Hot Mix Asphalt Plants
Hot mix asphalt (HMA) paving materials are a mixture of size-graded, high quality aggregate (which can include reclaimed asphalt pavement [RAP]), and liquid asphalt cement, which is heated and mixed in measured quantities to produce HMA. Aggregate and RAP (if used) constitute over 92 percent by weight of the total mixture. Aside from the amount and grade of asphalt cement used, mix characteristics are determined by the relative amounts and types of aggregate and RAP used. A certain percentage of fine aggregate (less than 74 micrometers [µm] in physical diameter) is required for the production of good quality HMA.
Hot mix asphalt paving materials can be manufactured by: (1) batch mix plants, (2) continuous mix (mix outside dryer drum) plants, (3) parallel flow drum mix plants, and (4) counterflow drum mix plants. This order of listing generally reflects the chronological order of development and use within the HMA industry.
In 1996, approximately 500 million tons of HMA were produced at the 3,600 (estimated) active asphalt plants in the United States. Of these 3,600 plants, approximately 2,300 are batch plants, 1,000 are parallel flow drum mix plants, and 300 are counterflow drum mix plants. The total 1996 HMA production from batch and drum mix plants is estimated at about 240 million tons and 260 million tons, respectively. About 85 percent of plants being manufactured today are of the counterflow drum mix design, while batch plants and parallel flow drum mix plants account for 10 percent and 5 percent respectively. Continuous mix plants represent a very small fraction of the plants in use (#0.5 percent) and, therefore, are not discussed further.
An HMA plant can be constructed as a permanent plant, a skid-mounted (easily relocated) plant,or a portable plant. All plants can have RAP processing capabilities. Virtually all plants being manufactured today have RAP processing capability. Most plants have the capability to use either gaseous fuels (natural gas) or fuel oil. However, based upon Department of Energy and limited State inventory information, between 70 and 90 percent of the HMA is produced using natural gas as the fuel to dry and heat the aggregate.