PROCESS

ASPHALT

Asphalt plants deal with a harsh environment and are subject to great mechanical and thermal constraints. Process monitoring and optimization is becoming an increasingly important issue for plants, especially in terms of energy savings.

Working closely with many of the world’s leading asphalt producers, ENVEA has developed an in-depth understanding of monitoring conditions faced by the plants.

As a result, ENVEA offers a specific package of rugged and reliable online measurement solutions helping plants to optimize their process : moisture measurement, filter performance monitoring, etc.

Download the asphalt production process brochure
Asphalt Production Process

(click on the blue dots on the diagram to see the measurement solutions interactively)

Moisture measurementMaterial flow monitoringLevel and limit detectionFilter performance monitoringEmission monitoringAmbient air or/and process leak detection

1

Moisture measurement

Moisture content monitoring of several materials featured in the production process is a significant element that can be leveraged in order to optimize operating parameters and improve its efficiency.

Moisture measurement can be implemented on the following materials:

  • on aggregates of all sizes, such as sand, that are sent to the rotary kiln via cold conveyors
  • on recycled materials inserted in the mixing tower.
  • on bitumen injected in the mixing tower. Requirement: it needs to be dry and cold.

ENVEA’s solution: M-Sens

Customer benefits:

  • Optimized dryer combustion, reduced gas consumption
  • Time saving and product quality improvement thanks to online and continuous moisture measurement

2

Material flow monitoring

Due to the harsh conditions within the process, material flow monitoring is essential to ensuring a better yield of the final product and thus increasing the productivity.

ENVEA’s solution: FlowJam

Customer benefits:

  • Quick detection of production stoppages
  • Reduced downtime and maintenance

3

Level and limit detection

Minimum and maximum level detection at various points within the asphalt plant is critical.

If silos, bucket elevators, chutes and hoppers are overfilled or insufficiently this will lead to blockages and plant downtime.

ENVEA’s solution: ProGap

Customer benefits:

  • Online warning of materials level
  • Quick detection of production jams

4

Filter performance monitoring

Optimizing filter performance is key to ensuring the smooth running of production facilities. The ability to identify or predict filter failure ensures production is kept at its required demand.

ENVEA’s solution: LEAK ALERT

Customer benefits:

  • Reduced downtime
  • Increased productivity
  • Reduced filter replacement costs

5

Emission monitoring

Continuous measurement of particulate emission flow and concentration enables to meet and exceed national and international standards.

That can be achieved through ENVEA’s ElectroDynamic™ range of products designed for use in harsh environments.

ENVEA’s solution: STACK, VIEW or STACKFLOW range, DUST TOOLS software

Customer benefits:

  • Compliance with Emission Limit Values (ELV)
  • Reduced environmental impact

6

Ambient air quality monitoring or/and process leak detection

Real-time odour monitoring (ex: H2S), particulate leaking and PM sizing can help to better identify environmental issues as well as protecting the workforce/neighbours from exposure to hazardous material.

ENVEA’s solution: Cairsens® micro-sensors (H2S and PM), AirSafe

Customer benefits:

  • Help to reduce environmental impact on population
  • Anticipate at-risk situations
  • Reduce maintenance costs

TESTIMONIAL – MR. PIERRE BEAUQUESNE, EQUIPMENT MANAGER AT EUROVIA

The EUROVIA MPRO asphalt plant in Mitry Mory (France) was commissioned in 1988.
The site produces more than 120,000 tons of asphalt each year for road construction sites.

What is the context for upgrading the site in terms of emissions control?

“The installation is equipped with a bag filter covering a surface area of more than 1,100 m2, which is composed of more than 700 Nomex® type textile bags. It is intended to ensure the filtration of dust-laden raw gases in order to guarantee a weight index set by local authorities’ order at 50 mg of total dust/Nm3.
As the filter bags of this dust collector are highly strained, we were looking for a reliable measuring device to alert us immediately if the 50 mg threshold was exceeded.”

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