For this reason it offers a system designed with slit fins that have a strong mechanical
mixing action and a unique system for adding the fine aggregates.
• Fins with teeth: The exclusive system of fins with teeth makes it so that the material stays removed
from the bottom part of the rotational external mixer, which receives an elevated number of strong paddle
strokes resulting in great mechanical energy for the mixing process and consequently a homogeneous
asphalt mixture of the highest quality.
• Bolted fins in the dryer - possibility of adjusting the fins, allowing the customer to control with perfection
the variables of time and mechanical energy of the mix, which results in a better mix quality and higher
level of homogeneity under any situation.
• Fins made out of USI AR 400 steel (optional) - the utilization of very hard steel to make the fins has
the purpose of extending their durability, reducing maintenance costs, and increasing the equipment's
productivity.
• Mixer bottom is coated with USI AR 400 steel (optional) - the utilization of very hard steel to coat
the mixer's bottom has the purpose of extending its durability, reducing maintenance costs, and increasing
the equipment's productivity.
• Dosing system for the fine aggregates:
The mixing zone is divided into two parts. The first is used to mix the binding agent mixture with
the larger size aggregates and the end section is used to dose the finer aggregates.
The dosage of the fine aggregates is done all along the entire final section so that it is not
concentrated on a single mixing area.
doorway for adding fibers/polymers
6
This dosing system makes it possible to treat the
different materials used in the mixing process
according to their properties. This ensures that the
larger-sized aggregates are perfectly coated by the
binding agent in the right thickness. Only after this
are the fine aggregates added and mixed in with
greater ease with the asphalt binding agent. All
these factors combined contribute to an effective
production of a top quality asphalt mixture.
Because of the way the rotational external mixer
was designed, together with its process, it has the
following advantages:
- Low maintenance
- Energy-saving
- Self-cleaning mixing zone
mixer's coating
ROTATIONAL EXTERNAL MIXER
Magnum Series | Specifications
HOT RECYCLING
The recycling of materials is becoming continually more important, especially for its economic and
ecological aspects. It helps to conserve the environment by using less virgin mineral aggregates and
it is extremely economical because it reclaims the existing elements from the road itself.
Equipped with a spout for adding the recycled materials and with an exclusive external ring for
heating, the Magnum Series Asphalt Plants can process them up to 40%.
ASPHALT ELEVATOR DRAG MIXER
Concern with quality should not cease after the mixing process. For this reason TEREX Roadbuilding
developed the Drag Mixer system, a retractable elevator that keeps the asphalt mix from segregating
in the prepared mix elevator. This is a very common problem with redler-type elevators with conventional
blades because their smooth shape can cause segregation.
The Drag Mixer system has fins with teeth distributed in such a way that they cause a non-linear
movement of the mix, while still keeping its superb homogeneous level.
• Driven by a gear motor.
• The fact that it is connected to the mobile and retractable chassis makes it easier to transport the plant.
Its positioning to carry out tasks is done automatically. Because
the plant is equipped with an electrically driven hydraulic unit,
neither physical force nor auxiliary equipment is needed.
• Highly resistant chain and blades.
• The pneumatic opening of the floodgate to the silo is controlled
by a PLC.
• The wear plates are made out of cast iron that is highly resistant
to abrasion.
• Bottom of the elevator made out of AR 400 steel (optional) the utilization of very hard steel for making the bottom of the
elevator has the purpose of extending its durability, reducing
maintenance costs, and increasing the equipment's productivity.
• Side of the elevator coated with AR 400 steel (optional) - the
utilization of very hard steel for coating the side of the elevator
internal detail
has the purpose of extending its durability, reducing maintenance
costs, and increasing the equipment's productivity.
•
coating of the dryer's outflow chute
7
Magnum Series | Specifications
BAG FILTER
The TEREX Roadbuilding bag filters were produced under close cooperation with TEREX Corporation
with the objective of making them a global product. Sophisticated computational resources and
modern mathematical modeling tools of turbulent flows were used in order to reach the best operational
parameters that ensure the filtering system's perfect performance. The result is filters that reach
high levels of efficiency with emission levels of particles lower than 50 mg/Nm3 and therefore meet
up to the most strict environmental standards.
• Low ascending speed:
- Ensures the effective cleaning of the bags by the air
pulse jets.
- Keeps the bag filter from holding back the plant's
production.
• Uniform distribution of the filtering load throughout all
of the bags:
- Longer durability of the filtering elements.
- More effective filtering process.
• Minimization of re-circulation and high-speed points.
• Ample filtering area.
• Conventional polyester bags (standard) or Nomex
(optional).
• Pleated bags (optional).
entrance of cold air into the bag filter (Damper)
Control system for the bag filter
Automatic control of the temperature and exhaust gas flow.
The control panel can be independent, which makes it possible to install it on older plants as well
as a manual operation.
• Designed to operate at a broad range of temperatures, making the filter's operation safer.
• Automatic control of the burner.
• Longer durability of the filtering elements.
•
•
The plant is equipped with an electrically driven hydraulic unit. Therefore, the positioning of the
retractable filter chimney is automatic, so neither physical force nor auxiliary equipment is needed.
THE GASES AT THE BAG FILTER ENTRANCE
SHOULD BE AT A HIGHLY SATURATED VAPOR
STATE IN ORDER TO AVOID CONDENSATION
INSIDE THE FILTER AND CONSEQUENTLY
R E D U C E I T S F I LT E R I N G C A PA C I T Y.
8
Magnum Series | Specifications
flexible piping
INTELLIGENT TANK USAGE
P2
V2
V7
V4
V9
V8
maintenance
asphalt
temperature
regulator
fuel
temperature
regulator
maintenance
P4
boiler
V1
V5
V10
P1
pressure
V3
V6
P1A
P5
line 1”
return
P2A
asphalt
P3
asphalt
P3A
fuel
Electronic managerial system of temperatures and thermal oil pipe flow in a set of tank units for
asphalt plants.
• Asphalt temperature regulator: the utilization of this equipment ensures two important gains for
the asphalt plant process:
- It makes it possible for the binding agent to be sprayed on the aggregates at an ideal temperature,
controlled by the plant's PLC, that in turn ensures that
it has the ideal viscosity to make it easy to mix in with
the aggregates.
- It makes it possible for the binding agent to be stored
at lower temperatures, which reduces considerably the
evaporation of its lighter fractions and preserves its
viscoelastic properties. Consequently, it contributes so
that the pavement has a longer life. The reduction of
the storage temperature also lowers the costs with fuel
for keeping the temperature of the storage system higher.
V - solenoid
valve
P - temperature
sensor
line 2”
flow example
ASPHALT SILOS
Basic machine equipped with Drag Mixer elevator and 1 m3
silo.
• Silo for weighing the asphalt mixture - this silo is located
after the basic asphalt silo and connected to four load cells
that weigh the product once it is ready and before it is loaded
on to the dump trucks. This option also allows the loaded
mixture ticket to be printed if the customer purchases a
printer for this purpose. It can be adapted to any one of the
different silo models.
•
10 m3 mobile self-erecting silo
Asphalt Silo Options:
• Elevator with 10 m3 fixed and mobile self-erecting silo
- Silo is made out of SAE 1020 4.75 mm-thick sheet
metal. The discharge floodgates are pneumatically activated by two cylinders. Its
framework is designed with an I-beam which makes it possible for trucks to go under
it without the need of lower the flooring. The access stairs have guardrails.
• Elevator with 25 m3 fixed and mobile self-erecting silo
• Elevator with 50 m3 fixed silo
- Made out of SAE 1020 4.75 mm-thick sheet metal that is thermally coated.
The discharge floodgates are pneumatically actuated by two cylinders and are thermally
coated. Assembled on an I-Beam framework with four support feet, which makes it
possible for trucks to go under it without the need to lower the flooring. The access
stairs have guardrails.
• All of the silos are integrated with the Drag Mixer-type hot mix elevator, is completely
closed, and the bottom has extra wear plates. It has an overflow chute actuated by
two pneumatic cylinders and designed with a by-pass duct.
• The anti-segregation pre-silo has an automatic unloading system and is pneumatically
actuated, coming with a lubricator and separator on the compressed-air line.
25 m3 mobile self-erecting silo
Fixed silo 10 m3
Moveable silo 10 m3
Moveable silo 25 m3
Fixed silo 25 m3
10 / 353
10 / 353
25 / 882
25 / 882
50 / 1765
3.500 / 11,50
3.500 / 11,50
3.740 / 12,27
3.740 / 12,27
3.740 / 12,27
Width (mm/ft)
2.300 / 7,54
3.200 / 10,50
3.200 / 10,50
3.100 / 10,17
3.100 / 10,17
Height (mm/ft)
7.600 / 24,93
7.600 / 24,93
10.500 / 34,44
7.630 / 25
11.250 / 39,90
Weight (kg/lb)
2.500 / 5512
14.000 / 30.865
22.500 / 49.604
6.800 / 14.992
8.500 / 18.740
Capacity (m3 / ft3)
Length (mm/ft)
Fixed silo 50 m3
9
Magnum Series | Specifications
CONTROL CABIN
TEREX Roadbuilding's broad experience in the manufacturing of highly portable asphalt plants was
the starting place for several of the decisions for the project that guided the development of the
Magnum Series Plant.
One of these configurations is concerning the position of the control cabin. Experience shows that
the location of the cabin not only gives a complete view of the truck loading area but also should
be as far as possible from the feed bins of the aggregates
to stay clear of an area with a lot of dust and possible
spills of material due to an error on the part of the loading
tractor operator.
• Positioned strategically away from the feed bins
• Plenty of space for the operator
• Comfortable working environment
• Excellent seal
• LCD monitor
• DELL Computer
• Air-conditioned
• Good visibility
• Integrated control panel
• Electric power switch panel is separate - more space
and greater maintenance ease
Cab mounted on a semi-trailer with a generator and 5,000-liter diesel
tank (optional) - facilitates the installation of the equipment in locations
where electric energy is not available.
• New Holland support - quality in all the details.
•
COMPACT PRE FILTER
Designed based on advanced computer resources and
mathematical modeling of turbulent flows, the Compact Pre
Filter easily catches the larger particles and retains
approximately 80% of this total. This increases considerably
the durability of the filtering elements.
10
The mathematical and computational modeling of turbulent
flows also made it possible for the dimensions of the Compact
Pre Filter to be extremely reduced when compared to the
older systems such as the cyclone. This reduces the amount
of dust abrasion on its surface and increases its durability.
Magnum Series | Specifications
AUTOMATION
Software
Diagnosis and eventual maintenance of the system is done remote, by telephone line.
Four video chambers control the plant's operations from the control cabin.
Example of configuration:
- 1 chamber for controlling the flame
- 1 for controlling the feed bins
- 1 for controlling the loading of the trucks
- 1 for the tank area
All visualization is done remotely, by telephone line.
• Management software developed in English, Spanish,
French, Italian, and Portuguese.
• System for automatically diagnosing failures via PLC.
• Catalog of parts and operational manual on CD.
• Backup of the hard drive on CD-ROM.
• Total control of the plant's operation by monitoring
software.
• Electrical ducts - all the electrical cables are protected
by electrical ducts, which increase their protection and
organization.
•
•
Control
The motors in the process can be started up manually or automatically,
which makes it possible to operate even if the PLC fails.
• Control over all motors and features by monitoring software.
• Automatic control of the temperature and exhaust gas flow.
• Material flow sensors in order to detect the lack of material in the feed bins.
• Feed bins equipped with level sensors.
• Feed bins equipped with humidity sensors.
• Automatic actuation of the vibrators.
• Automatic control of the burner.
• Automatic control of the temperature of the asphalt and fuel tanks by
means of sensors and actuators.
• Automatic control of the temperatures of the asphalt and fuel tanks in
the process - temperature regulators, sensors and actuators.
• Automatic control of the opening time of the floodgate for the storage silo.
• Automatic control of the flame - flame modulation.
•
overall layout of the plant
Hardware
Dedicated PLC with a Motorola processor, configured according to client's needs
and expandable.
• Electric power switch panel - easy access for maintenance and positioned in an
area of less dust.
• Electrical installation - completely assembled and tested before leaving the factory.
• The electrical hookup is independent for the plant and the tanks.
• The Danfoss frequency converters assembled on the electric power switch panel
are protected from dust and the effect of the outside weather conditions.
• LCD monitor.
• DELL Computer.
• Printer (optional).
•
11
Technical information table
Production (ton/h)
Output (basic machine) (kw / hp)
Feed bins
Individual capacity of the bins (m3 / ft3)
Diameter of the dryer (m / ft)
Length of the dryer (mm / ft)
Output of the CF-04 burner (standard config.) (kcal/h - btu/h)
Output of the Hauck burner (optional) (kcal/h - btu/h)
Travel width (mm / ft)
Travel height (mm / ft)
Total length (mm / ft)
MAGNUM 80
60 - 80
180 / 196
3
5,5 / 194,23
D1 = 1,8 (5,9ft) x D2 = 1,5 (4,2ft)
6.000 / 19,7
10.000.000 / 39,6 x 106
upon request
3.200 / 10,5
4.400 / 14,43
25.000 / 82
MAGNUM 140
100 - 140
280 / 305
4
5,5 / 194,23
D1 = 2,2 (7,21ft) x D2 = 1,8 (5,9ft)
6.600 / 21,65
10.000.000 / 39,6 x 106
12.420.000 / 49 x 106
3.200 / 10,5
4.400 / 14,43
25.000 / 82
• On both versions of the Magnum Series Asphalt Plant, the mixing system is the rotational external mixer.
• Type of bags: smooth polyester (standard machine) and smooth Nomex (optional). The quantity of the bags will be informed
upon request.
TEREX ROADBUILDING LATIN AMERICA
Rua Comendador Clemente Cifali, 530
Distrito Industrial Ritter | Cachoeirinha/RS | Brasil
Fone: +55 (51) 2125 6677
Fax: +55 (51) 470 6220
www.terexrb.com.br
All of the pictures, illustrations and specifications are based on current information on the date this publication was approved. TEREX Roadbuilding Latin America
reserves the right to change specifications and designs and eliminate components without previous notice. The performance data depends on the conditions
of the plant site. Some of the components mentioned are optional though not explicitly indicated as such in the text. May/2006