When the most expensive product in an asphalt mix is one that can be created on-site using recycled materials, smart producers seek alternative means to use that surplus product in a new way to improve their bottom lines.
For Brauntex Materials, a leading provider of hot-mix asphalt and crushed limestone products in central Texas, a cost-benefit analysis quickly showed that investing in equipment that could produce fractionated reclaimed asphalt pavement (FRAP) would not only eliminate unused material from the company's operation, but save money at the same time.
New Material Production
Using a KPI-JCI and Astec Mobile Screens ProSizer 3100 and a Fold 'n Go 2612D mobile screening plant purchased from T-K-O Equipment in New Braunfels, Texas, Brauntex Materials found it could produce a variety of new materials, including a 1/2 in x 3/8 in (1.27 cm x 0.95 cm) product and a minus-3/8 in (0.95 cm) for its FRAP product, according to company employee Albert Flores. The company also owns a FT2640 track-mounted jaw crusher to crush recycled concrete and oversized rock that is brought from other jobsites.
"The 1/2 in x 3/8 in (1.27 cm x 0.95 cm) product is one of the most valuable products in our asphalt mix because it is the most expensive to purchase as virgin aggregate," Flores said. "By processing the recycled material using the mobile high frequency screening plant, Brauntex Materials is able to save on virgin aggregate and bring costs down, as well as offer an environmentally-friendly solution for our end-users."
By incorporating a high percentage of FRAP into an asphalt mix, producers not only reduce the amount of virgin rock mined and use less oil, but they also conserve the energy used for trucking and decrease the energy used for processing.
Brauntex Materials currently produces 160,000 tons (145,149 tonnes) of aggregate per year, 20 percent of which is recycled, Flores said. The company has five virgin aggregate bins and two RAP bins on-site.
"The high frequency screen works much differently than any conventional screen we've ever used," Flores continued. "Because you can't fractionate the finer products required for FRAP efficiently using a conventional screen, this high frequency screen makes all the difference to our operation, and allows us to get the sizes we require for our asphalt mix."
The ProSizer high frequency screening plant functions by providing an aggressive screen vibration directly applied to the screen media that allow for the highest screen capacity in the market for fines removal, chip sizing, and dry manufactured sand. The closed-circuit mobile plant incorporates a double-deck Pep Vari-Vibe high frequency screen with a 3136 horizontal shaft impact crusher, which allows Brauntex Materials to recirculate the oversized material so two sizes are produced, leaving no wasted product behind, Flores said.
"We can handle up to 6 in (15.24 cm) minus material in our mobile screening plant," Flores said. "The horizontal shaft impactor will break down that pancake-size product into usable material, which means we have less waste, giving us a higher return."
By incorporating a high percentage of FRAP into an asphalt mix, producers not only reduce the amount of virgin rock mined and use less oil, but they also conserve the energy used for trucking and decrease the energy used for processing, according to regional sales manager John McGimpsey.
Brauntex Materials selected the ProSizer 3100 because it knew incorporating FRAP into its asphalt mix was important to achieving a better bottom line, as well as staying environmentally friendly in its operation.
"The portability of the ProSizer 3100 allows the producer to move around to multiple jobsites and process FRAP back to its original size," McGimpsey said. "It allows producers like Brauntex Materials to increase its RAP and FRAP usage, while adding flexibility and improved control in mix designs."
Brauntex Materials produces hot-mix asphalt and crushed limestone products in central Texas.
On-site material is recycled for use as virgin material in asphalt mixes.
The closed-circuit mobile plant allows oversized material to recirculate leaving no wasted material behind.