MAGNUM MAX ASPHALT PLANTS F A Y A T M I X I N G P L A N T S
MAGNUM MAX MARINI LATIN AMERICA brings the best solution for your projects. The MAGNUM MAX plants series offer all the necessary components for the production of the most varied types of asphalt mixtures of high quality. Get to know the differentials of MAGNUM 80 MAX, MAGNUM 120 MAX, MAGNUM 140 MAX and MAGNUM 160 MAX plants. 2
Introduction MAGNUM MAX Highlights of the MAGNUM MAX series Super mobility and ease commissioning Efficient dosage of aggregates Counterflow dryer External rotational mixer Recycling solution Ease and low maintenance cost Technologies that preserve the environment Technical specifications Optional - Tanks Optional 02 04 06 07 08 09 10 11 12 13 14 15 3
Highlights of MAGNUM MAX Series SUPER MOBILITY AND EASE COMISSIONING Magnum MAX plants have super mobile design that ensures easy and economical transportation between jobsites and it is a strategic solution for the cost reduction of civil installation and operation. EFFICIENT DOSAGE OF AGGREGATES Individual weighing system with centralized loading cell, gearmotor drive, speed control by frequency inverter ensuring the correct proportion between aggregates. 4
RECYCLING SOLUTION The use of reclaimed asphalt pavement (RAP) is consolidated as a proven sustainable solution with an economic advantage. The Magnum MAX plants already have the pre-disposition of the RAP ring as standard, and can process up to 30% of recycled material. EXTERNAL ROTATIONAL MIXER The Magnum MAX series mixer uses modern American and European techniques to perform all types of asphalt mixtures, from the use of conventional asphalt to polymer and rubber modified binder. EASE AND LOW MAINTENANCE COST Magnum MAX plants have been developed with high technology, keeping the profile of ease and low maintenance cost. 5
Super mobility and ease commissioning The super mobile design of the Magnum MAX plants guarantees easy and economic transport between jobsites, and it is also a strategic solution for the cost reduction of installation and operation. The plant only needs a small area for installation on a compacted base, without the need for cranes. The MAGNUM MAX plants have great savings in the assembly time, promoting more practicality and speed in the jobsite. Within a week, with the execution of a few steps, the plant is ready to work. 1st Machine arrives at the job site... 2nd Anchoring of support feet and leveling... 3rd Articulation of drag elevator... 4th Set the cabin in work position... 5th Assembly of chimney... 6th Plant in operation. Option for two frames - More flexibility, shorter chassis for restrict access. 6
Efficient dosage of aggregates Individual dosage of the aggregates through centralized load cells, driven by gear motors, speed control by frequency inverter ensuring the correct ratio between aggregates. Depending on the configuration, the plant may have from 3 to 6 * feed bins with individual volumes of 6 m³ up to 10 m³ *; CANopen network communication; Mechanic floodgate with adjustment for the weighing of the aggregates; High efficiency in dynamic weighing; Individual centralized load cell for each feed bin; Design that facilitates the feed of aggregates with optimal angle for the flow of material; Wide opening for the feeding of aggregates; Gearmotor installed on the front roller, with variable speed through the frequency converter; Automatic vibrator in silo 01 (standard) and optional in other silos; Flat dosing belts with vulcanized sides; Optional scalping screen; Robust and high precision system. * According to the product configuration. 7
Counterflow dryer The drying system of the Magnum MAX Plant was designed to provide excellent drying of all types of aggregates, while ensuring the interrelation between combustion gases and the temperature of the virgin aggregates for subsequent mixing with the asphalt binder in the desired temperature. The initial section, designed with a larger diameter than the rest of the dryer body, reproduces the effect of a Venturi (reverse), decelerating the gases and preventing a significant percentage of larger particles from being drawn into the exhaust system. Consequently, there is a reduction of work load on the bag filter, significantly increasing the life of the filtering elements. Entry of RAP / Fiber / Filler Section 1 Drying zone Venturi Section Section 2 Drying and heating zone Section 3 Thermal exchange zone Mixing zone Dryer Mixer Dryer with 3 sections Section 1: larger diameter providing Venturi effect, with higher drying volume; Section 2: maximum heat exchange between aggregates and flame; Section 3: internal convection area that enables the heat exchange. 8
External rotational mixer Mixing zone external to the dryer A mixer capable of working with all types of asphalt mixtures. The External rotational mixer of the Magnum Max plants produces both conventional mixtures and polymer/rubber modified asphalt. In the case of applications with filler (lime or cement) or fiber, they can be introduced directly into the mixer through a side window or through the recycling ring. Some applications require the thermal exchange between the hot aggregates and the fiber (for SMA production), in this case the use of the recycling ring is the most appropriate solution due to the dry mixing time between the elements. The exclusive Marini Latin America mixer differentiate by a longer mixing time (dry + wet), providing greater homogeneity and quality of the final mixture. The mixer design, with bolted fins and bottom wearing plates facilitates maintenance and reduces operating cost. These components are manufactured from high abrasion resistant steel, which guarantees long life to the mixing system. Main advantages: Great mechanical power for the mixing process; Mixing zone with very low oxygen levels; Greater mixing time guaranteeing perfect homogeneity of materials; Exclusive Double Coating system; Low maintenance; Power savings. Longer durability of mixing flaps over conventional mixers; 9
Recycling solution Increasingly used in a variety of markets, the use of recycled material, known as RAP (Reclaimed Asphalt Pavement), is consolidating itself as an ecological, sustainable and economically advantageous application that is already required for some specific projects. The Magnum MAX line of plants already has the predisposition of the RAP ring as standard, being able to process up to 30% of recycled material. The Marini Latin America dryer and mixer design ensures a dry mixing time for thermal exchange between the virgin aggregates and the recycled material, which is essential for working with high RAP capacity and guaranteeing the quality of the final mixture. The dryer design ensures that the RAP does not get in contact with the flame of the burner. The gases generated in the thermal exchange between the RAP and the hot virgin aggregates are incinerated before proceeding to the bag filter, ensuring longer life-span of the filters, in addition to not harming the environment. Highest RAP capacity of the market, in compact plants, reaching 30%. The RAP ring in the dryer is the most recommended for application of special mixtures such as SMA, as it ensures a dry mixing time before the asphalt injection. 10
Ease and low maintenance cost The Magnum Series of plants is renowned for the durability of its components and the low maintenance costs, which guarantees profitability throughout its useful life. The dryer has bolted fins that facilitate maintenance and allow them to be removed and added in order to obtain a great performance in any situation; Mixing chamber with full access for maintenance; Mixer with all fins built on special steel of high wear resistance with a life-span of up to 300,000 Tons; High mechanical power of the dryer for the mixing process. Manual and Automatic Control The flexibility to operate with an automatic system, through a friendly and easy-to-use panel, and to guarantee the possibility of manual operation. Factory remote access for diagnosis and updates. Safety Inclusion of protection in all moving parts, ensuring the protection of the people involved in the process of production and maintenance of the equipment. 11
Technologies that preserve the environment Bag House Filtering system that retains the solid particles from the drying of the aggregates, and incorporates them to the mixture, avoiding their release into the atmosphere. The filtering element system guarantees an emission of particles of less than 50 mg/nm³, in accordance with the international environmental standards. The filtering process through the bag filter takes place in two steps: The first step of particle retention occurs in the Venturi dryer, where the particles larger than the passages in the #200 sieve remain in the dryer due to low gas speed. These particles are reinserted into the mixing process, directly through the dryer. The second stage of particle retention occurs at the inlet of the bag filter, which has a high mechanical strength plate, which receives the smaller particles, passing through the #200 sieve. This system provides a reduction in gas speed. The process of cleaning the filters occurs through valves with compressed air pulse. 12
Technical specifications DESCRIPTION MEASURES MAG 80 MAX MAG 120 MAX MAG 140 MAX MAG 160 MAX Nominal production Ton hour (t/h)** 80 120 140 160 Suspension / Brakes Type Double Tandem / ABS CHASSIS Triple Tandem / ABS Double Tandem / ABS Triplo Tandem / ABS Triple Tandem / ABS Quadruple Tandem / ABS Mobility Chassis no. 1 1 2 1 2 1 2 Axles / Tires No. 2/8 3/12 Kingpin in / mm 2" / 50,8 DIMENSIONS Triple Tandem / ABS 2/8 3/12 3/12 3/12 4/16 1/4 1/4 1/4 Length m 19,5 21,5 14 / 16 22,3 16 / 18 22,1 18,5 / 20 Height m 4,4 4,4 3,5 / 4,4 4,4 3,5 / 4,4 4,4 3,8 / 4,4 Width m 3,2 3,2 3,2 3,2 3,2 3,2 3,2 Total Weight Ton 34 37 11/31 45,5 11/40 48,5 11/40 DOSAGE OF AGGREGATES Feed bins No. 3 / 4* 3 / 4* 4 / 5* / 6* 4 4 / 5* / 6* 4 4 / 5* / 6* Bin capacity m³ 6 6 10 7,5 10 7,5 10 Weighting system Type Individual weighing by centralized load cell Wall vibrator Type Bin 1 Bin 1 Bin 1 Bin 1 Width of dosing belt in / mm 20 / 508 Width of transporting belt in / mm 24 / 609,6 DRYER Dryer Type Counterflow Dimensions m Ø1,8 (major section) x Ø1,5 (major section) x 6,0 (length) BURNER Ø1,8 (major section) x Ø1,5 (major section) x 7,0 (length) Ø2,2 (major section) x Ø1,8 (major section) x 6,5 (length) Ø2,2 (major section) x Ø1,8 (major section) x 6,5 (length) Burner Tipo Marini CF 04 Marini CF 04 Marini CF 04 Hauck Starjet 4260 Thermal power kcal / h 8.000.000 10.000.000 12.000.000 12.425.000 Mixer Type MIXER BAG HOUSE External Rotational 15 second dry mixing / 40 second wet mix Filtering system Type Dry Filter Quantity No. 288 360 400 480 Material - Nomex Nomex Nomex Nomex Air compressor Quantity 2 x 80 PCM Efficiency % 99,9 Particle Emissions mg / Nm³ Below 50 Cleaning Type Pulsating air jet ELEVATOR Elevator Type Drag-Mixer Hot Mix Asphalt Silo m³ 1 / 10* / 25* / 50* RECYCLING Recycling ring - Standard Standard Standard Standard Capacity % Up to 20% Up to 20% Up to 30% Up to 30% CONTROL UNIT Cabin Type Metallic with control panel Air Conditioning Type Air conditioning of 9000 BTUs/h Operation Type Automatic and manual system (*) Optional items. (**) The production of the plant is variable and depends on the following factors: humidity of the aggregates, altitude of the equipment installation site, percentage of fines of the mixture, temperature of the mixture, calorific value of the fuel and specific weight of the aggregates. 13
Optional - Tanks TANKS - Heating and storage systems for asphalt and fuel Marini Latin America has a variety of horizontal mobile tanks for asphalt and fuel with a structure built on a chassis and own axles. Tank Features: Capacities of 60,000 L, 80,000 L and 100,000 L; Compartment options with asphalt and fuel; Full thermal insulation with external protection; Direct heating by internal serpentine; Thermal fluid heating system (300,000, 400,000 or 600,000 Kcal/h); Flexible pipes that connect the tanks and the plant; Asphalt loading and circulation system; Fuel loading system; Modified asphalt agitators system, polymers, etc.; Safety system with temperature sensors and controllers. Layout of the Asphalt Plant and Tank Asphalt agitators 14
Optional Hot Mix Asphalt Silo Screw Compressor Mobile Cabin RAP Unit Filler Bin Recovered Fines and Dosing Unit Fiber Bin Flow meter Rectifier Tanks - Heating and storage of asphalt and fuel system 15
All photos, illustrations and specifications are based on the information in force on the date of approval of the publication. Bomag Marini Latin America reserves the right to alter the specifications and designs and to delete components without prior notice, as well as to adjust the equipment into different operating conditions. The yield data depends on the conditions of the work. Some of the equipment mentioned are optional, even without explicit indication in the text. April/2017 BOMAG MARINI LATIN AMERICA Rua Comendador Clemente Cifali, 530 CEP 94935-225 Distrito Industrial Ritter Cachoeirinha/RS Brazil Phone: +55 (51) 2125 6677 Fax: +55 (51) 3470 6220 www.bomagmarini.com