Asphalt Plant Presentation - Guest Speaker


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  • Warren Brothers patent on asphalt
  • -In the late 1800’s - industrial revolution was in full swing-Asphalt was economical and quick-Need for larger production of asphalt
  • One of the first asphalt plants in AmericaPicture taken 1912Served purpose but many drawbacks – pollution, slow, very inefficientNotice horse in picture
  • Through 1900’s, Demand gave rise to increased productionStill no modern features such as accurate blending, fuel efficiency, pollution controls AND SAFETY
  • Today’s plants are clean, efficient, automated and SAFE
  • They handle various levels of demand and products.
  • Drums plants are most popular currently but still account for only 40% of total plants - Parallel Flow - Counter Flow - Double BarrelBatch Plant
  • Some of the various components of an asphalt plant from bird’s eye view.
  • Burner from early plant – pipe with a nozzle-very inefficient-no control of emissions and pollutants-usually only diesel fuel or propaneModern Burner – traits similar to jet engine-fuel is sometimes heated/pressurized/atomized/mixed with air/ignitedTypes of Fuel
  • Dust Collection – Environmental Compliance
  • In the old days no concern for pollution-released dust and pollutants in the air-Affecting the surrounding environment and the employees-Need for improved controls
  • Baghouse – Modern baghouseold plants utilized wet scrubber/washer
  • Air flow through baghouse. Some utilize cyclone or knock down boxAir flows below and up through bags and into top of baghouseBag pulse to release built up dust materialDust augured back to drum and blended with mix
  • Silo System
  • Mix dumped directly out of plantDrawbacks-No trucks equal plant shut down-One type of mix at a time.-Dangerous
  • First Modern Silo System-allowed storage of asphalt-lack of trucks didn’t require shut down of plant
  • Modern Silo System-Multiple silos allow plant to continue production while waiting on customers-Allow production/sale of multiple mixes
  • Plant Control-Heart of plant (the brain)Sophisticated controls-Control blending system-Updated Status & Control-Process Management and Diagnostics-Inventory ControlLoading and TicketingTime Entry
  • Cost breakdown of Asphalt from 1950 to 2012Largest component cost are materials drivenModern control system manages materials within tolerance of .5%Accounts for variations in specific gravities, temperatures, moistures and waste.
  • Asphalt Plant Presentation - Guest Speaker

    2. 2. Introduction• Shawn A. Riley – VP of APAC Kansas City & Missouri• Career – Hall & Riley Construction – APAC – Oldcastle
    3. 3. Who is APAC?• Until 2006 – Leading Construction Company in U.S. • #1 Asphalt • #5 Quarry
    4. 4. History of APAC• 1900 Warren Brothers Company, the forerunner of APAC, was founded February 5, 1900 in Nashville, Tennessee.• 1900 Frederick J. Warren filed a patent for "Bitulithic" pavement, a mixture of bitumen and aggregate.• 1901 The first modern asphalt production facility was opened by the Warren Brothers in East Cambridge, MA.• 1968 Ashland Oil, Inc. acquired Warren Brothers and the name changed to Ashland-Warren, Inc.• 1980 the Ashland-Warren name was changed to APAC, Inc. still under the ownership of Ashland.• 2006 APAC was acquired by Oldcastle Materials Group.
    5. 5. Who is Oldcastle?• Subsidiary of CRH, Inc. – Dublin, Ireland• 2 Division – Oldcastle Products Group • Oldcastle Glass • Oldcastle Architectural Products • Oldcastle Distribution • Oldcastle Precast • Oldcastle Merchants Metals – Oldcastle Materials Group
    6. 6. Oldcastle Materials Group• Supplies aggregates, asphalt, and ready-mix concrete, and provides paving services.• Over 1200 locations• Employees 17,500• 44 states• Over $6 billion Revenues
    7. 7. Locations
    8. 8. Why Asphalt Plants?
    9. 9. Original Design
    10. 10. First Plants
    11. 11. Modern High Production?
    12. 12. Today’s Plants
    13. 13. Types of Plants• Drum Plant – Parallel Flow – Counter Flow – Double Barrel• Batch Plant
    14. 14. Components of Asphalt Plant
    15. 15. Material Blending (bins)• Keeps materials separated• Allows operator to blend materials at rates/percentages dictated by mix design• Weighs aggregate as it enters drum dryer• Screens Aggregate
    16. 16. Drum Dryer
    17. 17. The Aggregate DryerPerforms Two Functions:
    18. 18. Drying and Mixing
    19. 19. Burner•Types of Fuel •Diesel •Recycled Fuel Oil •Natural Gas •Propane •Coal •Glycerin •Bio fuel •Industrial By-products •Food Industry By-products
    20. 20. Environmental Controls
    21. 21. Baghouse
    22. 22. Baghouse Flow
    23. 23. Early System
    24. 24. Silo System
    25. 25. Silo Systems •Multiple Silos Systems •250 tons each •Load Trucks •Ticket System
    26. 26. Controls
    27. 27. Fully Integrated Computer Systems •Fully Automated Systems •System Cost $250k •High Speed Internet Connection •Integrated with Accounting Software •Remote Troubleshooting
    28. 28. Costs of Production Equipment 6% 2012 1950 Labor 4% FOH FOH 3% Rock Rock 3%Admixtures Fuel 1% 18% Labor Rock 8% Sand Rock 19% 26% Asphal Sand t Asphalt Admix Sand tures Admixtures Fuel 13% Equip 6% Equipment ment Fuel Fuel Equipment Labor 11% Labor Asphalt Sand FOH FOH 47% 22% Asphalt Admixtures 13% 0%
    29. 29. Next Project