TOP TOWER Tomorrow and beyond

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TOP TOWERTomorrow and beyond

TOP TOWER Gb_5 2013 29-05-2013 14:09 Pagina 1

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Sustainable road building and energy saving requirements are majorconcerns for today’s road builders. Production equipment must be adaptedto suit all types of recycling and modern low-energy mixes, in addition toincorporating the most recent developments designed to optimiseproduction costs. These concepts are behind the development of the FayatGroup’s new generation asphalt plant – Top Tower.


T O P T O W E R

Brimming with technology

Top Tower is the result of over 50 years’ experience in the development andconstruction of hot-mix asphalt plants. It is also the synthesis of an ongoing dialoguewith our clients which has allowed us to incorporate all of their desiredimprovements into this plant, resulting in a functional and highly efficient machine.

4 Focus

8 Specifications

19 The range

At each stage, our engineers have focusedprimarily on developing innovative solutionsdesigned to enable our clients to produce high-quality asphalt mixes at the best cost.

Contents:

The entire life cycle of the plant has been re-engineered and optimised, from the transportationand assembly of the equipment to its routinemaintenance, not forgetting production managementand energy consumption.

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F o c u s

Innovation and sustainable development

Energy savings and the reduction of greenhouse gas emissions are at the heart of theTop Tower design. All types of recycling and special or warm asphalt productiontechnologies are also offered.

Environment

� the plant innovative design helps to reduce electricity

and fuel consumption, resulting in significantly

reduced CO2 emissions

� atmospheric particle emissions comply with the

latest environmental regulations

� the mixing tower is designed to incorporate total or

partial cladding, for even lower particle and dust

emissions and reduced noise

� the plant also has a smaller footprint

Energy savings

� by positioning the filter above the dryer drum and

redesigning the drying-filtering unit, we have

optimised the gas and recovered fines circuits

� thanks to the shorter dryer-filter duct, the gases at

the dryer mixer outlet lose less heat and the burner

consumption is significantly reduced

� the treated fines are collected by gravity into the

hopper positioned under the filter and are stored next

to the fines weighing hopper, which reduces the

number of augers required and the overall electrical

consumption. These recovered fines are kept in a hot

environment and are reintroduced into the final

mixture at the highest possible temperature

� the screen and hot bins are insulated and cladded in

order to reduce energy losses


Special asphalt mixes

The mixer is preconfigured to accept all types of solid additives and fibres in bags orbig-bags and calibrated RAP, without reducing the plant production output.

Warm-mix asphalt

The production of warm-mix or low-energy asphalt is

possible regardless of the technology used:

� introduction of wet sand into the mixer via the supply

circuit for cold RAP

� addition of zeolite crystals

� addition of liquid additives to the bitumen line in

order to reduce the binder viscosity

� production and injection of foam bitumen

Recycling

The crushed RAP is stored in and supplied from specific

RAP feed bins.

It is introduced into the dryer drum recycling ring and/or

directly into the mixer via a dedicated elevator. It may also

be dried separately in an additional parallel drum.

T O P T O W E R

Special asphalt mixes

Coloured or clear asphalt mixes can be easily

manufactured by adding pigments directly into the mixer

and via a dedicated clear binder line.

Special binders (modified bitumen and bitumen

emulsion) can be injected into the mixer via the

conventional bitumen line or via an additional line. They

are metered using the bitumen weighing hopper

supplied.

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F o c u s

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Transportation, assembly and ergonomics

The plant modular design and factory pre-wiring facilitate transportation and speedup the assembly of its components. The ergonomics of the plant have also been redesigned in order to improve usercomfort and safety.

1 Steel foundations (optional) 2 Dryer drum 3 Under-filter hopper,filter and walkways

Assembly sequence

Drying-filtering unit

Mixing tower

4 Hot-mix asphalt storage and cabin

5 Mixing, metering, hot bins and screen stages

6 Hot-mix elevator, filler silo and filler elevator


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Improved ergonomics

� the layout of the plant has been optimised, thus

simplifying the movement of site equipment

� a spacious cabin offering a perfect view of the plant

houses all of the electrical control cabinets

� the stairs and walkways allow easy access to all

parts of the plant and its peripheral components

� wide access points allow for ease of movement in

complete safety

Easy maintenance

� maintenance operations are facilitated as there are

fewer servicing points

� thanks to our patented system, the screen meshes

can be quickly dismantled and replaced

� drum installation is faster as the rollers are very easy

to adjust

T O P T O W E R

Quick assembly and transfers

� the plant modular design facilitates the

transportation and assembly of its components

� the self-supporting steel foundations allow the plant

to be assembled on a stabilised ground (2.5 kg/cm2),

for easier transfers

� all of the tower cable tray is built into the structure

and walkways

� Option: decentralization of power panel control

signals


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S p e c i f i c a t i o n s

General operation of the plant

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1 Storage and metering of virgin aggregates

2 Storage and metering of recycled materials

3 Drying-filtering unit

� Dryer drum and recycling ring

� Under-filter storage silo

� Filter

4 Imported filler silo

5 Mixing tower

� Hot elevator

� Fines elevator (mix storage under mixer configuration)

� Screen

� Hot aggregate bins

� Metering of components

� Mixer

6 Hot-mix asphalt storage

7 Binder storage tank

8 Control cabin and automation


T O P T O W E R

Hopper

� basic capacity: 11 m3

� loading width: 3.5 m

� extension up to 18 m3

� from 1 to 12 hoppers

Features

� synchronisation of extractor outputs

� LED indicators showing extractor operation

and the need to reload the hopper

� reduced loading height

Aggregate cold feeders

Storage of materials and recomposition of the gradation curve

Cold feeder

� volumetric metering (accuracy: ± 5%)

� output from 6 to 150 T/h

Options

� metering controlled by weight (accuracy: ± 2.5%)

� antiadhesive coating

� protective grids

� steel foundations



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Dryer feeding belt

� reversible belt for easy calibration of the aggregate

metering devices

� a vibrating scalping screen can be fitted at the start

of the feeding belt

Drying-filtering unit

The filter is now positioned directly over the dryer drum. The flows of gases andmaterials have been optimised and the plant smaller footprint facilitates themovement of site equipment and supply vehicles.

High-output counter-flow dryer drum

Design

� robotically arc-welded special steel tube

� shape and layout of the flights are designed to

optimise heat exchanges between combustion gases

and aggregates

� temperature probe for continuous monitoring of the

aggregates at the drum outlet

� aggregate outlet chute protected by a wearing plate

� air space insulation (rockwool insulation available as

an option)

Quick and easy drum position adjustment

� powered by 4 friction drives.

� drum can be adjusted simply by turning the external

adjusting screws, without stopping the drum

Drum E 220 E 250 E 270

Diameter 2,20 m 2,50 m 2,70 m

Lenght 9 m 10 m 11 m

Output * 225 t/h 300 t/h 370 t/h

*at 3% moisture content, ΔT = 140°C


T O P T O W E R

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Burner

The burner/dryer unit has been designed with maximum

thermal efficiency in mind: for optimised fuel consumption

and lower CO2 emissions.

Design

� reliable closed total air burner, with a simple design

� automatic start-up and adjustment of the burner and

regulation of heating power according to output

temperature of aggregates

Versatility

� suitable for all types of fuels on the market: diesel,

heavy fuel oil, natural gas and brown coal powder

� mechanical or electronic adjustment of the air/fuel

ratio

Filter and storage hopper

Filter

� the elliptical shape of the aramid fibre bags reduces

the size of the housing while maintaining the same

filtering efficiency

Recovered fines storage hopper

� as the storage hopper is situated directly underneath

the filter, the fines can be collected via gravity

� the feed auger operates at constant efficiency,

regardless of the quantity of fines stored

Filter FM 375/400 FM 540 FM 576

Filtering area 705 m2/750 m2 970 m2 1280 m2

Under-filter 25 m3 40 m3

38 m3

storage hopper 70 m3 80 m3



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Hot aggregate elevator

� sealed system for transporting hot aggregates from

the dryer drum to the screen

� self-adjusting chain tension using a counterweight

system

� easy and secure adjustment located at the foot of the

elevator via a lockout key

� totally sealed internal chain tensioning system

� easy to maintain marine-type double chain drive

system (single roller chain available as an option)

Mixing tower

With larger and more comfortable access points and a new patented quick screenmesh replacement system, servicing the tower has never been easier. Gravitymetering of bitumen is another of the Top Tower new features.

Vibrating 5 or 6-size screen

Direct access to the area behind the screen

The lateral position of the by-pass allows easy access to

the screen mesh, in order to facilitate maintenance.

Quick and easy mesh replacement

Easy access to the screen mesh, both from the front and

back. The lower screen mesh are in one or two parts

depending on the model, for quick and easy replacement

using a patented system.

Upgrading

It is very easy to move up from a five to a six-size screen.

Hot aggregate bins

Insulated to minimise heat losses, the hot aggregate bins

are designed to accommodate one or two bypasses,

depending on the model.

Screen VM 200 VM 240 VM 280

Total area 27,5/32,6 m2 32/38,4 m2 37/45 m2

(5/6 screen sizes)

Sand screen 6 m2 6,6 m2 8 m2

area

Hot aggregate 5 compartments 5 compartments 5 compartmentsbins (6 available as (6 available as (6 available as

an option) an option) an option)

By-Pass 1 separate 1 separate 1 separate

Hot aggregate 25 ton 25 ton 25 tonbin storage (60 ton available (60 ton available (80-140 ton as

capacity as an option) as an option) an option)


T O P T O W E R

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Bitumen metering

Design

The bitumen gravity metering system allows you to

change binder types “on the fly” without wasting

materials.

The weighing hopper is mounted on 3 weighing scales for

maximum accuracy.

It is emptied via an electrically-heated butterfly valve and

activated by an electro-pneumatic cylinder.

Safety

The weighing hopper is equipped with a safety level

indicator linked to the cutoff for the metering pump.

Overflow pipes channel any overflow into the mixer.

Metering of aggregates and fines

Aggregates and fines/fillers are both weighed in a

dedicated weighing scale.

Recovered fines/ imported filler elevator

Double, sealed elevator with rubber belt and steel

buckets.

TOP TOWER 4000

Weighing Number of Capacityhopper scales

Aggregates 3 2700 / 2900 kg (direct/screened)

Fines/fillers 2 410 kg

Bitumen 3 225 l

Weighing Number of Capacityhopper bilance

Aggregates 4 3500 / 3600 kg (direct /screened)

Fines/fillers 3 500 kg

Bitumen 3 350 l

TOP TOWER 3000



Mixer

Design

The drive system for the twin-shaft mixer consists of two

motor-reducers which are directly connected to the shafts

and synchronised by splined couplings. The shafts and

paddles have a honeycomb design for optimal mixing.

Versatility

The mixer is ready to accept all types of additives in bags

or big-bags, in addition to recycled materials. It also

features a water vapour disposal system.

All types of modern asphalt mixtures can be produced

(modified bitumen, warm-mix asphalt, etc.).

Safety

Operators are protected by a lockout key system which

prevents access to the interior of the mixer when the plant

is operating.

Reliability

The mixer seals and shaft support bearings are situated

outside the mixer, allowing for easy access and easy

maintenance while offering unrivalled durability, as they

are not in direct contact with the hot mix.

The mixer also benefits from a centralised lubrication

system, which can be automated upon demand.

Mixer

This essential part of the Top Tower has been completely redesigned. With its newshafts, honeycomb paddles and ingenious sealing system, this new-generation mixeris now even more reliable and efficient.

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T O P T O W E R

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Recovered fines and importedfiller circuits

The desing of the new drying-filteringunit optimises the recovered finescircuit.

Recovered fines circuit

As the filter is situated immediately above the dryer drum,

the fines descend into the storage hopper via gravity for

collection. As the distance travelled by the recovered fines

has been minimised, they can be added back into the

mixture without losing heat.

Pre-separator

The filter integrated pre-separator collects the largest

fines, which are reintroduced directly at the dryer mixer

outlet.

Recovered fines circuit

� Hot-mix asphalt storage on side

The fines are transported to the weighing scale by an

auger that is directly connected to the under-filter

storage hopper.

� Hot-mix asphalt storage under mixer

The recovered fines are transported to the buffer

hopper by a double fines/ filler elevator, and then

transferred to the weighing scale by an auger

Imported fillers

� Hot-mix asphalt storage on side

The weighing scale is supplied by a feed

auger that is directly connected to the raised

storage silo.

� Hot-mix asphalt storage under mixer

The fillers are transported to the weighing

scale by a double fines/filler elevator.

� Alternative fines/filler circuits may be

designed upon demand in response to specific

configurations.



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Binder storage equipment

The binder storage equipment is designed for loading tanks and supplyingthe asphalt plant in complete safety. Featuring vertical or horizontal tanks,heated electrically or by oil, the equipment on offer is capable of storing alltypes of hydrocarbon or synthetic binders.

Vertical, electrically-heated tanks

Specifications

� rockwool-insulated tanks

� heated by a thermostatically-controlled electrical

heating element

� continuous level indicator

� high-level safety indicator to prevent overflow

� purging vent

La gamma delle cisterne verticali elettriche

Thermo-fluid heated tanks

Thermo-fluid heated storage equipment can be supplied

with horizontal or vertical tanks. Horizontal tanks are also

available in mobile versions.

La gamme des citernes thermofluides

Boilers

Different models of boilers are available, depending upon

the desired heating power. All are equipped with

automatic burners and can use different fuels: light fuel

oil, natural gas and LPG.

La gamme des chaudières

Single-compartment Dual-compartment60 m3 70 m3

80 m3 (35 + 35 m3)

Vertical Horizontal

60 m3 50 m3

80 m3

Model Heating power200 232 kW400 465 kW600 698 kW800 930 kW


T O P T O W E R

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Asphalt plant management

The new CYBERTONIC control system manages all calibration, production andmaintenance operations. User-friendly and reliable, it guarantees the totaltraceability of production parameters.

Ergonomics and safety

� new visual design

� starts up the entire plant in complete safety - each

motor can be controlled with just one click

� easily identifiable alarms

� safety system for temperature monitoring

� monitors the absorption of the main motors

Production management

� easy management of mix formulas and production in

progress

� integrated extractor calibration system

� complete control of the heating of aggregates

� complete management of binder storage tanks

(loading, storage, transfer, etc.)

� management of hot-mix asphalt storage silos

� possible to incorporate a description of materials

used

Data management and traceability

� history of quantities of materials used or produced

according to formulas and production dates

� production data can be exported in Microsoft®

EXCEL© or ACCESS© file formats

� data may be transmitted by ADSL modem


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Hot-mix asphalt storage

Several different capacities and configurations are available to satisfy allrequirements. Thanks to the modular design of the storage silos, up to 3 modules canbe combined, in an in-line or perpendicular configuration.

TOP TOWER 3000Under mixer storage

Perpendicular version Loading by shuttle bridge

25 to 320 ton

Design

� truck clearance for under mixer storage: 4 m (4.36 m

on steel foundations)

� rockwool-insulated storage hoppers

TOP TOWER 3000 e TOP TOWER 4000Storage on side

Loading by skipand shuttle bridge

220 to 336 ton


In-line versionLoading by shuttle conveyor

25 to 580 ton

� electrically-heated and insulated discharge doors

� high-level indicator in hoppers (continuous level

available as an option)


Perpendicular version Loading by shuttle bridge

30 to 580 ton


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T O P T O W E R

The range

TOP TOWER 3000 TOP TOWER 3000 P TOP TOWER 4000 TOP TOWER 4000 P

2,20 m 2,50 m 2,50 m 2,70 m

3 ton 3 ton 4 ton 4 ton

200 t/h 240 t/h 280 t/h 280 t/h**

Dryer drum diameter

Mixer capacity

Nominal production *

*3% moisture, ΔT = 140°C**6% moisture, ΔT = 140°C

Hot mix asphalt storage on side

Hot mix asphalt storage under mixer


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www.marini.fayat.com

MARINI S.p.A.

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TOP TOWER Tomorrow and beyond

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