The Stationary Asphalt processing Plant adopts a physical method to achieve limited separation of old aggregates and old asphalt in RAP, enabling precise classification management of RAP. The RAP aggregate gradation processing plant significantly reduces the phenomenon of false particle size and RAP variability, effectively solving and improving the key issues of RAP content and performance, truly maximizing the utilization of materials.
According to requirements, RAP Asphalt Aggregate Recycling Equipment can be divided into 2-5 grades and stored separately, typically in the following categories: 0-3-5-12-16-22 (25). Strict control of moisture content and mixing aggregation is maintained.
In terms of process, two methods are available: screening first and then crushing, or crushing first and then screening, depending on the working conditions.
The horizontal type RAP asphalt recycling plant adopts a compact, modular horizontal layout that simplifies installation, enhances maintenance access, and reduces the structural height, making it suitable for both urban and remote job sites. This layout integrates seamlessly with other equipment in a Stationary Asphalt Processing Plant setup.
2.Flexible Processing Configurations The horizontal type RAP asphalt recycling plant allows multiple configurations depending on RAP quality and usage requirements. It can be equipped with systems for:
(1)Simple classification
(2)Moderate stripping and three-level grading
(3)Precision stripping and five-level grading
3.Advanced Aggregate Gradation Control
Integrated RAP aggregate gradation processing plant systems allow for precise control of particle sizes (e.g., 0–3–5–10–15 mm), reducing false gradation and ensuring consistent material performance. This is critical for achieving reliable asphalt mixture quality in high-percentage RAP usage.
4.Efficient Asphalt Binder Removal Utilizing equipment such as the HCC(S) Flexible Milling and Disaggregation Machine, the horizontal type RAP asphalt recycling plant enables physical stripping of aged asphalt without over-crushing aggregates, preserving material properties while preparing the RAP for optimal reuse.
5.Integrated Dust, Moisture & Iron Control Systems The RAP Asphalt Aggregate Recycling Equipment features integrated dust collection, moisture regulation, and iron removal units, ensuring clean, dry, and contaminant-free reclaimed material. This setup enhances the performance and lifespan of the entire Stationary Asphalt Processing Plant.
6.High-frequency Fine Screening Technology Especially for fine RAP fractions (0–3 mm or 0–5 mm), the RAP Asphalt Aggregate Recycling Equipment employs high-frequency, low-amplitude vibration technology to prevent screen clogging and maintain throughput. This ensures efficient separation in the RAP aggregate gradation processing plant.
7.Scalability & Customization Whether used as a standalone horizontal type RAP asphalt recycling plant or as part of a complete RAP Asphalt Aggregate Recycling Equipment chain within a Stationary Asphalt Processing Plant, the system supports scalability from 20% to 80% RAP content, allowing flexible application in highways, municipal engineering, or patch repair.
8.Intelligent Control & Data Integration The RAP Asphalt Aggregate Recycling Equipment features intelligent automation systems for monitoring, control, and data logging. These systems optimize each processing stage across the RAP aggregate gradation processing plant, increasing efficiency and reducing manual intervention.
Product Details
To enhance the incorporation and utilization of reclaimed asphalt pavement (RAP) in new mixtures, with replacement ratios ranging from 20% to 80%, Stationary Asphalt processing Plant is essential to address several critical technical challenges. These include asphalt stripping from the RAP material, precise aggregate gradation, elimination of false particles and inaccurate gradation, and stabilization of both the residual asphalt content and its activity on the aggregate surface.
By solving these issues, the Stationary Asphalt processing Plant is significantly developed, promoting effective blending and penetration between the reclaimed and virgin asphalt. This reduces mix variability and ensures that the asphalt mixture meets all required technical specifications for asphalt concrete.
1.The Stationary Asphalt processing Plant can be customized with various processing configurations based on the characteristics of the RAP source and specific application requirements. These configurations may include:
(1)Basic classification without stripping
(2)Simple stripping with three-level aggregate grading
(3)Precision stripping with five-level grading (e.g., 0–3 mm or 0–5 mm fractions suitable for use as asphalt mortar in repair projects, partial cold recycling, or asphalt extraction and separation)
Additionally, the equipment can perform fine crushing to produce asphalt powder, which may be used in centrifugal extraction or modified for application in new energy battery materials.
Regarding the aging level of the asphalt binder, heavily aged RAP typically exhibits reduced viscosity, making the binder easier to strip. In contrast, newer asphalt is more difficult to strip. Furthermore, stripping efficiency is generally higher at lower temperatures than at elevated ones.
2. Dual-Screen Precision Processing Solution This advanced scheme typically employs a "moderate stripping followed by screening" process. The output includes five specific RAP aggregate gradations: 0–3 mm, 3–5 mm, 5–10 mm, 10–15 mm, and above. Asphalt on the aggregate surface is stripped, and false particles are removed to improve homogeneity. Indicative asphalt content by fraction is:
(1)0–5 mm: ~5–8%
(2)5–10 mm: ~1.5–2.5%
(3)Above 10 mm: <1.5%
(Note: These values are for reference only and may vary depending on RAP source and material properties.)
The processed material from the RAP Aggregate Gradation Processing Plant can be used in high proportions within new mixes, ensuring consistent mixture quality and significantly reducing virgin asphalt consumption—offering strong economic value.
For fine material (0–10 mm), a dedicated fine screening system is used (0–3–5–10 mm gradation), featuring:
(3)High-frequency motor or electromagnetic vibratory mechanisms
(4)Anti-clogging technology to prevent screen blinding from fine material adhesion
3.HCC(S) RAP Flexible Milling and Disaggregation Machine – Patented Product
This machine is an industry-first, patented innovation that integrates shearing as the primary mechanism, combined with moderate flexible impact technology, to perform composite processing of RAP materials. It is specifically designed to remove aged asphalt while minimizing aggregate breakage, preserving the integrity of the reclaimed material.
The machine offers high versatility through multiple adjustable parameters, including:
(1)Operating frequency
(2)Spacing between milling rods
(3)Milling rod shapes (square, hexagonal, rhombic, comb-tooth configurations)
(4)Rod materials and diameters
(5)Number of rotor cages (adjustable from 2 to 6)
Production Process
Process for Determining the Final Production Mix Ratio
Production Process Flow
Procedure for Determining the Optimum Binder Content of Reclaimed Asphalt Mixture
Finished asphalt aggregate sample
Range of Configuration
1.Municipal Road Maintenance and Upgrades In city road networks, where environmental impact and cost control are critical, the horizontal type RAP asphalt recycling plant allows for localized and efficient reuse of RAP. Combined with a Stationary Asphalt Processing Plant, it supports sustainable municipal infrastructure development.
2.Asphalt Patch Repair and Pavement Rehabilitation Fine-graded materials (e.g., 0–3 mm, 0–5 mm) processed through the RAP aggregate gradation processing plant can be used for asphalt mortar in patch repairs. This enables quick, durable fixes for potholes and damaged sections, using recycled materials from the RAP Asphalt Aggregate Recycling Equipment line.
3.New Energy Materials – Asphalt Powder Production When equipped with fine milling and classification units, the RAP Asphalt Aggregate Recycling Equipment in the horizontal type RAP asphalt recycling plant can process RAP into asphalt powder. This powder can be used in centrifugal extraction, modified for use in new energy battery materials, or further analyzed via the RAP aggregate gradation processing plant.
Can the equipment be customized according to customer requirements?
Yes, we provide fully customized equipment solutions based on client requirements, including size specifications, functional configurations, and capacity design to meet the unique demands of each project.
Is Ninon provide installation and commissioning services?
Yes, we provide comprehensive installation and commissioning support, either on-site or through remote technical assistance, to ensure optimal equipment performance.
What is the warranty period for the products?
The standard warranty period for most core equipment is generally 12 months, with exact terms defined in the purchase agreement.
How to Choose the Most Suitable Equipment?
First, customers should provide information on the type and hardness of local raw materials (e.g., granite, river pebbles, limestone etc.).
Next, customers need to specify the desired finished product requirements, including fineness modulus and particle shape.
Then, based on the required production capacity (e.g., tons per hour), different models can be recommended—for example, a shaping sand making machine for higher output, or equipment tailored for ordinary or specialized mortar production depending on the application.
Finally, customers can select and customize the equipment based on site conditions, installation environment, energy consumption, maintenance costs, and overall project budget.
What certification standards do the machines comply with?
Our equipment complies with international standards, including ISO 9001 quality management certification，ISO 14001 – Environmental Management System. Third-party inspections, such as SGS reports, can be arranged based on specific customer requirements.
What are the available payment methods and Incoterms ?
We accept multiple payment methods, including T/T, L/C, and others as agreed upon in the contract. The Incoterms accepted are generally FOB,CFR,CIF,DAP,and also depending on the terms specified in the contract.
