Asphalt Batch Mix Plant

“HIMALAYA” asphalt batch plants are specifically acclimatized to India’s normal aggregate conditions, input dust levels, moisture content in stones, average environmental standards, fuel availability and production variables. Therefore, our customers have absolutely no bad surprises.

Our plants reflect one of the most exhaustive plant systems available in the market. Standards configuration of our systems are perfectly matched to the capacity, production demands and site requirements for each model.

“HIMALAYA” -Batch mix asphalt plant is the most widespread type of asphalt plant in the world and their popularity lies in the fact that they guarantee top quality and maximum flexibility.

AGGREGATES DRYER WITH BURNER:

The dryer drum, with a series of flights inside, which have the function of lifting the virgin material and heating it through contact with the hot gas produced by a modulating type burner with maximum fuel combustion efficiency. A burner is mounted at the discharge end of the drum for higher heating efficiency by counter flow heating.
The heat of the flame inside the dryer is conveyed to the aggregates via thermal radiation, by conduction &convection due to close thorough contact of aggregates with hot gases produced by burning of fuel.
It is natural that combustion exhaust gases, fine dust and water vapor are produced inside the dryer, and these are then passed through a bag filter via primary dust collectors before being released into the atmosphere.

THE BAG FILTER:

Due to increasingly restrictive limits 150mg/Nm' for atmos- pheric emissions, together with new technologies for greater filter efficiency, problems related to environmental impact have now been greatly simplified.
Filler materials collected in the bottom hopper of RA type bag-filter with a number of fabric filter bags, then conveyed by a screw conveyor and bucket elevator into a surge hopper, ready to be weighed and re-fed into the mixer in the correct quantity.
The filler plays a fundamental role in regulating the asphalt adhesion and improving the bitumen binding to the aggregates. So, bag filter with proper filtering efficiency play major role in asphalt batch plant.

Batch Tower

Fully enclosed inclined linear vibrating screen with high quality vibrating screen cloths, contribute to top notch performance. The inclined linear vibrating screen is provided with duplex spring absorbers, and is powered with two numbers of six-pole maintenance free vibro motors. The free-floating design prevents any vibration from being transferred to the weighing scales. A wider platform with easy access eases the maintenance of the screen.
Highly reliable weighing system load cells and an easy calibration system makes the HBM series highly popular with site engineers and plant operators.
The 3D mixer unit is the heart of the HBM plants and has a large live zone, realizing a quick and even mixing of asphalt. The mixer unit is hot oil jacketed and supplied with a low- maintenance oil-bath type chain drive. The paddles, arms and tips are made of wear resistant high nickel hardened cast alloy steel. The reversible design of the paddle tips ensures a lower operating cost.

Cold Aggregate Bin Feeders

18 Years of experience in this industry units means design expertise or top performance even under the toughest of operating conditions. The Bins are all-welded and modular in construction, permitting easy addition of bins to meet growing needs. Steep bin walls and valley angles allow free flow of aggregates from the feeders minimizing hold-up of materials in the corners and bridging with sticky aggregates. The bins suppled with adjustable calibrated gate openings and variable speed feeder drives together offer a total proportional control, greater flexibility and accuracy of operations.

Control System

Fully computerized air-conditioned control cabin with onboard electrical power control console, distribution switch board, fully automatic process and sequence control are a standard on all HBM series plants.
User-friendly software on the computer with a parallel PLC main machine interface gives you total reliability and ensures top notch performance.

The control is equipped with function keys and numeric keys, and does not require skills for operation.
The operator can monitor the complete process control, motor status and pneumatic controls through the color CRT display.

SCADA features:

THERMIC OIL HEATER

The HBM series plants are supplied with hot oil jacketing on bitumen pipe line, asphalt pumps, bitumen weigh hopper section and Pug mill body; Opting for hot oil heating reduces asphalt pump binding, asphalt pipe line blocking, smoother bitumen weigh batcher and pug mill operations.
The Thermic oil heater is supplied with independent automatic control panel including oil temperature indicator controller, low level switch, low circulation pressure switch over temperature cut of thermostat burner operating circuits. Capacity range up to 500 000 kcal/hr

FEELER FEEDING AND STORAGE SOLLUTION

Himalaya offers a wide range (4-40 Tons) of foreign filler storage solutions. The filler from the silo is transported into the filler elevator on the batching tower, which then is weighed and mixed in the pug mill unit.
The filler silos can optionally be supplied with filler feeding bucket elevator to suit bagged filler feeding. As a option the filler silos are supplied with level indicators and process interlocks.

BETUMEN HEATING AND STORAGE SOLLUTION

The indirect heating tanks are supplied with a high efficient thermic oil heater. All tanks are supplied with auto thermostatic controls and level indicators.

HOT MIX STORAGE SILO

Himalaya offers a complete range of Hot mix storage solution 25 t to 80 t, to meet plant requirements. Hot mix storage silos can be offered with options to store different types of mix designs to meet varied site demands.
All HBM series are supplied with state of the art fully automatic controls together with automated safety and un-interrupted productivity. By opting for a hot mix silo customers gain large benefits. achieve increase efficiencies through longer continuous production runs. Fuel savings - thanks to the uninterrupted and constant dryer drum burner operations. Helps cater to clients with different mix design requirements. Reduce the number of transporting trucks.

Technical Specification

Main plant

		HBM 1000	HBM 1200	HBM 1500	HBM 2000	HBM
Plant capacity @ 3%	moisture content	80 tph	100 tph	128 tph	160 tph	2500 200 tph
Cold Feed Bins	No. of Feeders*/Total Cap	4/25m3	4/31.25m3	4/37.5 m³	4/43.75m3	5/46.50m2
Charging Conveyor	Capacity	100 tph	120 tph	140 tph	180 tph	220 tph
Dryer Drum	Diameter X Lenth	1.8mx7n	1.8mx7m	2.1mx8m	2.1 m x 8 m	2.3mx9m
	Drive Type		Saddle type chain drive		Four wheeled Friction	drive
Burner	Capacity	6.5MW	9 MW	11.8 MW	13.6 MW	17.3 MW
	Type		High pressure,	Fully automatic,	modulating
	Fuel*	Diesel	Diesel	Diesel	Diesel	Diesel
Pilution Control Unit	Dual Stage Type
Primary	Centrifugal Double Cyclone	1.4mx3m	1.4 m x 3 n	1.4mx3m	1.4 m x 3 m	1.4 m x 3 m
Secondary			Wet Dust	Type / Bag House	Filter
	Bag House Filter		Reverse air flow	type with emission	level 150 mg/Nm³
	Filtering Area	285 m²	325 m²	390m2	435 m²	590 m²
Hot elevator	Capacity	100 tph	120 tph	140 tph	180 tph	220 tph
Screening Unit	Type			Four deck vibrating
	Capacity	100 tph	120 tph	140 tph	180 tph	220 tph
Hot Aggregates Bin	Number of Bins	4	4	4	4	4
Aggregates Weigh Bin	Capacity	1000 kgs	1250 kgs	1500 kgs	2000 kgs	2500 kgs
Filler Weigh Bin	Capacity	200 kgs	200 kgs	300 kgs	300 kgs	400 kgs
Bitumen Weigh Bin	Capacity	150 kgs	150 kgs	225 kgs	225 kgs	300 kgs
Filler Feeding System	Filler Elevator Capacity	14 tph	14 tph	21 tph	21 tph	21 tph
	Filler storage Bin Capacity	0.4 m³	0.4 m³	0.6m3	0.6m3	0.6m3
Asphalt Feeding Pump	Capacity	240 lpm	240 lpm	450 lpm	450 lpm	450 lpm
Asphalt Spray Pump	Capacity	460lpm	460 lpm	800 lpm	1000 lpm	1000 lpm
Mixing Unit	Type		Twin shaft	hot oil jacketed	pugmill unit
	Capacity	1000 kg/batch*	1250 kg/ batch*	1600 kg / batch*	2000 kg / batch*	2500 kg/batch*
Cycle Time		45 Secs.	45 Secs.	45 Secs.	45 Secs.	45 Secs.
Control Panel	Type		Fully	computerized with manual	over-ride

Accessories

Filler Silo	Capacity	10 / 15 / 25 / 40 tons
Bitumen Tanks	Capacity	15 / 25 / 30 / 50 tons
Heating Type	Direct / Hot Oil heating type
Hot Oil Heater	Type	Normal Pressure horizontal tubular boiler with oil fired burner
	Capacity	3/4/5 Lac Kcal / hr.
Hot Mix Storage Silo	Capacity	25 / 50/25×2/ 80 tons