E 100P - Terex Products

TEREX E 100P ASPHALT PLANT
E 100P
ASPHALT PLANT
TEREX E 100P
PRODUCES UP TO 100 t/h (aggregates moisture up tp 5%):
greater productivity from a single chassis
COUNTERFLOW DRYING SYSTEM:
perfect and economical drying
EXTERNAL ROTATIONAL MIXER:
superb mechanical mixing energy
LOW OXYGEN LEVEL AND LOW TEMPERATURE MIXING:
longer working life for the HMAC
BAG FILTER WITH LARGE FILTRATION AREA:
in compliance with EPA emissions standards
EXTREMELY STRONG, HEAVY-DUTY MATERIALS:
minimizes maintenance downtime, increasing production time
AUTOMATION:
full control of processes
E 100P complete portability and optional special paint job
TEREX E 100P Asphalt Plant
Terex Roadbuilding Latin America, with its more than half-century
of experience on the market, in connection with the Terex
Roadbuilding division, for its part a subsidiary of the Terex Group
with its more than 60 companies - one of the three largest
suppliers of construction equipment in the world - is able to
ensure its robustness and has a deep understanding and
knowledge of the market, new and larger distributors, a diversified
product line and professionalization of its sales processes.
As further confirmation of its commitment to excellence for its
products and services, Terex Roadbuilding has developed the
Terex E 100P Asphalt Plant. The plant has four axles, with the
purpose of better distributing its weight, making it possible to
transport it on highways in countries where weight-per-axle
regulations are extremely strict.
Even the standard version of the E 100P has an efficient, precise
Hauck burner, known the world over as one of the best burners
on the market. The Hauck can precisely control its flame, which
makes it easy to adapt to many different working situations,
thereby reducing unnecessary fuel consumption, avoiding wasted
material at the beginning of production (very common in plants
equipped with other types of burners) and even improving the
plant's drying performance.
Terex Roadbuilding, which pays close attention to all the factors
that have an influence on final asphalt mix quality, is also focused
on guaranteeing the equipment's durability, which is why it offers
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heavy-duty steel coverings on all of the main surfaces in contact
with the mix. Areas such as the bottom of the mixer and conveyor,
as well as the drying and mixing fins, are all made out of SS 400
AR steel, leading to greater durability and reducing maintenance
downtimes, ensuring the equipment's higher productivity.
Terex Roadbuilding used sophisticated computation and modern
mathematic flow modeling tools to provide filters with high
efficiency rates and particulate emissions of less than 50 mg/Nm3,
in full compliance with the strictest environmental legislation.
The E100P also has a larger filter area (480 Nomex bag filters)
leading to perfect hot air circulation and better absorption of the
fine aggregates in the mixture at high production. Also demonstrating
Terex's concern for the environment and ecological awareness,
the plant is equipped with a floodgate for the addition of reclaimed
materials (RAP) and is able to process up to 40% old materials
from the road to replace virgin aggregates while still maintaining
the same high quality of the asphalt mix.
Additionally, the height of the plant's conveyor makes it possible
to load large volume dump trucks, without the need to lower
the floor.
Take a closer look at the details, main characteristics and
innovative features of the Terex E 100P Asphalt Plant's
components.
AGGREGATE FEED BIN
SINGLE CHASSIS PLANT:
• Side-by-side quadruple feed bin;
• Loading is only from one side;
• Spacious top openings - 3.8 m widths make it possible to use large loaders to
fill the bins;
• Individual capacity of the feed bins - 7 m3;
• 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 very strong material. All of these factors together result in a perfect loading process that
is free from contaminants between the bins;
• 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;
• 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 specified recipe.
DOUBLE CHASSIS PLANT:
Equipment divided into two different chassis
• Mobility which takes unity of drying, mixing and control into
consideration;
• Another chassis, also mobile, with the dosing unit;
• Four feed bins in a row (with the ability to extend to up to
six bins);
• Individual capacities of 7 m3;
• Bins with 3.1 m top openings;
• Choice of setup in a line or at a 90°.
• New floodgate on the feed bins - mechanical
activation set easy access. High-precision, effortless
adjustment;
• Steep Angle of the bin's side walls - facilitates the
flow of materials;
• Only 1.5m high ramp - reduces the amount of
preparation work (retaining walls);
• V-shaped feeding belts - ensure a greater sample
of material going across the load cell and greater
precision for the weighing system;
• Security rings - installed on the rollers to avoid
misalignment of the feeder belt;
• Rollers with shielded bearings - positioned on the
inside of the roller, these increase the unit's durability;
• Rollers assembled at a 2 degree angle - make
the system self-centering.
individual weighing system with a centered load cell
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• High-performance vibrators - in addition to vibrating, they also exert
a strong mechanical action on the aggregates via a plate connected directly
to the vibrator;
• Machine comes standard with two vibrators - positioned on the feed
bins that operate with finer materials. Optional: Vibrators on the other bins;
• Flow sensors - automatically detect a lack of material in the bin, without
intervention of the technician. Composed of a material feeler and an endstop key;
• Level sensors (optional) - extremely useful because they help the operator
control the loading of the feed bins, always keeping them at an ideal level.
• Scraper - positioned on the internal part of the dryer, it makes sure that
all heavy materials actually enter the dryer.
COUNTERFLOW DRYER
section 1
section 2
section 3
Terex plants have a counterflow drying system that maximizes their drying
efficiency and fuel economy.
The initial section, designed with a bigger diameter than the rest of the
dryer's body, produces 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, thereby increasing the durability of the
filtration elements.
section 1: larger diameter leads to the Venturi effect,
with greater drying volume
section 2: maximum heat exchange between aggregates
and flame
section 3: prevents the material from falling on the fire
The dryer is driven by gear motors,
which eliminates the use of belts.
HIGH DRYING EFFICIENCY AND MAXIMUM FUEL SAVINGS:
• The dryer's size, 2.20 m in diameter at the largest section and 1.8 m at the smallest
and with a 7.8 m length, give it a large drying volume;
• The different formats of internal fins, designed with the help of state-of-the-art
computer tools, maximize heat exchange between the aggregates and the flame.
Bolted fins in the dryer make it possible to obtain a better adjustment for any situation,
ensuring superb drying performance and therefore greater fuel economy;
• 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 unit's
thermal performance and reduces the emission of toxic gases and the contamination
of the aggregates by unburned fuel;
• Fins made out of SS 400 AR steel - the use of hardened steel for the fins extends
their working life, reducing maintenance costs and increasing the equipment's productivity.
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BURNER
Hauck, recognized worldwide as one of the biggest and best burner manufacturers in the world,
supplies the Starjet 4260 burners for Terex's E100P plants. The flame on the burners can be
adjusted perfectly, allowing them to adapt to all working conditions, reducing fuel consumption,
and improving the plant's drying performance.
The Starjet 4260 can work with a low flame and this avoids wasting material in the beginning
of production, which is very common with plants equipped with other burners.
The Hauck burner can burn different types of fuel such as: diesel, heavy oil, and ethanol:
The E 100P comes standard with a video camera for real-time viewing of the flame, in addition to
an ultra-violet sensor flame control system. An optional kit for burning gas in the burner is available.
Hauck burner
FUEL AND ASPHALT TEMPERATURE REGULATOR (RECTIFIER)
Fuel Temperature Regulator (Rectifier): By making sure that the fuel is at an ideal temperature
for combustion, the regulator therefore decreases waste, in so far as it improves use of the
thermal energy yield. The temperature regulator also makes it possible to store the fuel at lower
temperatures, in this way making better administration possible while it is in the holding tank.
Optional Asphalt Temperature Regulator (Rectifier): The use of this accessory makes it
possible for the binding agent to be sprayed on the aggregates at an ideal temperature,
controlled by the plant's PLC, which in turn ensures that it has the ideal viscosity for ease of
mixing with the aggregates. The binding agent can be stored at a lower temperature in the
storage tanks, significantly reducing the evaporation of its lighter portions and even more
importantly: it greatly reduces the effects of oxidation and aging of the asphalt.
Additionally, the use of fuel and asphalt temperature regulators makes it possible to
store heavy fuels and HMAC at lower temperatures, resulting in significant increases in fuel
economy for the thermal fluid heater.
Visual representation of the asphalt and fuel regulators
asphalt
regulator
fuel regulator
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EXTERNAL ROTATIONAL MIXER
The biggest advantages of using Terex asphalt plants are the results of the exchange of
experiences between Terex Roadbuilding Latin America and Terex Roadbuilding's main
offices in the United States. All factors which have an influence on the end quality of the
asphalt mix have been exhaustively taken into account. This is why the external rotational
mixer was designed with a toothed fin system that has a strong mechanical mixing action
and a unique system for adding the fine aggregates.
• Toothed fins - our exclusive toothed fin system keeps the material in the lower part
of the external rotational mixer where it receives an elevated number of strong paddle
strokes, lending greater mechanical energy to the mixing process and, consequentially,
a homogeneous asphalt mixture of excellent quality;
• Bolted fins in the dryer - possibility of adjusting the fins, allowing the customer to
perfectly control the variables of mix time and mechanical energy, resulting in a better mix
quality and a higher level of homogeneity under any situation;
The components, with their high durability and strength (covering of the mixer bottom
and fins in SS 400 AR steel), have been designed to achieve a longer working life,
reducing maintenance costs and increasing the equipment's productivity;
mixing chamber
• 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. 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.
mixer's coating
external rotational mixer - mixing zone divided into two parts
Because of the way the external rotational mixer was designed together with its process,
it has the following advantages:
• Low maintenance;
• Energy-saving;
• Self-cleaning mixing zone.
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internal view
MIXTURE CONVEYOR (DRAG MIXER)
The Terex E 100P has a large scale retractable conveyor (at a height of 3.9 m off the
ground) for working with large scale trucks and has a Drag Mixer system that prevents
the asphalt mixture from segregating during the loading process.
• The Drag Mixer system has heavy-duty steel toothed fins distributed in such a way (for
every two toothed fins, there is one dull fin) that they cause a non-linear movement of
the mix, while still keeping its superb level of homogeneity;
• Driven by a gearmotor;
• Connected to the mobile, retractable chassis, facilitating the
plant's transport. Preparing its placement for carrying out tasks is fast
and easy to adjust;
• Heavy-duty belts and fins;
• Bottom and sides of the conveyor made out of SS 400 AR steel - the
utilization of hardened steel for the bottom of the conveyor extends its durability,
reducing maintenance costs and increasing the equipment's productivity;
• Storage bin for 1 m3 of ready mix;
• The bin floodgate's pneumatic opening is controlled by a PLC;
• Optional asphalt mix weighing hopper.
ENVIRONMENTALLY AWARE PRODUCTIVITY - HOT RECLAIMING
Terex Roadbuilding is a pioneer in Latin America in hot reclaiming for asphalt
plants. Material recycling is becoming increasingly important, especially due
to its economic and ecological aspects. It helps to conserve the environment
by using less virgin mineral aggregates and it is extremely economical because
it reuses the old material already on the road. Equipped with a floodgate for
the addition of reclaimed materials and with an exclusive external heating
ring, the E 100P asphalt plants are designed to process up to 40% reclaimed
materials while still maintaining the same asphalt mixture quality. Ask about
the optional mobile recycling unit.
BAG FILTER
The E100P's automatic damper system
The Terex E 100P has an ample filtering area, equipped with 480 Nomex bags, which
ensures the minimization of recirculation and high-speed points. In this way, the plant
is able to ensure efficiency rates greater than 99.9%, with particulate emissions of
less than 50 mg/Nm3, in full compliance with the strictest environmental legislation.
The use of Nomex filters makes it possible to work with a much wider range of
temperatures, between 110° C and 210° C, without reducing the filtration elements'
working life.
The bag filters' safety system automatically and simultaneously blocks the asphalt
and fuel pumps if the temperature of the filters becomes too high.
Our exclusive automatically activated damping system makes absolute control of
fume temperature possible, keeping it stable at the bag filters, thereby ensuring the
system's efficiency and long life.
• Low ascending speed: ensures the effective cleaning of the bags by the air jet pulse,
which prevents the bag filter from bottlenecking production.
• Uniform distribution of the filtering load throughout all of the bags:
- longer working life for the units (bag filters)
- more effective filtration process
• Automatic control of the burner.
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CONTROL CABIN
Spacious and comfortable control cabin, ideally located and with excellent view.
The location of the cabin not only gives a complete view of the truck loading, it is also far away
from the aggregate feed bins, in this way avoiding a dust-filled area and possible spills of
material due to loading tractor operating errors. It also provides contact between the plant's
operator and the driver of the truck being loaded. The electric power switch panel is
located outside the control cabin, thus leaving more free space and facilitating maintenance.
• Air-conditioned control cabin;
• Plenty of space for the operator;
• Comfortable operating post and environment;
• Excellent sealing system;
• 17" LCD monitor;
• DELL Computer;
• Ample view of the entire process;
• Panel for complete manual control in parallel control via PLC.
• Access window for delivering weighing ticket.
AUTOMATION AND CONTROL
• State of the art control system via PLC with Ethernet interface;
• Real time communication and operation;
• Monitoring software in English, Spanish and Portuguese;
• System for automatically diagnosing failures via PLC;
• Parts catalog and operating manual on CD;
• Backup of the hard drive on CD-ROM;
• Full control of the plant's operation via monitoring software;
• Complete control of the process and variables;
• Generates a wide variety of reports:
- production
- temperatures
- truck loads (issues tickets)
- alarms and events
manual control panel
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• The motors can be started up manually or automatically, which
makes it possible to operate even if the PLC fails;
• Control over all motors and devices via monitoring software;
• Monitoring of the temperatures of the fumes, filter, binding agent
and mixture through 06 temperature sensors: fumes (02), filter (02),
binding agent (1) and mixture (1);
• Material flow sensors in order to detect the lack of material in the
feed bins;
• Level sensors in the feed bins (optional);
• Automatic activation of the vibrators;
• Burner control - flame modulation via PLC;
• Automatic control of the fuel temperature regulator and optional
asphalt temperature regulator;
• Automatic control of the opening time of the floodgate for the
storage bin;
• Monitoring of the process' electrical variables.
OPTIONAL EQUIPMENT
FILLER FEED BIN
Terex Roadbuilding is constantly
paying attention to and responding
to client needs, and that is why
we have developed a 1 m3
capacity filler feed bin for two
applications: filling in voids in the
mixture or adhesiveness. Easy to
install with an additional assembly
kit, it serves a wide variety of
asphalt mixture traits.
FIBER FEED BIN
The 2 m3 fiber feed bin was designed to add any type of fiber to special asphalt
mixes in a controlled way.
Attached to the asphalt plant, it precisely measures the desired percentage of
fibers by way of a screw conveyor, activated by a gearmotor, which is controlled
by a frequency inverter connected to the Sistex control system.
In order to meet the needs of a wide variety of special mixes, like SMA (Stone
Matrix Asphalt) and PFL (Porous Friction Layer), the manner in which the fibers
are processed is just as important as how they are dosed:
- The fibers are usually supplied in the form of pallets that "open up" by way of
the mechanical energy of the mix with the virgin aggregates and the heat (without
contact with the flame);
- Only after this quick mixing process, called the "dry mix", the asphalt binding agent is added and the moist
mixture is processed;
- The efficient injection of the fibers will make it possible to add greater asphalt content without exudation, as well
as making higher quality binding agent film possible over the aggregates in these high performance asphalt
mixtures.
This is why Terex asphalt plants have an important competitive advantage: the fibers can be incorporated into
the mix - through the reclaiming ring inflow (where they will go through heating), and first mixed with the virgin
aggregates (mixing zone 3), meeting international requirements for special mixtures.
SYSTEMS FOR COLLECTION AND CONTROL OF FINE AGGREGATE DOSING
Consists in the extraction of fine aggregates from the bag filter filtration and depositing
them in a 1 m3 or 20 m3 feed bin.
The percentage of fine aggregates to be added to the process is determined by the
traits of the mixture to be used. The injection of fine aggregates takes place by way
of a screw conveyor, which is
activated by a gearmotor controlled
by a frequency inverter connected
to the Sistex control system. The
excess material goes through an
overflow chute or screw conveyor for
loading onto a specialized vehicle or
discarding area.
fine aggregate collection system with 1 m3 feed bin
fine aggregate collection system with 20 m3 feed bin
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OPTIONAL EQUIPMENT
ASPHALT MIX WEIGHING HOPPER
Bin placed after the basic mixture bins 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
optional feature also allows for the printing of a loaded mixture ticket if the customer
purchases a printer for this purpose. It can be adapted to any of the different bin
models. Available for the 1 m3, 10 m3 and 25 m3 bins.
READY MIX STORAGE BINS
• CONVEYOR WITH 10 m3 FIXED AND MOBILE SELF-ERECTING BIN
• CONVEYOR WITH 25 m3 FIXED AND MOBILE SELF-ERECTING BIN
- Bins built out of heavy duty steel. The discharge floodgates are pneumatically
activated by two cylinders. Their framework is designed with an I-beam support
which makes it possible for trucks to go under it without the need to lower the
flooring. The access stairs have guardrails.
• ELEVATOR WITH 50 m3 FIXED BIN
- Made with heavy duty steel and thermally coated. The discharge floodgates are
pneumatically activated by two cylinders and are thermally coated. Assembled on
an I-Beam framework with four support feet makes it possible for trucks to go under
it without the need to lower the flooring. The access stairs have guardrails.
25 m3 mobile self-erecting bin
• All of the bins are integrated with the Drag Mixer-type hot mix elevator, are completely
closed, and their bottoms are covered with wear plates. They have overflow chutes
activated by two pneumatic cylinders with by-pass ducts.
• The anti-segregation pre-bin has an automatic unloading system and is pneumatically
activated, coming with a lubricator and drain valve on the compressed-air line.
Fixed bin 10 m3
Capacity
10
m3
Mobile 10 m3 bin
10
m3
Fixed bin 25 m3
25
m3
Mobile 25 m3 bin
25
m3
Fixed 50 m3 bin
50 m3
Truck passage
Height
4,450 mm
4,450 mm
3,510 mm
3,510 mm
3,020 mm
Width
3,650 mm
3,650 mm
4,000 mm
4,000 mm
3,450 mm
Weight
9,000 kg
15,000 kg
18,500 kg
21,800 kg
20,000 kg
fixed bin 25 m3
SEMITRAILER WITH CABIN
Cabin assembled on a semitrailer, with room for coupling a generator and 5,000 liter
fuel tank (optional): makes it easier to install the equipment where electricity is not
available.
VIDEO CAMERAS
semitrailer with cabin
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Three video cameras control the plant's operations from the control cabin.
Example of configuration:
- 01 for controlling the feed bins
- 01 for controlling the loading of the trucks
- 01 for the tank area
All visualization is done remotely, by telephone line.
OPTIONAL EQUIPMENT
MOBILE RECLAIMING UNIT
The recycling of asphalt pavement, commonly known as RAP (Recycled Asphalt
Pavement), consists in reusing the material from pavement milling. Use of reclaimed
asphalt pavement can replace the use of some kinds of virgin aggregates in a new
asphalt mixture.
The purpose of the reclaiming system is to reincorporate materials from milling processes
into the asphalt mixing process. These are introduced by way of the reclaiming cover
(recycling ring), allowing for the use of RAP, leading to savings, environmental awareness
and high quality for the end product.
Recycling
cover
HEATING AND STORAGE SYSTEM FUEL - TANKS
Terex Roadbuilding has a variety of horizontal tanks for asphalt and fuel, in fixed
or mobile versions (with a framework assembled over the chassis and their own
axles for highway transport).
The tanks have:
• Complete thermal insulation with external protection;
• Indirect heating via coil;
• Thermal fluid heating system (300,000, 400,000 or 600.000 kcal/h);
• Interconnecting flexible piping between the tanks and plant (optional);
• Asphalt/fuel loading and circulation system (optional);
• System of agitators for modified asphalt - polymers and asphalt-rubber, among
others (optional);
• Intelligent tank system - with temperature sensors (optional).
50,000-liter heat insulated tank
Configurations available with 15,000 L for fuel and 35,000 L
for asphalt or 50,000 L for asphalt
60,000-liter heat insulated tank
Configurations available with 20,000 L for fuel and 40,000 L
for asphalt or 60,000 L for asphalt
80,000-liter heat insulated tank
Configurations available with 20,000 L for fuel and 60,000 L
for asphalt or 80,000 L for asphalt
100,000-liter heat insulated tank
Configurations available with 20,000 L for fuel and 80,000 L
for asphalt or 100,000 L for asphalt
* Other tanks available: 5,000 L, 20,000 L and 30,000 L.
OTHER OPTIONAL ITEMS FOR THE TEREX E 100P:
Fuel flow gauge
Asphalt flow gauge
Capacitor bank
Impulse System control
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TECHNICAL SPECIFICATIONS TEREX E 100P PLANT
Single chassis
Double chassis
(aggregates
moisture
up
to 5%)
100 *
Production (ton/h)
1
2
Number of chassis
4 axles / 16 tires
Chassis 1: 4 axles/16 tires
Number of axles/tiress
Chassis 2: 1 axle/4 tires or 2 axles/8 tires
4 (side by side)
4 (std)/5 or 6 (optional)
Feed bins
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7
Capacity (m3)
Individual weighing system with a centered load cell
Dosing system
Counterflow type
Dryer
2.2 m at the largest section
1.8 m at the smallest section
Dimensions
7.8 m long
Hauck Starjet 4260
Burner
12,425,000
Thermal output (kcal/h)
External rotational
Mixer
Bag filter: 480 units (Nomex treated)
Filtration system
Greater than 99.9%
Particle emissions less than 50 mg/Nm3
Efficiency
Drag Mixer type with antisegregation toothed fins
Conveyor
1 m3 (std) - options for 10, 25 or 50 m3
Ready mix bin
Standard
Ring for the inflow of reclaimed material
( )
* The plant's production rate can vary depending on the following factors: aggregate moisture, altitude where equipment is installed, percentage of
( )
fine aggregates in mixture, mixture temperature, fuel's calorific power and the specific weight of the aggregates.
Height: 4.4 m
Travel dimensions:
Length: 22.5 m
Weight: 56,000 kg
Width: 3.2 m
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 prior notice. The performance data depends on plant site conditions. Some of the components mentioned are optional though not explicitly indicated as
such in the text. May/2009
TEREX ROADBUILDING LATIN AMERICA
Rua Comendador Clemente Cifali, 530
Distrito Industrial Ritter | Cachoeirinha/RS | Brasil
Fone: +55 (51) 2125 6677
Fax: +55 (51) 3470 6220
www.terex.com.br