your asphalt plant · 2018. 6. 15. · asphalt calibration systems in-line fuel heaters ... of...

YOUR ASPHALT PLANTPROVEN SOLUTIONS: FROM SMALL COST SAVINGS ACCESSORIES TO MAJOR PLANT TRANSFORMATIONS.

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800.826.0223STANSTEEL /HOTMIX PARTS® ®

For a full version of the story behind the cover photo, access: www.stansteel.com/transformation

Table of ContentsCombo PlantsCounter�low Drum ConversionsLeverage Your Investment

Used or ReconditionedTake Your Rap Pile From PAIN to GAINCounter�low Drum Mixers Complete

Rotary Recycle MixerTM Retro�its

Rotary Recycle MixerTM

Progressive Upgrades

Shingles, RAP & Multiple Size Blending

Turbo RAP Gator®

Ruggedize Your Silo System

ChainsSprocketsThe Accu Shear®

Special AdditivesAdditives In Action Accu-TrackTM Total Plant Control

Control Systems

Make Your Plant Run BetterCustomer Success StoriesTru-StorTM Tanks

Hot Oil Systems

Tru-FloTM - AC Pump Skid SystemAsphalt Calibration Systems

In-line Fuel Heaters

NiteOwl®

Silo SystemsSilos Get a Second Life

Slat Conveyors & Bucket Elevators

Wear Plate

More Chain - Slats & Buckets

Our Af�iliate CompaniesReplacement Shells Flighting

Trunnions

The T-TracTM

Low Energy Plant

Successful Custom ProjectAdditive Systems

Specialty Accessories

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THE LARGEST PLANT IN THE WORLD Engineered, Manufactured & Commissioned

100% STANSTEEL®

The plant was designed to run over 900 tons per hour. It is extremely heavy duty, massively built and is field proven by running 1,000,000 tons in one year.

The world leader in high-performance, high-production, low-downtime systems.

Complete New CouNterflow Drum mixer plaNts:

PAGE 2800-826-0223 • www.stansteel.com • www.hotmixparts.com

800-826-0223 • www.stansteel.com • www.hotmixparts.com

A 400 Ton/Hour Combo Plant™ new, used and Reconditioned has out-performed all expectations. The heart of this plant is a Stansteel® 400 TPH Counterflow Dryer and Rotary Recycle Mixer™. Drying, mixing and combustion process was properly matched to a primary collector and 75,000 aCfM baghouse that was reconditioned in Stansteel®’s factory. Two new Stansteel® 240 Ton silos were positioned to receive material from the used/reconditioned slat conveyor.

SPECIAL NOTE: The entire project was engineered to not interrupt the existing customer batch plant facility AND to re-use valuable existing components such as the cold feed and A.C. tank facilities. The mix quality is exceptional.

Combo Plants™ The Best Way to Save $1 Million or MoreUtilizing the Latest Technology

Custom conversion of a Cedarapids Parallel flow Drum to a Custom Heavy Duty and Efficient Stansteel® Counterflow

Drum with extended nose quiet burner and ability to recycle at much higher percentages without blue smoke.

Other important upgrades to the plant included a primary Knockout Box to lower the dust loading to the baghouse and

addition of two Stansteel custom engineered cold feed bins to extend their aggregate to a six-bin system. This upgrade

permitted the customer to handle more materials including Superpave and SMa without costly and time wasting bin

clean-out.

A dual Recycle Bin Assembly was added to permit blending of multiple RAP sizes and increase the use

of this valuable material.

IS IT NEW? IS IT USED? IS IT RECONDITIONED?The answer is YES!One of the best examples of innovative value….Stansteel® Reconditioned Equipment with New Technology. A used Boeing parallel flow drum mixer still had good value with the frame, drive and portability feature. Our engineers, technicians and factory personnel custom configured the latest technology Counterflow Drum technology with high efficiency flighting, low emission combustion zone and an extended nose Hauck combination fuel burner. An excellent portable drum was provided at a much lower investment.

BEFORE

AFTER


Counterflow Drum Conversions

AFTER

BEFORE

What’s an old skip hoist silo system worth? It was completely TRaNSfORMED in our Stansteel® reconditioning facility.

AFTER

BEFORE

Used 70,000 aCfM Baghouse, before reconditioning.

Reconditioned baghouse with new bags, reconditioned top house and valves. Note this unit has passed the EPa New Source Standards.

afTER RECONDITIONING: an exact plant size duplicate was found to meet the very sensitive zoning and environmental requirements. It was a fraction of an all new replacement.

Used and reconditioned portable cold feeds. Feeders were upgraded to a drum mix style with variable speed drives, no flow switches and tachometer feedback.

A completely reconditioned silo system utilizing two of the used skip hoist silos, with tops squared, new Stansteel® bintop conveyors and batchers. Also upgraded, a reconditioned 400 TPH slat conveyor.

PAGE 5 800-826-0223 • www.stansteel.com • www.hotmixparts.com

Leverage Your Existing Plant's Investment

Used Equipment • Reconditioned • Packaged Used, New & Reconditioned

a used counterflow drum offers fast installation and can start saving immediately. Customers frequently purchase for a few large projects and then have Stansteel® resell it in a couple of years to minimize their per ton investment.

An undersized or discarded component may function well for another contractor or in different conditions. We help customers part-out plants or replace and upgrade the non-performing components.

a deluxe 500 TPH counterflow stationary drum plant with (3)300 Ton Silos and 85,000 aCfM baghouse. This plant was over capacity in the original market. Stansteel found a home for this plant several hundred miles from the original installation.

Two used 25,000 gallon aC tanks. With fluctuating aC prices, limitations on polymer modified aC and other special liquids that are required for Superpave, SMa and special projects, extra tank capacity is often mandatory. Producers do not want to waste expensive and special types of AC on commercial or private paving projects.

Used or Reconditioned: Can Save $Hundreds of Thousands Every Time


Add multiple recycle bins for blending RAP, for any brand plant.One, two or more RAP bins and all other components such as screening units, belt feeders or closed loop systems. Stansteel Counterflow Drum that replaced parallel flow.


to ... gainPainTake your plant’s RAP pile from...

BEFORE

AFTER

Since more producers have the requirements to have properly proportioned recycle ingredients, Stansteel salvaged and reconditioned this RAP system to give many more years of service. Select idlers were replaced, and the drive and flow control upgraded. The buyer has Stansteel/Hotmix Parts equipment at each on of their 10 asphalt plants.

COUNTERflOW DRUM MIxERS; COMPlETE NEW DRUM MIxER PlaNTS

Based on our 1,500 years of accumulated advanced drying experience, we replace:- out of date parallel flow units - batch dryers - first generation high wear counterflow drums

with custom engineered, state-of-the-art technology

CONvERT OlD PaRallEl flOW DRUMS TO COUNTERflOW TECHNOlOGy; MUlTIPlE OPTIONS

OR


(NO PaINfUl JaCK HaMMERING TO ClEaN OUT EvERy 40,000 TONS aS REQUIRED By CERTaIN DESIGNS)

Rotary Recycle Mixer™ Retrofits


PROvEN - coast to coast - add a Rotary Recycle Mixer™ to old dryers or drum mixers to achieve the ultimate recycling capabilities. Many have run millions of tons at 25% - 35% - 40% RaP or more with no clean out required and extremely low maintenance.

The best transforming upgrade for Batch Plants - The Rotary Recycle Mixer™. This System converts your batch plant into the latest technology counterflow drum mixer with very high recycling capability.

Rotary Recycle Mixer™


Custom Stansteel Progressive Metering and

Proportioning System™ to increase RAP fed to the batch tower. Reduces the massive steam explosion common on many batch towers by weighing and metering directly to the

pugmill mixer.

Burner evaluations and air system and flighting

recommendations are all part of a plant upgrading

process. Stansteel® will recommend the style and type of burner to

meet many performance requirements. Pictured

here is a low NOx burner proven to meet even the

standards of the South Coast of California Air

Quality District.

Progressive Upgrades


Our custom engineered system takes advantage of extensive shingle material, either Tabs or Tear Offs. Even a small quantity of shingles can provide substantial new liquid aC savings since shingles can contain 18 to 40 % liquid aC.

PLEASE NOTE: The use of powerful magnets above the feeder discharge.

SHINGLES, RAP AND MULTIPLE SIZE BLENDING Maximize Recycling of all types of materials.


TURBO RAP GATOR®

BIGGER AND BEEFIER THAN EVER BEFORE

Sizes material to your specs. Shatters phone book size millings down to one inch or less giving you 250 TPH of spec material without plugging, or giving you baseball size chunks or hard compressed material. It maintains your specified milling size by ripping materials that have stuck together. Even settled RaP piles are shattered and broken. large chunks don’t float on top. Its hardened steel teeth, with chrome-carbide plated tips, devour 40 pound chunks with ease. It can save your season by rejecting scrap metal and large stones that foul equipment downstream. It improves heat transfer by generating consistently finer

material. you save energy and reduce the temperature of exhaust gas that feeds into the baghouse or wet collector.

Portable or stationary, batch plant or drum mixer, the Turbo RaP Gator® makes recycle more profitable than ever before. It can be installed with an entire Hotmix Parts® recycle system, or it will retrofit to your existing RaP system.

you baseball size chunks or hard compressed material. It

The RAP Gator®’s Massive Teeth: Crush RAP chunks into usable recycle product with ease. Massive construction assures performance with minimal maintenance.


Ruggedize Your Silo System


Upgrading and Rebuilding Slat Conveyors, Bucket Elevators & Silo Systems

slats

chains

gear reducers

wear plates head & tail shafts

Slats can be pre-assembled for faster field installation. Upgrade options available!

Over 17 types available for slat conveyors. Single chain options and conversions are provided by the special applications group.

For everywhere on your plant - dryers, pugmills, bucket elevators. Heavy duty and upgrade units available.

All types of easily replaceable bottomplates - Everlast™ ceramic, Ni-Hard castings and Evermor™ chrome carbide.

Custom built hubs and sprockets to fit any conveyor. Sprocket Plus™ System - Precision machined and hardened sprockets to prolong chain life and keep production going.

Evermor™ chrome carbide.

sidewall/tubwall liner platesRolled to radius

Three steel options custom made and emergency shipments available.

batcher linersDesigned and built for easy installation

cone linersSegmented and tapered, custom-made for all brands and types.

It does not matter what brand, we can completely upgrade and improve your silo system with better components than it was shipped from the factory. Drag slat chains, sprockets, wear bottom plates, cone liners, batcher liners and anything for a silo system or the transfer conveyors associated with it.

CHAINSHotmix Parts® offers the world’s largest on-hand inventory of hotmix asphalt plant chain. Any application you can think of, we have chain for it - in stock and ready to ship out the door. All of our chain has been strengthened to exceed original equipment specifications. So, if you’re in a breakdown situation or upgrading your existing equipment and are in need of chain or any other hotmix replacement part, give us a call. We will assist you from the beginning of the sale and stand behind you during start-up. Remember, we’re committed to customer service.

• Don’t Settle for Sub-Standard Original Equipment Specifications.

• Don’t Pay Grossly Inflated Original Equipment Prices.

• Don’t Settle For Average Service and Late Delivery.

UPGRADE AND RUGGEDIZE YOUR REPLACEMENT CHAIN...FOR EVERY BRAND• Astec• Bituma• CMI• Gencor• Cedarapids• Terex

• ADM• Madsen• Barber-Greene• H&B• McCarter• Standard Havens


sprockets

SPROCKETSHotmix Parts®/Stansteel® maintains an extensive inventory of hard-to-find sprockets engineered specifically for hotmix asphalt applications.

Precision split hubs with replaceable hardened segments.


Our standard sprocket is a completely machined piece of equipment. It’s hardened, with no jagged, flame-cut edges that are common in cheap sprockets. We’ve even replaced screws with an advanced bolt tensioning device.

THE ACCU•SHEAR

The Accu-Shear® is a comprehensive assembly custom engineered to offer the advantages of accurately injecting water, other liquid additives or a combination of these materials. liquid asphalt and water do not mix naturally, in fact, they will separate if possible. The principle that the Accu-Shear® operates under is the shearing process of forcing the two (or more) liquids to mix together. The colloidal pump and the mixing action that takes place with the application of horsepower is similar to an emulsion process. By mechanically blending, in lieu of simply injecting, the producer avoids the inherent nature of laminar fluid flow. By positively blending the additives with the liquid asphalt, the foaming action is DRaMaTICally INCREaSED. More importantly, the fusion is maintained for a longer period.

WARM MIX • CHEMICAL LIQUID • WARM MIX FOAM

Dual warm mix aDVaNtaGe

®

• A complete bypass is built in for regular hotmix production.• Industrial heavy duty components.• Quality is assured by proper metering and monitoring.• Comprehensive three module system.

CUSTOM ENGINEERED

• Eliminates laminar flow and separation of liquids.• Utilizes horsepower and a shearing process to force the two (or more) liquids to mix together.• The variable speed drive permits adjusting the speed of the shear to DYNAMICALLY FOAM the materials.

UlTIMaTE lIQUID BlENDING

• Proven components for repeatability and long term performance.• No valves, nozzles or screens to plug.• No downtime for component clean out.• Operates over a full range of production without manual adjustment.

lOWEST MaINTENaNCE


• SAVES significant operational and material cost.

• Blend liquids at the plant. Avoid upcharges by the AC terminal for expensive additives or “pre-blended” high specification liquid AC.

• A by-pass mode is designed to immediately return to hotmix production.

• Reduce the cost and need for mechanical agitation within AC storage tanks or re-circulation.

• Makes the plant multi-function and can reduce material re-handling for cold mix or specialty patching materials.

THE faCTS:

Custom Designed and configured aCCU-SHEaR® aDvaNCED to blend up to five liquids with the regular aC. The customer wanted the maximum flexibility to utilize anti-strip, latex, fuel oil, special cold mix chemical additive and water. After even the initial runs, the customer reported that this was the best mix that the plant had ever made.

• Reduce the cost and need for mechanical agitation

REVOLUTION IN LIQUID ON-LINE BLENDING:

Pre-assembled skid assemblies for the various liquids. The units contain the pumps, metering system, electrical interlocks and other critical items to assure accuracy. Depending on the liquid, a tote structure is provided and certain units have automatic refilling provisions.

tHe aCCu-sHear ADVANCED


®

More companies are stretching their capability by processing shingles, both tabs and tear offs, as well as combining other ingredients. The system illustrated was also utilized to run crumb rubber on a plant. This eased the handling of crumb rubber on the plant and, in fact, received every bonus available for the project. The entire recycling system was custom designed by Stansteel.

Special AdditivesShingles and Crumb Rubber: Another Specialty of Stansteel/Hotmix Parts


Additives IN ACTION


Another utilization of Stansteel and Hotmix Parts’ custom retrofit capabilities. The customer wanted to utilize both water and a special latex for making a blended polymer A.C. inline at the plant. Significant savings can often be realized over buying the more expensive material from a third party supplier. Stansteel also custom designed a reconditioned mineral filler silo with a new comprehensive reverse weigh pod assembly.

The Accu-Shear™ (Handling Multiple Liquids)Precise Dust Weighing

BaTCH & SIlO CONTROlS BURNER CONTROlS

NITEOWl® aDvaNTaGE PlaNT alERT SySTEM

RaDaR TaNK lEvEl INDICaTOR

INfRaRED TEMP SENSOR

CUSTOM PaNElS

MOST COMPREHENSIvE aND DEPENDaBlE CONTROl SySTEMS



make your plant run better With Stansteel’s Used and Reconditioned Equipment

This California customer had operated a Cedarapids parallel flow drum plant a number of years. With changing regulations, it was important for them to change to counterflow technology, both from an emissions standpoint as well as increasing the ability to run recycle. Stansteel completed a successful conversion by reusing the existing Cedarapids plant equipment including material feed, silo equipment, air pollution, etc. a straight counterflow drum was designed including extended nose, highly efficient Eco-Star II burner. a primary knockout box was installed based on the high volume of dust particle carry-out on the counterflow drum versus the parallel flow. The unit has been installed and operating successfully for three seasons.

AFTERBEFORE

This company had operated a moderately sized batch plant for a number of years. They determined that they needed to go to both a higher production rate as well as the ability to run more RAP material. The company worked with the Stansteel Used Equipment Group to provide an economic solution which would include primarily a used plant and also upgrading to their rigid state specifications. Stansteel found a good, used Standard Havens low Rider 300 TPH drum mix plant. The customer chose not to use the CMI 65 ton self-erect pop-up silo and felt that they wanted more capacity. We matched a 200 ton silo and slat conveyor for it and custom designed a very elaborate dust runaround system that was required by their state. It, in effect, weighed the dust coming out of the baghouse and weighed the dust going back into the process. This unit had our Accu-Track™ Controls and, therefore, it was a minimum to upgrade for precise weighing and measuring that was required. The final result was that the customer closed down their batch plant soon after getting started up and has been very successful running in a lower cost, lower fuel usage and more RaP production profile.

See www.stansteel.com for more innovative products, success stories and plant solutions.

Previous Plant Condition: The silo system could only handle about 230 tons per hour; there would be plugging and capacity problems.

After Evaluation and Recommendation by Stansteel: The company had converted from a smaller batching plant to a higher production used drum mix plant, however, kept the existing silo system. The productive capacity of the drum plant could have been up to 400 tons per hour, but was limited by the slat conveying capacity. First of all, it was determined that more silo capacity was needed and the ability to store a second mix type. a 250 ton Stansteel Silo was added and a new Heavy Duty Custom Engineered and Inclined Bintop Slat Conveyor with remotely controlled flop door. The main drag slat conveyor was a nominal 300 ton per hour twin chain conveyor and this was salvaged and upgraded to a heavier duty single chain internals for the conveyor with taller slats and larger horsepower motor and drive. The two major components were converted to over 400 ton per hour capacity and the customer has been operating successfully for a number of years.

826-0223 • www.stansteel.com • www.hotmixparts.com

Customer Success Stories Achieve superior results with custom engineered technological advancements from Stansteel

Customer Business Opportunity/Threat: The customer had been growing to larger volume in a market and a quarry location became available because of the exit of another competitor. They needed to have a plant to anchor this location, but were very limited by their corporate structure annual capital budgeting.

Stansteel Business Solution: Stansteel came up with a Combo New/Used Drum Mix Plant. The plant had certain new components such as cold feeds, electronic controls and an asphalt tank and a new Pulsejet Baghouse by Stansteel. Used components included a reconditioned drum mixer, 400 ton silo system and other plant components. The customer was able to purchase this for less than 65% price of new, however, it performed and gave the tonnage and helped anchor this new quarry location. The plant operated and produced tonnage as expected and promised and has been a dependable performer for years.

Customer Control Problem: The customer had bought an off brand asphalt plant and had many surprises including that the electronic controls were produced and programmed in Singapore. It was extremely difficult to communicate with the people in Singapore, both based on language and time zone differences.

Stansteel Solution: Stansteel supplied an actual used control system to replace these basic blending units. The customer has run for approximately an 18 month period with zero downtime from the used controls supplied by Stansteel.

Previous Plant Condition: The plant operating conditions were that the plant production was not up to the plant design standard or production needed.

After Evaluation by Stansteel: It was determined that there was a great deal of static pressure or pressure drop within the customer’s air handling system. They still had a multi-cone type primary collector and a reverse air type baghouse. After recommendations by Stansteel including changing to a knockout box and conversion to a Pulsemaster conversion on top of their baghouse, the entire plant breathed easier, the burner was able to get enough air/oxygen for proper combustion and the production rate was increased by over 35% and 150 tons per hour.

See www.stansteel.com for more innovative products, success stories and plant solutions.

a new Stansteel Counterflow Drum Mixer was selected to replace an aging parallel drum that had been converted from an original 88 x 28 batch plant dryer and could not recycle. The new complex and tight fit up conversion also included a new long nose burner, primary knockout box and ductwork, mineral filler silo and reconditioned recycle system. This was the first recycle plant in the entire market area. This producer has purchased numerous counterflow and parallel flow drums and other hotmix plant equipment from Stansteel/Hotmix Partsover the last 50 years.

TRU-STOR™ TANKSASK WHY OUR TANKS ARE CALLED Tru-Stor ™

Vertical or horizontal – you make the call. Hotmix Parts®/Stansteel® manufactures brand new aC or fuel tanks in either configuration. Using our asphalt tanks with our twin shaft blending system offers you production of high performance asphalt at significant cost savings. Hotmix asphalt storage tanks are built to heat and store even the most sensitive liquid asphalt mixtures. Superpave’s modified liquid asphalts, complete with an infinite variety of polymer mixtures, are fast pushing standard asphalt storage techniques into obsolescence.

That’s why you get several standard features with Hotmix Parts®/Stansteel® asphalt storage tanks that, even when available from other manufacturers, come only as expensive options. Hotmix Parts® tanks have more coil surface than any others on the marketplace. you heat asphalt more consistently - at hotter temperatures -maintaining a generous reserve for high production. High density industrial insulation locks the heat inside. We offer a wide selection of portable, skid mounted, horizontal and vertical tanks... all built to yourexact requirements.

Another comprehensive AC storage tank and AC handling system by Stansteel.

Pictured are two 30,000 gallon aC tanks with unloading pump, manifold and well designed jacketed AC piping and valving.

Pictured are three 30,000 gallon aC tanks. Why is the Stansteel so much taller? That’s why they are referred to as Tru-Stor™. We also feature comprehensive and complete Tanks with valving, maximum thermal retention fiberboard insulation, several options on level indicators and safety access provisions. Note the Stansteel anti-strip tank and metering system at the bottom right.


Hotmix Parts®/Stansteel®’s Hot Oil Heat Exchanger supplies super heated oil throughout the asphalt plant. It is the superior alternative to old-style chamber or direct fired heaters. Designed with efficient sections of coil, the Hot Oil Heat Exchanger provides up to 200% more surface area than convection heaters.

Return oil from the asphalt plant enters the system through an air/oil separator that feeds the positive displacement pump. The Hot Oil Heat Exchanger is

available as a standard in units rated at 500,000 to 4 million BTUs.

as the need for storage of more grades of liquid a.C. has become a reality, the need for increased heater capacity and flexibility has increased. The very efficient Hot Oil Heat Exchanger is custom sized for each plant application.

HOT OILSYSTEMS

an 8 Million BTU Hot Oil Heater being readied for shipment to a multi million gallon AC Tank farm. In conjunction with our affiliated company, First Thermal Heaters, we can supply any hot oil heating requirement with proven Heaters, Heat Exchangers and vaporizers up to 85 million BTUs including vertical and horizontal tanks, piping, pumping, valving and system design.

In stock hot oil heaters for

emergency response.


The Tru-Flo AC Pump is a state-of-the-art continuous pumping and electronic asphalt metering assembly built to ensure precise measurement of liquid asphalt.

The system is completely skid mounted. Its inlets and outlets are flanged, and all internal parts are jacketed and plumbed for hot oil for quick field installation.

a removable basket strainer is provided on the inlet side of the pump skid. a 3-way valve is controlled using a solenoid to direct the flow from the aC tank to the plant. a second 3-way valve is provided to manually divert the flow to the tanker during the AC meter calibration.

an aC motor is used to drive the asphalt pump. a variable frequency drive is included to control the pump speed pending flow requirement. By changing the speed of the motor, the rate of the asphalt flow changes.

The operation of the Tru-Flo AC Pump Skid has a special rotor which is the only moving part in the system. Attached to one end of the motor is an optical encoder. as the asphalt flows through the asphalt meter, the encoder turns and sends a signal back to the electronics. A temperature sensor indicates the asphalt temperature, providing additional feedback to the electronics. The electronic controller also provides automatic temperature compensation.

One moving meter part reduces the chances for out of tolerance conditions. Adding precise electronic calculations gives the meter an accuracy of 0.2%. In comparison, other asphalt flow meters maintain accuracy of between 0.5 to 5%. This translates into a dramatic annual cost savings by lowering the amount of liquid asphalt used.

TRU-FLO™

SPECIAL NOTE: The Tru-Flo AC Pump Skid is an excellent replacement for the old-style “Brodie Type” meters and completely eliminates multiple gear electronic stack-ups.


AC PUMP SKID SYSTEM

ASPHALT CALIBRATION SYSTEMHotmix Parts®/Stansteel® asphalt calibration system automates liquid asphalt metering. The system enables you to calibrate the asphalt flow meter at your plant within a few minutes, eliminating the hazardous and complex logistics of providing a tanker truck, truck scales, special liquid asphalt hoses and asphalt pump. fill the calibration tank with liquid asphalt, simply weigh the a.C. then pump the liquid asphalt back into the storage tank. The a.C. calibration system also eliminates the safety hazard of handling hot liquid asphalt.

To operate the new calibration system, the plant operator diverts asphalt flow into a specialized holding vessel designed for 1,000 gallons of liquid asphalt. The tank has a heated base to prevent asphalt from solidifying. The load cells, which support the tank, measure the liquid asphalt to the nearest pound. The operator then compares totals generated by the load cells to those generated by his metering system. The operator then reverses the pump to send the liquid asphalt through the fully jacketed 3” line into the permanent a.C. storage tanks. The system is equipped with an automatic, high level cut off safety switch to stop liquid asphalt flow if the plant operator is distracted during the procedure. The A.C. calibration system makes it possible to generate precise liquid asphalt flow with accuracy not attainable through the manual calibration methods.

SAFETY + SAVINGS = FAST PAYBACK• avoid dangerous loading/off-loading of aC just to calibrate.• Calibrate much more frequently (not once/year) to save costly liquid aC.• If the metering system is inaccurate by .2%, it could mean making out of specification mix or wasting $250,000/year in liquid aC overuse.


Stansteel®/Hotmix Parts® has pioneered the installation of in-line fuel heaters, both hot oil and electric, on all types of drum mixers and batch plants. Extremely heavy duty construction and capable of maintenance and clean-up. you don’t have to scrap the in-line heater just because of poor fuel coking or collection of poor quality heavy/waste oil.

IN-LINE FUEL HEATERS

HEAvY/WASTE OiL PREHEATiNg AND BLENDiNg SYSTEMS TO iMPROvE YOUR DEfENSE AgAiNST NATURAL gAS OR HigH fUEL COST.

Electric in-line heaters are also used in applications where there is low cost power. The unit functions very similar to the hot oil in-line heater but uses the lower cost electrical energy to pre-heat the fuel before being burned in the plant. Note that the heavy/waste oil is raised to the viscosity level similar to fuel oil for proper atomization and combustion.

ELECTRiC ALSO AvAiLABLE!Here’s a custom engineered process for a large multi-state contractor desiring to have outstanding control on the waste oil process without operation problems.


+++ ---

The NiteOwl® Advantage Alert System, from Hotmix Parts®/Stansteel®, is a multi-purpose electronic watchman for asphalt plants. The NiteOwl® System is designed to automatically call up to four phone numbers repeatedly until someone is alerted if the temperature of liquid asphalt or hot oil exceeds the pre-set high or low limits or when conditions are abnormal.

While liquid asphalt and hot oil monitoring is the most useful feature of the system, the NiteOwl® can also be programmed to call when confronted with a variety of upset conditions. For instance, if the power or a motor starter fails, if an intruder or smoke is detected, the system will alert the pre-set numbers. A prime benefit of the system is the remote accessibility of the NiteOwl® which allows an immediate update of plant conditions available 24 hours a day, 7 days a week from any location, using any telephone equipment. The system’s integrated microphone permits a caller to “listen in” for 10 seconds with each call to detect and monitor sounds or voices in the plant.

The system includes a rugged and reliable back-up battery that automatically recharges and provides 20 hours of continuous operation should A.C. power fail. Other standard equipment includes a temperature probe in a stainless steel drywell placed directly into the hot oil circulating line to continuously monitor temperature levels. A surface mounted temperature sensor is also available.

The well designed, easy-to-use keyboard permits the plant operator to set various control ranges, including time, dial-out phone numbers, number of rings before incoming call is answered, high and low temperature alarm limits and identification numbers, among other programmable features. The basic system installation is as simple and fast as installing a home telephone answering machine.

The NiteOwl® Advantage Alert System, from Hotmix Partsdesigned to automatically call up to four phone numbers repeatedly until someone is alerted if the temperature of liquid asphalt or hot oil exceeds the pre-set

400

300

200

100

YOUR PLANT WATCHMANYOUR PLANT WATCHMANYOUR PLANT WATCHMANYOUR PLANT WATCHMANYOUR PLANT WATCHMAN

You can call the NiteOwl® or it places warning calls, with as many as four back-ups and receives status calls.

Equipped with sound sensor for

fire/smoke alarm.

Probe in hot oil line monitors

high and low temperatures.

6V battery back-up.

Standard telephone jack.

120V A.C. Wall Outlet and power sensor keyboard allows operator to set a variation of commands & data.

Intruder sensors for

doors & windows.

Motor contact sensor.

Can Save $10,000 in Downtime Avoidance - on The First Emergency Alert


silo systems Dependable & Durable Storage with Multiple Options

Stansteel offers the most comprehensive options for new storage silo systems built for years of dependable and trouble-free operation. Because we’ve been involved in building thousands of silos over the years, we understand the importance of having a dependable unit like our MTR (Maximum Thermal Retention Silo). Our experience at Hotmix Parts of rebuilding every brand of slat conveyor, bucket elevator, transfer conveyor and other items, lets us build a unit for you that can give the service and duty cycle needed for your operation. We also feature used, reconditioned and combinations of new, used and reconditioned equipment.


Silos Get a Second Life


Stansteel’s customization ability can revive any old system

Example of a silo system that had been operated successfully for over 35 years, but now upgraded and renewed by Stansteel’s customization. The customer upgraded the facility to a Stansteel Rotary Recycle Mixer and, therefore, there was a need for continuous feeding of the silo system. The customer was able to keep the valuable four silos, foundations, dual truck scales and heating circuitry. Stansteel custom designed the proper length main heavy duty 400 TPH slat conveyor and three horizontal top-of-silo transfers and four new batchers for the top of the silo. Everything was custom fit to the existing site and old silo design. Performance has been excellent for the entire operation.

BEfORE

AfTER

Top of Silo Transfer Conveyors & Batchers

Hotmix Parts®/ Stansteel® builds every kind of drag slat conveyor and bucket elevator with conveying capacities up to 850 tons per hour. We offer a wide selection of options to give you the best choice in application-matched chains, bearings, slats, buckets and wear plates. Hotmix Parts / Stansteel also rebuilds and resizes used conveyors. We stock nearly every component for any drag slat conveyor or bucket elevator ever built. We build every type and size, from small bintop and under-plant slide-out conveyors to conveyors stretching over 120 feet.

Our drag slat conveyors are

custom designed to your requirements.

They can include chrome carbide or EverlastTM ceramic

wear plate, roller bearing chain, oil or electric heated

bottoms, reinforced slats and sprockets,

and other heavy duty components.

We know Slat Conveyors, Bucket Elevators & Silo Systems...INSIDE OUT

Regardless of new, used or reconditioned conveyor, we can upgrade it to longer wear life chrome carbide, Everlast ™ or Ni-Hard.

Pre-assembled chain and slats can be retrofitted to increase the capacity and service life of the conveyor.

Rugged floating bearings are recommended in critical transfer areas.


This used and very serviceable drag slat conveyor was custom extended and reconditioned in our facilities in order to fit a customer’s yard layout requirement and the taller height of a new Stansteel® silo. A newhigher capacity motor/gear reducer was added plus new Hotmix Parts® special performance chain and slats.

DURING RECONDITIONING Transforming the entire plant operation by the addition of a new Stansteel® slat conveyor and storage silo. The existing silo was retained in order to have flexibility with mixes.

Addition of a new Stansteel® 240 ton silo and bintop transfer conveyor to an old Standard Havens unit.The new deluxe long term storage silo has skirted design and safety gates.

A good used silo system was custom

engineered to match with a new Stansteel®

270 Ton Silo. an inclined top of silo

transfer was designed to permit dependable

service.

Heavy duty dual six inch pitch engineered roller chain and beefed-up idler wheel helped upgrade an existing slat to handle over 550 Tons per Hour.


WE OFFER THE WORLD’S LARGEST SELECTION,INCLUDING EVERLASTTM WEAR PLATE

EverlastTM Wear Plate gives you 10 to 30 times more protection than conventional materials. It outlasts everything in high wear areas including drag conveyors, bins, silos and dryer chutes. In fact, if you put it in the highest wear areas of your plant, it will probably outlast the plant equipment.

WEAR PLATE

Chrome carbide wear plate. Hotmix Parts® offers multiple styles, custom lengths and widths.

Hotmix Parts® high abrasion alloy.

Ni-Hard wear plate.

Custom made liners can be made for very high wear areas.


We supply upgraded parts (including an extra heavy duty line of buckets that are reinforced throughout) that fit any elevator. We can even extend your bucket elevator and make complete changeouts including chains, motor drives and reducers.

Buckets & Chain

Our slats are hardened and reinforced, the heaviest in the industry. Slats can also be precision punched and reused. Super SlatsTM are also available for even longer life. We have invested in thousands of feet of chain in inventory to serve the hotmix industry. Pre-assembly of chain and slats can speed the field installation time required.

Slats & Chain


Louisville Dyer Company® has been specializing in designing and building custom dryers for the international market since 1870. The LDC portfolio isn’t limited to the custom design of exceptionally operating dryers, but has expanded over its long history to include kilns, coolers or any other rotary devices specifically configured for your application. The expert team at LDC understands the equipment needs from process to mechanics and prides itself in the record-breaking longevity of units in the field. There are some LDC-designed units currently in the field that have operated consistently for seventy (70) years while the majority of common shop-built/will-fit dryers have often lasted less than five years. Learn more at:

www.louisvilledryer.com

• Unit built in our ASME Louisville manufacturing facilities and shipped to Zhuhai, China.• Featuring shell thickness up to 2” thick, all continuous ASME welded with 100% X-ray weld inspection confirmations.• Over 5 miles of stainless steel tubing internal to the unit.• Unit weighs over 550,000 lbs. as built.


Our Affiliate Companies Provide the Strength

Industrial Kiln& Dryer Group™

industrial Kiln & Dryer group™ (iKD) is the leading solution provider for dryers, kilns, ball mills and other rotary processing equipment. iKD boasts a 24/7 Customer Support help line, custom parts, field service expert crews and vast areas of expertise in an array of diverse industries using rotary equipment. IKD’s Innovative Solutions Team remains at the forefront of new technology in preventive equipment maintenance. Their latest endeavor, the DATscan™, provides customers with optical instrumentation and software producing unique rotary surveys detailing measurements of the unit even while the units are still in operation. Learn more at: www.industrialkiln.com

Extremely complex replacement of worn kiln section in field by IKD personnel while maintaining existing unit ovalities and 100% sub arc welding to ensure integrity of entire system. You can see a gallery of this specific project at www.industrialkiln.com/kilnsection.html

of 1,500+ Years Combined Industry Experience


Stansteel®/Hotmix Parts® custom engineered an upgrade and conversion to a straight counterflow Drum Mixer shell with Engineered Efficient fuel Saver flighting, while saving many dollars by keeping the same frame, gear reducer and drive, and trunnion sizing. The costly extended burner was even modified and re-used. The customer has now had four (4) years of trouble free usage. AFTER

Problematic Triple Drum - with accelerated wear patterns, the shells often split in this design.

BEFOREExact specification flights for all OriginalEquipment Designs or Custom Engineered Flighting System Upgrades by Hotmix Parts®.

These customers chose Hotmix Parts/Stansteel to evaluate, design and upgrade their replacement shells regardless of brand or application. In conjunction with Louisville Dryer Company®, we have built over 5,000 dryers and shells.

Counterflow Drum Conversion • Parallel flow • Dryers

CMI(Conversion

to straight drum)

BARBER- GREENE

(Thicker shell)

CEDARAPIDS(Drum mixer expansion)

PROCESSINDUSTRY

UPGRADEDFLIGHTING

IMPROVED COUNTERFLOW

REPLACEMENT DRUMASTEC

(Parallel replacement)

STANSTEEL(With gear drive)

Replacement Shells


all flighting produced by Hotmix Parts® exceeds original equipment specifications and has been designed and reinforced to produce improvements beyond the original manufacturer’s requirements. flighting is kept in stock for immediate shipment. Hotmix Parts® regularly produces custom flighting to meet special requirements, such as high moisture aggregates, super heating of materials for Superpave or accommodating the increasing use of recycle or warm-mix.

How effiCieNt are Your fliGHts?

BEFORE

AFTER

FLIGHTINGThis in-process photo illustrates

improper combustion

flighting. There is flame impingement from material

carry over.

At right a Hotmix Parts® extended flighting zone will permit complete

combustion plus lower fuel usage and reduced CO levels.


TRUNNIONS

Excellent trunnion design and alignment is the foundation of your dryer or drum mixer. We can replace any brand and upgrade your trunnion materials, shaft quality, selective hardening and base support. We have custom engineered and built trunnion systems to last longer and handle higher tons per hour.

Trunnion rolls are machined for concentricity at our in-house machine shop prior to installation or shipment. Machining critical wear parts such as trunnion rolls for concentricity assures a consistent tangent interface between the trunnion wheel and the dryer or mixer’s tire. Hotmix Parts® does this in-house to assure a quality finished product that meets or exceeds our customer’s expectations, time and time again.

• Trunnion wheels with pre-pressed shaft & pre-assembled bearings await shipment.• Hotmix Parts® stocks thrust rollers for immediate shipment.


the T-TRAC

HOW IT WORKSDryers, drum mixers, rotary mixers and other rotary equipment rotating on an inclined support develop a downhill axial thrust from the weight of the equipment and product. Most rotating equipment is designed such that this axial thrust needs to be offset by force developed from skewing the trunnion rollers in a precise manner. The T-Trac™ establishes a properly skewed trunnion roller setting to thrust the equipment in the uphill direction.

the T-TRACthe T-TRACFor tire/trunnion maintenance, purchase our newest alignment tool:

™

• establishes true neutral trunnion roller positioning

• sets trunnion thrust with confidence

• a MUST for trunnion drive dryers/drums

• has digital indicators for real-time adjustments

• is lightweight, portable and comes with storage case

• designed with over 1,500+ combined years of alignment experience

• sets trunnion thrust with confidence• sets trunnion thrust with confidence

• designed with over 1,500+ combined years of


Low Energy Plant The Latest in Plant Customization and Innovative TechnologyStansteel was selected to construct a Special low Energy asphalt facility™. This unit will provide the maximum flexibility for introducing aggregates, wet sand, additives, recycle and liquid asphalt and many other ingredients in the future. There also are arrangements to be able to introduce these materials at various stages in the process for both constructing the highest quality product and having significant energy savings. The ultimate in mixing technology is also incorporated by the Stansteel Rotary Recycle Mixer with extended length for retaining and mixing materials in excess of 80 seconds.


AFTER

BEFOREA great example of the Stansteel/Hotmix Parts custom ability is helping customers utilize existing equipment. This particular company had a massive 100,000+ ton pile of recycle material and could not utilize it in their existing parallel flow drum. Stansteel custom designed a system including keeping their existing parallel flow drum and converting it to be a counterflow dryer feeding into a Rotary Recycle Mixer® directly underneath the modified counterflow dryer. This allowed the company to utilize better technology on an existing footprint of plant and required minimal permitting changes which can be very sensitive. In addition, there were other feed and screening upgrades as well as going to two recycle bins to better utilize the RAP material that had been screened into different sizes.

Successful Custom Project

Rotary Recycle Mixer®

Recycle Bins


Stansteel® helped a customer meet a new state requirement to add Hydrated lime to certain mix designs. a new 500 barrel lime silo with both metering and a pugmill to pre-blend and coat the aggregate while moisture was still present before the drying process was required. a pugmill bypass circuit was configured to decrease wear and horsepower at times when lime was required to be included but not pre-mixed.

ADDITIvE SYSTEMS

Custom designed special liquid anti-Strip Additive System for the State of California. It incorporates a mass flow metering system to signal the plant electronics of the small amount of anti-strip that is required for certain high end performance mixes. A unitized skid design facilitates fast installation and allows mounting with a pre-filled tote assembly.

Custom dust runaround to prevent the surge of baghouse fines.

Accu-Shear® Warm Mix system quickly installed.

Continuous Reverse Weighing can be retrofitted to customers’ existing mineral

filler, baghouse dust return, hydrated lime or other products. Comprehensive supply

includes variable speed airlocks, dust blowers, electronics controls and new or used silos.

Custom Engineered & Manufactured


Specialty Accessories Temperature monitoring, dust handling & special material handling

Weigh Pod - Continuous Reverse Weighing. In order to meet rigid new hotmix material specification, the process cannot have too much or too little dust (or other ingredients). With a properly designed continuous weigh pod system, the fines can be weighed and returned with high accuracy in order to meet end result specifications.

Bearing monitor system and alert. Hotmix Parts has custom engineered all types of bearing monitor systems for critical motors on the plants. This could include slat conveyor bearings, dryer drive bearings or other critical bearings that are temperature- and performance-sensitive. The unit can provide both an alarm and even send warnings to the operator remotely by interface to the NiteOwl Plant Alert System.

Advanced Belt Scale Technology: We offer an outstanding time saver with an automatic test weight actuation for extremely rapid (even daily) testing verification. The Hotmix Parts/Stansteel Dual Belt Scale Deviation alert ™ provides the ultimate in continuous weighing reliability and hitting exact specifications for all mix designs.

Accu Agg Temp™. Finally - a way to monitor the aggregate/material temperature even in a counterflow drum where the material can be 10’-20’ from the final hotmix discharge location. The Accu Agg Temp is especially useful as producers are increasing the use of RaP and shingles, thereby requiring the superheating of the virgin aggregate.

Accu-Meter. Meter dust, lime, fibers and fines with the accu-Meter Impact Handling Subsystem. This unit is particularly designed to retrofit to existing hotmix asphalt plants. Since many governmental requirements for additives frequently change and specifications may require a combination of ingredients, the accu-Meter can retrofit to all types of plants without major modifications or relocation of equipment.

New - Used - Reconditioned Silos, Mineral Filler Silos and Dust Weighing. Stansteel has helped producers and contractors throughout the country meet requirements for fines, meeting SMa standards, lime, flyash, fibers and more. Often, we custom engineer a system as an example of utilizing a used or reconditioned silo with the latest in electronic weighing and metering.

Problems, state specification changes, OSHA guidelines and changing materials DEMAND solutions. Stansteel & Hotmix Parts can solve all

types of these problems with economic solutions and innovations.

NEW - Just Released


DO YOUR OLD CONTROLS BREAK DOWN OR LACK SUPPORT? WE HAVE CUSTOM DESIGNED AND RUGGED SYSTEMS BUILT FOR HOTMIX ASPHALT PLANTS

SIZING , REBUILDING AND UPGRADING YOUR SLAT CONVEYORS

www.stansteelused.comWWW.STANSTEEL.COM REDUCE YOUR PLANT FUEL

USAGE WITH PROPER FLIGHTING AND AIR SYSTEM ANALYSIS

BOOST YOUR RECYCLE PERCENTAGE AND STOP BLUE SMOKE

1-800-826-0223 12611 Townepark Way Louisville, KY 40243502-245-1977 • 502-244-4046 (Fax)

Stansteel®& HOTMIX PARTS®

your asphalt plant · 2018. 6. 15. · asphalt calibration systems in-line fuel heaters ... of...

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