Cold recycling

Cold recycling

Economical and resource-friendly: not only does recycling save limited resources, it also significantly lowers costs while increasing efficiency.

As a competent partner, BENNINGHOVEN offers a wide range of products in the area of RAP feed systems. For cold feed systems, we can already achieve RAP feed rates of up to 40% with a variety of technologies ranging from dosing into the dryer drum or mixer to a multi-variable dosing system.

Technologies work with both our own plants and third-party plants and are available as retrofits or expansions to existing hot feed systems to maximize flexibility.

Middle ring feed system

The middle ring dosing system allows up to 25% recycling material to be added.

Retrofitting on existing systems from all manufacturers is possible without problems. For center-ring feed, large quantities of RAP material are used. The material is introduced into the dryer drum with a belt and a ring elevator, mixed with the virgin mineral, and heated gently.

BENNINGHOVEN has designed a special solution to avoid caking in the drum and the chutes. The generated rough filler from the dedusting system is used to coat the RAP material with the aim of improving the transport characteristics of the heated recycling material through the asphalt mixing plant (reduces adhesion).

Highlights

> Dosing of up to 25% RAP material possible
> Easy retrofitting of existing plants, regardless of brand
> Gentle heating of the material in the dryer drum

Middle ring dosing system

1. RAP collecting/inclined conveyor
2. Transfer unit (hopper)
3. Conveyor belt
4. Knife valve
5. Dryer drum
6. Filler blower

Mixer feed

For mixer feed, up to 30% RAP material can be added, depending on composition, quality, and moisture content.

Retrofitting on plants from any manufacturer can be implemented without problems. For the mixer feed, large quantities of RAP material are possible.

The RAP material is conveyed directly from the feed hopper to the mixer level with an inclined conveyor or alternatively with a space-saving elevator. Dosing is carried out with belt scales so that a precisely defined RAP volume is fed to the mixer through a chute.

Highlights

> Dosing of up to 30% RAP material possible
> Easy retrofitting of existing plants, regardless of the brand
> Dosing with belt scales
> RAP material is added directly into the mixer with an inclined conveyor or a RAP elevator.
> The RAP elevator is a space-saving alternative to the inclined conveyor.

Mixer feed

1. Bucket conveyor
2. Drive with service mode
3. Chute with wear lining and service cover
4. Overfill protection
5. Conveyor belt with belt scales and belt cover
6. Pneumatically actuated flap

Multi-variable feed and variable feed

The multi-variable dosing system allows the addition of 40% RAP material – the highest possible ratio for cold recycling.

Unlike a variable feed system, the multi-variable feed system can be used for adding RAP material as well as adding bulk materials or additives. The additional weighing belt allows for exact dosing of these substances. In addition to the powder and granulate feed systems, this offers another option of introducing additional substances into the mixing process.

The RAP material is conveyed directly from the feed hopper to the mixer level with an inclined conveyor or alternatively with an elevator. A RAP quantity defined in the mixing recipe is added to the mixer in portions. Highly precise weighing technology allows for very exact dosing. Gentle, cyclic addition prevents strong hydraulic shocks during water expansion and is therefore gentle on material and components.

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Highlights

> Dosing of 40% RAP material possible
> Smooth, sequential loading of the mixer prevents hydraulic shock during steam expansion
> Exact dosing with high-precision weighing equipment
> Gentle on material and components
> Highest possible dosing capacity in the cold RAP
> Dosing option for all non-adherent bulk materials, e.g. Trinidad asphalt, rubber granulate

Multi-variable feed system

1. Bucket conveyor / 2. Drive with service mode / 3. Chute with wear lining and service cover / 4. Overfill protection / 5. Buffer container (3 t, 4 t *) incl. level indicator / 6. Frequency-controlled feeder belt / 7. Frequency-controlled weighing belt and belt cover / 8. Chute with wear lining and service cover / 9. Pneumatically actuated flap

* In combination with hot recycling system

Variable feed

1. Bucket conveyor / 2. Drive with service mode / 3. Chute with wear lining / 4. Maintenance cover / 5. Overfill protection / 6. Buffer container (5 t, 6 t *) incl. level indicator / 7. Buffer container, lower section / 8. Frequency-controlled conveyor belt with belt scales and belt cover / 9. Chute with wear lining and service cover / 10. Pneumatically actuated flap

* In combination with hot recycling system


Benninghoven value

Using technology to work towards a more efficient use of energy and raw materials is the challenge of today and tomorrow. Solutions from Benninghoven can help to cut energy consumption and emissions, and enable the operation of asphalt mixing plants with high rates of RAP usage – which also ensures the long-term future of the mixing plant site.

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BENNINGHOVEN technologies

Asphalt production, recycling systems, combustion technology, control systems, and bitumen technologies – thanks to BENNINGHOVEN’s technologies, each of our customers can find the right solution for their specific site that fully complies with requirements and conditions.

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