Fixed Asphalt Mixing Plant

Product Introduction: What is a Fixed Asphalt Mixing Plant

A fixed asphalt mixing plant (also known as a stationary asphalt batching plant or batch-type asphalt mixture mixing complete equipment) is a large-scale core production facility for pavement engineering. It is permanently installed and integrates the entire process flow: cold aggregate screening and drying, precise asphalt metering, mineral powder feeding, forced batch mixing, finished product insulation and storage, as well as environmental protection dust removal and purification.

The whole equipment is fixedly installed on a steel structure foundation with a permanent reinforced concrete base, which cannot be moved or transferred as a whole. It is specially used for large-scale and continuous production of hot-mix asphalt mixture, modified asphalt mixture and recycled asphalt mixture. As the mainstream standardized professional production equipment for high-grade highways, urban arterial roads and asphalt mixing commercial concrete stations, it is also the core raw material production source equipment for asphalt pavement construction.

Product Selection: When to Choose a Fixed Plant and When to Choose a Mobile Plant

Applicable Scenarios of Fixed Asphalt Mixing Plant

1. Long-term fixed-operation asphalt mixing commercial concrete stations and self-owned asphalt material yards, supplying and selling asphalt mixture stably all year round.
2. High-grade and high-standard pavement construction projects such as expressways, first-class national and provincial highways, airport runways and large urban arterial roads.
3. Projects with large production capacity, long-term continuous production demand, construction period over 1 year and year-round operation.
4. Large-scale projects requiring large-batch asphalt recycling production, high-precision proportioning and stable high-capacity output.
5. Projects with sufficient site, complete formalities, long-term fixed plant construction and no consideration of later relocation.

Applicable Scenarios of Mobile Asphalt Mixing Plant

1. Multi-section turnover, short-term construction projects, road maintenance, emergency repair and rural highway short-line projects.
2. Remote field construction sites, sites with limited space and temporary construction sites where permanent concrete foundations cannot be built.
3. Small and medium-sized hourly production capacity (60-160t/h), requiring disassembly and transfer to the next construction site after project completion.
4. Projects with short-term investment, lightweight input and no intention to bear the infrastructure cost of permanent stations.

Product Advantages of Fixed Asphalt Mixing Plant

1. Ultra-large and stable high production capacity, 24-hour uninterrupted production
   Heavy steel structure ensures high rigidity and stability, supporting an ultra-large hourly production capacity of 120~400t/h. It can operate at full load continuously 24 hours a day all year round, fully meeting the large-batch supply demand of large-scale expressways and commercial concrete stations, with a much lower failure rate during long-term operation than mobile plants.
2. Higher proportioning precision and more stable discharge quality
   Equipped with independent heavy-duty metering system, high-precision weighing sensors and double-shaft forced heavy-duty mixing host, it achieves top-tier metering precision for aggregates, asphalt and mineral powder, with closed-loop control of temperature and proportioning throughout the process, fully meeting the national standards for expressway and high-grade pavement construction.
3. Great potential for environmental protection upgrade, easy to pass environmental acceptance
   Independent large-scale pulse bag dust removal, flue gas desulfurization and denitrification, and oil fume purification system realize fully enclosed ultra-low emission. Dust, flue gas and noise meet standards in all aspects, adapting to the requirements of permanent plant construction in urban areas and areas with strict environmental inspections.
4. Strong compatibility for regeneration transformation
   It can be seamlessly equipped with asphalt thermal regeneration and warm regeneration systems, adding large quantities of old milled asphalt materials for cyclic production, greatly reducing raw material costs, which is the standard upgrade direction for formal asphalt mixing plants.
5. Stable and durable structure, lower full-life-cycle cost
   Heavy steel structure platform and large wear-resistant components ensure long service life, with a complete daily maintenance system. The unit discharge cost for long-term continuous production is much lower than that of mobile plants.
6. High degree of automation and intelligence
   Standard equipped with fully automatic PLC central control system, cloud remote monitoring, unmanned production and automatic data retention and traceability, facilitating station qualification acceptance, construction data filing and refined production management.

Product Usage and Scope of Application

Core Usage

Fixed asphalt mixing plant professionally produces hot-mix asphalt concrete mixture, modified asphalt mixture, colored asphalt mixture, warm-mix asphalt mixture and plant-mix thermal recycled asphalt mixture in batches. It is the only qualified raw material production equipment for the construction of upper, middle and lower layers of asphalt pavement, directly determining the strength, flatness, rutting resistance and service life of the road pavement.

Scope of Application

1. Highway engineering: New construction/reconstruction and expansion of expressways, first-class/second-class national and provincial trunk highways, mountainous high-grade highways.
2. Municipal engineering: Urban arterial roads, expressways, urban ring roads, municipal pipeline network overhaul and renovation, standardized construction of urban asphalt pavements.
3. Transportation hub engineering: Airport runway/taxiway, port heavy-duty pavement, logistics park heavy-duty asphalt pavement.
4. Commercial concrete operation projects: Formal licensed asphalt mixing plants, asphalt mixture external sales and supply bases.
5. Large-scale infrastructure engineering: Large-area asphalt floor projects such as industrial parks, large factory areas, stadiums, squares and parking lots.
6. Recycling projects: Formal production bases for recycling and resource utilization of old pavement milled materials.

Components of Fixed Asphalt Mixing Plant

1. Cold aggregate batching and screening system: Multi-bin independent cold hoppers, variable-frequency belt feeders, linear vibrating screens for graded storage and precise feeding of sand and gravel aggregates of different specifications.
2. Drying and heating drum system: Heavy-duty horizontal counter-flow drying drum and high-power burner for aggregate dehumidification and constant temperature uniform heating.
3. Hot aggregate lifting, screening and storage system: Heavy-duty bucket-type hot aggregate elevator, multi-layer vibrating hot screen, divided-bin hot aggregate storage bin and hot aggregate dynamic weighing and metering system.
4. Asphalt storage and supply system: Large vertical asphalt insulation storage tank, heat-conducting oil constant temperature heating system, high-precision volumetric metering pump for asphalt.
5. Mineral powder supply and storage system: Vertical mineral powder bin, screw conveyor, independent weighing and metering system for mineral powder.
6. Heavy-duty double-shaft forced mixing host: Fixed thickened wear-resistant special mixing host for asphalt, realizing high-speed uniform forced mixing of aggregates, asphalt and mineral powder.
7. Finished product insulation storage bin: Large vertical insulation finished bin for constant temperature storage of finished asphalt materials to avoid scrapping due to temperature drop.
8. Full-process environmental protection dust removal system: Large pulse bag dust collector, air duct negative pressure dust removal, oil fume and flue gas purification system.
9. Fully automatic PLC intelligent central control system: Independent operating console, electrical control cabinet, temperature monitoring, proportioning control and data recording and traceability system.

Technical Parameters of Fixed Asphalt Mixing Plant

Working Process of Fixed Asphalt Mixing Plant

Full-automatic batch-type closed-loop assembly line operation, standard production process of fixed plant:

1. Cold material graded batching: Loader sends sand and gravel aggregates of different particle sizes into corresponding cold bins, and the central control system controls variable-frequency belts to convey aggregates quantitatively and gradedly according to the construction formula.
2. Screening, impurity removal and conveying: Cold aggregates are filtered for impurities and graded screened by linear vibrating screen, then conveyed to counter-flow drying drum at a constant speed.
3. Drying, heating and dehumidification: High-temperature hot air conducts counter-flow heat exchange in the drum to completely evaporate aggregate moisture and heat uniformly to the set process temperature.
4. Hot aggregate lifting and secondary screening: Heated hot aggregates are sent to multi-layer vibrating hot screen by heavy-duty elevator, after secondary precise graded screening, stored in corresponding hot bins at constant temperature.
5. Synchronous precise metering of multiple materials: Hot aggregates, mineral powder and asphalt are independently and dynamically weighed and metered with high precision according to the construction mix ratio.
6. Forced batch uniform mixing: All raw materials are put into the heavy-duty double-shaft mixing host synchronously, and stirred at high speed for a set time to produce qualified hot-mix asphalt mixture.
7. Finished product insulation storage and unloading: Mixed finished asphalt materials are sent to vertical insulation finished bin for constant temperature storage, and unloaded to dump trucks quantitatively as required.
8. Full-process environmental protection purification: Dust and flue gas generated by drum, host and bins during production are all sucked into bag dust collector for purification under negative pressure and discharged up to standard.

Precautions for Operation of Fixed Asphalt Mixing Plant

Plant Construction & Pre-start Inspection

1. The equipment is permanently fixed. Before starting, check that the steel structure platform and anchor bolts are all firmly fastened, and the foundation has no settlement or looseness.
2. Preheat the asphalt storage tank, heat-conducting oil system and asphalt pipeline in advance, and check that the burner, lubricating oil of mixing host and hydraulic system are normal.
3. Calibrate all weighing and temperature sensors, and check that dust removal bags and seals are intact without damage.
4. No-load trial operation of the whole machine to confirm that the elevator, drum, mixing host and conveying mechanism have no jamming, abnormal noise or deviation.

Precautions for Production and Operation

1. Strictly set production parameters according to the design institute’s construction ratio. It is strictly prohibited to change asphalt dosage and aggregate gradation without permission; monitor the discharge temperature in real time, and stop the machine immediately for troubleshooting if the temperature is abnormal.
2. The burner shall strictly follow the process of preheating → small fire heating → large fire stable combustion. It is strictly prohibited to directly burn the cold drum with large fire to prevent drum deformation and cracking.
3. It is strictly prohibited to open the access doors of mixing host, drum and dust removal system during equipment operation, and no limbs or tools shall be extended into rotating components.
4. It is strictly prohibited to feed wet aggregates with moisture to prevent drum deflagration, unqualified water damage of asphalt mixture and equipment damage.
5. Asphalt is flammable and explosive at high temperature. Open fire is strictly prohibited in the whole station area. Complete fire-fighting equipment shall be equipped. Stop the machine immediately for cooling and pressure relief if asphalt pipeline leaks.
6. For 24-hour continuous production, regularly inspect equipment bearings, temperature, vibration and abnormal noise, and keep operation records.

Precautions for Shutdown Maintenance & Long-term Deactivation

1. Normal shutdown process: stop feeding → empty all residual materials in drum, host and pipeline → turn off burner → delay cooling of dust removal fan → turn off heat-conducting oil system → turn off main power supply. Emergency shutdown with materials is strictly prohibited.
2. Thoroughly clean the mixing host and asphalt pipeline every day after shutdown to prevent asphalt from cooling and solidifying to block the equipment.
3. Regularly calibrate the metering system, check steel structure welds, anchor bolts, dust removal bags and wear parts every month.
4. For long-term shutdown in winter, empty the medium in asphalt pipeline and heat-conducting oil pipeline, and take anti-freezing and insulation measures.
5. Operators must hold certificates to work. The fixed plant station shall establish a complete safety operation procedure and production account management system. Non-professionals are prohibited from operating the central control system.

Price and Customization

Price Influencing Factors

• Model and production capacity: the larger the production capacity, the higher the price;
• Configuration level: different prices for basic configuration, standard configuration and high-end configuration (accessory brand, environmental protection system, control system function);
• Customization demand: customized according to user’s site, production capacity and concrete demand, price adjusted according to customization content;
• Other factors: transportation distance, installation and commissioning demand, after-sales value-added services, etc., will affect the final quotation.

Quotation Service

Free on-site survey, free scheme design and free quotation service are provided. Users can contact the docking staff, provide construction scenario, production capacity demand and other information to obtain an accurate quotation.

Customization Service

• Production capacity customization: adjust equipment model according to users’ actual production capacity demand;
• Configuration customization: adjust the number and capacity of bins, conveyor length, metering precision, environmental protection system configuration and control system functions to adapt to site and material characteristics;
• Scenario customization: customize exclusive production schemes for different industries and construction environments;
• Customization guarantee: customized equipment also enjoys a full set of after-sales guarantee, including free installation and commissioning, free training and warranty service to ensure stable operation of customized equipment.

Related Products

Mobile Asphalt Mixing Plant (Special for Turnover Repair and Short-term Maintenance Projects)