RAPID MIX 600 C
The Rapid Mix 600 C has been designed to be
totally mobile and completely self-contained with its own power source. It is also
completely self erecting, using the hydraulic system to change the plant from
its travel mode into a fully operational plant in minutes. The Rapid
Mix 600 C is a continuous mixing system, mixing up to 600 tonnes per hour
depending on application. Feed rates
are fully adjustable for the aggregate, cement and water systems. The plant is designed for any mixing
application where a cement or binder needs to be mixed into a base material.
Products such as Roller Compacted Concrete, Cement treated base, Bentonite,
Contaminated Soil stabilisation can all be mixed in this machine.
DIMENSIONS
Length of Machine when ready for transporting 63’-11” (19.5m)
Width of Machine 9 ‘-10” (3.00 m)
Height of Machine (When
ready for transporting) 13
‘-5” (4.1 m)
Height of Machine (When
Erected) 44’-4” (13.5 m)
Weight of Machine total 78,892
lbs (35,860 KGs)
Weight on Rear Tri-axles 54,780
lbs (24,900 KGs)
Weight on Front Pin 27,780 lbs
(10,960 KGs)
CHASSIS
Ø
Construction: Hollow
section members fully welded into Lattice design with brackets fitted for
attaching hydraulic lifting rams, bin, silo, conveyors, mixer, and all
ancillary items which make up the plant.
Ø
Running
Gear: Axle type: Standard tri-axle. Suspension: Single leaf
steel spring. Brakes: Standard air operated hub brakes with automatic slack
adjusters. Wheels: twin wheels on each hub, (4
per axle total 12 tyres) Lights: Rear marker lights, including
indicators, brake lights and side markers in accordance with regulations.
Ø
Access:
Walkways are provided along the chassis of the machine for maintenance access.
The walkways are constructed from q
grating material with handrails at appropraite points.
Aggregate Hopper with Variable Speed belt feeder
Ø
Capacity:
15.6 cu yds (12.0 m3
)
Ø
Loading
Width: 14 ft 2½ ins (4330 mm). The hopper can be loaded from either
side of the machine.
Ø
Construction:
S275 plate with stiffening ribs. Steep sides for difficult materials. (end
slopes of 60 degrees).
Ø
Removable
Division Plate: The hopper has a removable division plate,
allowing two materials to be used.
Ø
Lining:
To aid the discharge of the materials the hopper surfaces are fitted the low
friction high molecular polyethylene lining material (1/2” (12mm) thickness).
Ø
Adjustable
Gates: The outlet end of the hopper is fitted with
adjustable level gates to enable the material height on the conveyor belt to be
varied. These are adjsusted manually.
Ø
Belt
Feeder: A Conveyor belt feeder is fitted on the bottom of
the hopper to provide feed from the hopper to the mixer. The conveyor is fitted
with a heavy duty geared motor drive with automatic variable speed control and is
fitted with adjustable rubber skirts and additional heavy duty support rollers.
The belt width is 1200mm (4’) and a heavy duty 3 ply belt is fitted.
Twin Shaft Continuous Mixer
Ø
Mixing Action: The twin shafts mix the material,
whilst moving the material toward the end of the mixer.
Ø
Paddles: The twin horizontal mixing shafts
are fitted with chill cast steel paddles, which are intermeshed in a specially
phased relationship to optimise mixing action, whilst maximising throughput.
Ø
Cleaning and Maintenance Access: Special attention has been paid to
give the user maximum access for maintenance and cleaning operations. The top
of the mixer is fitted with hinged access covers, which when opened give access
to all of the mixing chamber. Both sides of the mixing chamber hinge down, to
give access, the sides are lowered by hydraulic cylinders.
Ø Drive: The
shafts are driven by 2No 55 kW (75 HP) electric motors through reduction
gearboxes with twin gears to synchronise the shafts.
Ø Mixing Chamber:
The mixing chamber is formed by fabricated sloped sides with a troughed
conveyor under the mixer forming the bottom of the mixer.
Ø Water Addition:
Water spray bars fitted into the top of the mixer allow the water to be added
to the material as it progresses along the mixer.
Ø Clean-out conveyor: Mounted on the bottom of the mixer, forming the bottom of the mixing
chamber, this conveyor allows the bottom of the mixer to be easily cleaned
out, when production is finished. This
conveyor is used for clean out purposes only. The mixer should be lined with a
bed of material every morning before production starts.
Cement/ Binder Silo
Ø Capacity: 55 US Tons (50 Tonnes) based on material being 1500 kg/m3
(93.64 lbs/ft3).
Ø Construction: Square
silo design constructed from all welded box section S275 plate with stiffening
ribs.
Ø Access to Roof:
By folding access ladder with safety cage, to the roof level, which is fitted
with double tubular handrail and kicking strip. An access hatch is provided on
top of the silo.
Ø Outlet: Flanged to
suit the rotary valve paddle feeder. A shut-off plate is provided to close the
silo outlet to allow maintenance to the feeder below.
Ø Silo Venting:
20m2 Reverse Jet Filter with fan assistance. A pressure relief valve is fitted
to protect the silo from over-pressurisation.
Ø Filling Pipes:
2No 4” (100mm) steel pipe with screwed end for fitting unicone or other type of
delivery hose fitting.
Ø Level Indication:
Rotating paddle style level probes for high and low level control.
CEMENT PADDLE FEEDER
Ø Type: 750mm (30”) square rotary
valve paddle feeder to feed the cement or binder material out of the silo.
Ø Drive: 2.2 kW (3 HP) geared electric
motor with automatic variable speed control.
OUT-LOADING CONVEYOR
Ø Function: Transporting
the mixed material from the twinshaft mixer to the truck. The conveyor is
designed to handle the maximum feedrate from the mixer. A Gob hopper fitted to
the top end of the conveyor allows some mixed material to be “held” for a while,
for example whilst the next truck drives under for collection.
Ø Contruction:
Box section S275 steel construction with mounting brackets for rollers and
pivot mechanism. The top section of the conveyor incorporates a folding section
for transportation.
Ø Belt: 1000mm
(39.4”) 3 ply belt with heavy duty top cover and vulcanised joint.
Ø Drive:
Motorised drum with rubber lagging.
Ø Belt Scraper:
Polyurethane blade pre-cleaner scraper mounted on the face of the head drum.
Ø Belt Scale:
A belt scale weigher is fitted to this conveyor to monitor and control the
feedrate and hence output of the plant.
Ø Gob Hopper:
Hopper fitted to the top end of the conveyor with pneumatic discharge doors.
Constructed from S275 plate.
WATER SYSTEM
Ø
Water Tank: A
1750 litre (462 us galls) is fitted complete with ball valve and galvanised
steel pipework.
Ø
Pumps: Two positive
displacement pumps are fitted to supply 2No water spray bars within the mixer.
Ø
Spray
Bars: Each Mixer spray bar has a ball valve to allow
addition of water early in the mix, later in the mix or both together. A
calibration point for accurate water weighing is also included.
PNEUMATIC SYSTEM
Ø
Compressor: The Rapidmix is equiped with a compressor to provide
the air supply for the Gob Hopper doors and the silo filter.
Ø
Valves, Regulator: Solenoid spool valves are fitted for the control of the Gob Hopper
doors. A lubricator is provided for the Gob Hopper cylinders. A regulator (with
pressure gauge) is provided to adjust the pressure as required.
HYDRAULIC SYSTEM
Ø
The hydraulic system is
used to level the machine before erection to the working position and also to
erect the silo and out-loading conveyor.
Also used for opening mixer sides for maintenance.
Ø
Hydraulic Powerpack: This consists of: Electric motor close coupled to a hydraulic pump
unit, Oil reservoir, return line filter, directional valve, filler/ breather,
level gauge.
Ø
Control Valves: Lever operated valves for operating the cylinders.
Ø
Hydraulic Cylinders: Double acting type used on: Jacking / Leveling, silo elevation, out-loading
fold-out, mixer sides.
Gen-Set
This
unit provides electrical power for all machine functions. Diesel powered generating
set rated at 281 KVA, 3 phase, 480/277 volts, 60 Hz, 1800 RPM at NTP
conditions. Powered by a Iveco, 6 cylinder, turbocharged diesel engine with directly coupled brushless
alternator.
Each
machine features:
·
Heavy
duty fabricated steel skid type baseframe with anti-vibration mounting pads.
·
Electric
starting system with heavy duty lead acid type starting batteries and battery
charging system.
·
High
capacity air, fuel and lubricating oil filters.
·
Fuel
feed and return lines from engine to baseframe fuel tank.
·
Industrial
exhaust silencer system.
·
Automatic
engine shutdown protection equipment with LED indicator for low oil pressure,
high engine temperature, low coolant level, overspeed, and fail to start.
·
Set
mounted autostart control and instrument cubicle containing voltmeter with
phase selection switch, ammeter with phase selection switch. dual scale frequency/
tachometer, water temperature gauge, oil pressure gauge, battery,
voltmeter, hours run
counter, 3 attempt starting timer, mode selector switch run/off/auto, emergency
stop button, lamp test/reset button, terminals for remote start, remote
emergency stop and common alarm signal.
·
Set
mounted circuit breaker cubicle containing suitably rated 3 pole moulded case
circuit breaker.
·
Instruction
manuals and electrical wiring diagrams.
Plant Control sYSTEM
The system uses a Siemens
PLC to control all of the plant functions for automatic control with manual
backup. An operator panel is used for the display of all plant parameters.
Ø Operator Control Panel:
The operator control panel consists of a series of push buttons and selectors
to allow automatic and / or manual control of the following:
·
Mixer
·
Air compressor
·
Out loading conveyor
·
Aggregate conveyor
·
silo feeder
·
Water pumps
·
Hydraulic power pack
·
Mixer clean out conveyor
·
Silo filter fan unit
·
Internal lighting
·
External lighting
·
Gob hopper doors
·
Auxiliary feeder
·
High silo alarm
·
Low silo alarm
·
Low water alarm
·
Alarm mute button
·
Emergency stop push button
·
Emergency stop reset
·
Panel live indicator
·
Generator start switch
The operator
control panel also houses the following:
1.
Siemen’s OP25 operator interface which allows
the operator to store, edit and retrieve up to 30 recipes for the proportioning
of different materials.
2.
Manual rate meters which display the speed of
the in feeds during manual operation.
3.
Mixer amp meter to display the current being
consumed during manual or automatic operation of the plant.
4.
A 40 character per line thermal printer
Ø Starter
Panels: There are 2 No starter panels, Panel 1 for mixer and
Panel 2 for all other starters.
·
Panel
No 1 is located behind the mixer and houses the
contactors, overload relays, timers and current transformers required to start
and run the mixer motor using a star / delta sequence.
·
Panel No 2 is located under the operator
control panel and houses all contactors, overload relays, MCB’s, Hitachi A.C.
inverters, Siemens S7300 PLC and all other components required to control the
plant.
Commissioning
Upon
completion each machine will be subject to a two stage commissioning process.
Ø
Dry
run at our works.
Ø
Full
production at a site close to our works
MANUALS
Full
operating and maintenance reference manuals are supplied with the machine.