Plant for the production of cement and bituminous cold mixes in an automatic continuous cycle.

The F42-180T plant is equipped with sensors (load cells on all containers and the possibility of inserting moisture meters on the sands) in order to guarantee optimal control over production at all times. The machinery, in line with Industry 4.0 and 5.0, is made with leading brand components to guarantee quality and robustness. A 30 kW twin-shaft mixer enables it to process up to 180 cubic meters per hour of product. The final belt is then actuated by hydraulic cylinders to be able to tilt and change the maximum discharge height.

The F42-180T consists of:

• 4 inert tanks
• 2 cement/filler/lime hoppers
• 3 pumping systems: water, bitumen emulsion, liquid additives
• twin-shaft mixer
• cockpit
• tilting end tape
• 2 vertical silos

The plant is set up for the purpose of producing, through continuous batching and mixing, cement and bituminous cold mixes with the following components:

• virgin and/or recycled aggregates
• cement
• Non-reacting powdered supplements called “fillers”
• water
• cold bitumen emulsion
• liquid additives for concrete mixes

The production system consists of 6 main components:

1. ONE STORAGE, DOSAGE AND INERT TRANSPORT AREA TO THE MIXER:
   No. 4 aggregate storage hoppers in various sizes (storage aimed at feeding the extractor conveyor belts for feeding the mixer); the hoppers are equipped with weighing systems. Each hopper is equipped with fixed overdrains. Each tank, with over-probes, reaches to hold about 16 cubic meters of inert (maximum system load = 40 tons). No. 2 electro-vibrators are installed on each tank to facilitate the descent of material from the tanks. The extraction of material from the tanks is provided by a system of extractor belts controlled by gearmotors. The motors are driven at variable revolutions by inverters. Each belt is equipped with an inert presence sensor (limit switch). Each extractor belt conveys material to a conveyor belt (1 conveyor belt for each pair of extractor belts). The two conveyor belts convey the inert material from the tanks to another central belt that carries it to the mixer.
   
   
2. ONE STORAGE AND DOSAGE AREA FOR BINDING POWDER (FILLER, CEMENT):
   No. 2 on-board storage hoppers for cementitious binders and filler supplements or other powder additives. Each system consists of a hopper connected to an extraction auger controlled at variable speed by inverter. The hoppers are equipped with weighing systems (No. 4 cells for each hopper). Each hopper has a dust filtering system equipped with automatic compressed air cleaning system. Each hopper has an inspection spout on the top and an electro-vibration system to facilitate the descent of material from the tank to the extraction auger. Cement and filler are stored inside nr.2 vertical silos of 36mc each. The silos are equipped with special dust filtration systems. The filters are equipped with a self-cleaning compressed air system (blower management unit integrated in the filter). Each silo is equipped with pressure control valve, level sensors, compressed-air fluidization system, sailor-style stairs and guardrails.
   
3. NR. 3 PUMPING SYSTEMS (WATER, BITUMINOUS EMULSION AND VARIOUS ADDITIVES):
   1 process water pumping system: the system consists of a multistage centrifugal pump. The flow rate is measured by a sensor located downstream of the pumping machine with which to realize, through a valve, the variation of the flow rate itself according to the set production parameters. A calibrated overpressure valve protects the piping and the pump. A pressure gauge allows the pressure to be read;
   1 cold bitumen emulsion pumping system with a gear pump. The pump is driven at variable revolutions by an electric motor controlled by an inverter. The flow rate value is monitored by flow meter mounted downstream of the pump. The pump body is heated by three-phase electric glow plugs operated by thermostat.
   1 liquid additive pumping system for concrete mixes. The pump is driven at variable speed by electric motor controlled by inverter. The flow rate value is monitored by flow meter mounted downstream of the pump.
4. ONE MIXING AREA:
   No. 1 Continuous twin-shaft mixer for the production of cement and asphalt mixes. The nominal capacity of the mixer is around 150/180 cubic meters per hour maximum. The mixer consists of a synchronizing gearbox and two gear motors that give motion to the system. The motors are controlled at variable speed by inverters. The mixer is tiltable by hydraulic system. The mixer cover can be lifted by hydraulic system, and a safety sensor system “cuts the power” by acting on the emergency chain allowing access to the mixing box. The control of the solenoid valves is manual (manual distributor). The shafts are made from cold-formed steel square section to allow precise support of the paddle holders and variable mounting of the paddles depending on the type of material to be produced (cemented mix, asphalt reclaimed, concrete, etc.). Below are pictures of the CMF brand mixer model KB 150, previewed at GIC 2024:
   
5. A TRANSPORT ZONE OF MATERIAL PROCESSED FROM THE MIXER TO THE DISCHARGE INTO THE TRANSPORT VEHICLE (TRUCK, BETONER, WHEELER ETC.):
   The belt with variable inclination via dedicated hydraulic cylinder is equipped with a hydraulically tilting conveyor (manually operated coils) and an electro-vibrator to allow the material that remains attached on the inner walls of the conveyor to be able to detach and fall into the transport vehicle. In addition, covers are installed to shield the effect of wind. The final belt is equipped with a camera system to monitor the filling of the truck box from the comfort of the box-cabin.
   
6. OTHER COMPONENTS:
   • • WASHING SYSTEM: Consisting of a high-pressure piston pump equipped with a manual hose reel and a lance that allows the case to be cleaned every time it is used.

   

   • • • BOX-CONTROL BOX: On board the machine is a site box inside which is the control and command system of the plant, i.e., a touch monitor and a push-button panel. inside the box is the general electrical panel of the plant.

     

     • VISUAL PRODUCTION CONTROL SYSTEM: No.1 video camera for monitoring truck loading from the end belt connected to the main control panel (or other dedicated adjacent panel) enables visualization of truck/concrete mixer loading.