Asphalt Dryer Optimization: Astec's Energy Saving Solution with Altair EDEM
Technology Category
- Sensors - Liquid Detection Sensors
- Sensors - Temperature Sensors
Applicable Industries
- Aerospace
- Life Sciences
Applicable Functions
- Product Research & Development
Use Cases
- Behavior & Emotion Tracking
- Experimentation Automation
About The Customer
Astec, Inc. is a member of the Astec Industries family of companies, located in Chattanooga, Tennessee. The company is a manufacturer of continuous and batch-process hot-mix asphalt plants and related equipment and services. Astec is committed to improving its products and services by leveraging technology and innovation. The company has integrated EDEM into its design process, recognizing it as a valuable tool for its engineers. Astec's commitment to energy efficiency and process optimization led to the challenge of redesigning their drum dryer for better performance and reduced energy consumption.
The Challenge
Astec, Inc., a manufacturer of continuous and batch-process hot-mix asphalt plants, was faced with the challenge of developing a more energy-efficient drum dryer that could process a wide range of aggregate types at various tonnage rates. The drying process in asphalt production is energy-intensive, requiring hundreds of tons per hour of wet aggregate rock to be dried in a rotating drum dryer before being coated with liquid asphalt. This process ensures that the asphalt will bind to the rock. Inside the drum, the aggregate is kept in motion by shaped scoops called flights attached to the inner surface, which produce a 'veil' of falling material. Better veiling action improves heat transfer and speeds drying, reducing fuel consumption. However, direct observation of the drum in operation is very difficult, making it challenging to experiment with new flight designs.
The Solution
Astec deployed EDEM, a Discrete Element Method (DEM) software, to provide a virtual environment for observing and analyzing the effect of flight design and operating parameters on material flow. Astec imported CAD files of the drum dryer into EDEM and generated an aggregate rock DEM Material Model. After model calibration, EDEM accurately simulated the dynamics of the rocks being lifted and released by the flighting. Using EDEM’s binning function to calculate the number of rocks in a given volume, Astec could quantify the density of the veiled aggregate in a given drum section. By virtually comparing the performance of different flight designs, Astec was able to arrive at a new flight design, called the 'V Flight,' which optimized the distribution of rock during veiling, improving the aggregate drying process.
Operational Impact
Quantitative Benefit
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