Voyager™ 120 Portable Asphalt Plants

120 MTPH Portable Asphalt Plant

The Voyager 120 offers a compact, highly portable design. Unique for a plant in this class with the ability to run up to 30% RAP. In addition, it is backed by the best service support in the industry.

The ASTEC Voyager 120 is built around a counter flow drum featuring ASTEC v-fights. The v-flights provide greater uniformity of the aggregate veil during the drying process, which results in better heat transfer, a reduction of fuel use and increased productivity.

To enhance portability, a hydraulically driven swing out drag and batcher can be set and ready to go in about 10 minutes. Other features include a reverse pulse baghouse, a controls cab with fully automated PLC controls, gravity take-up with direct drive, air ride suspension and up to five (5) cold feed bins and two (2) RAP bins.

Features & Benefits

  • Compact and highly portable
  • Produces mix with up to 30% RAP content
  • Counter flow drum features ASTEC v-fights
  • V-flights provide greater uniformity of the aggregate veil during drying, which results in better heat transfer, a reduction of fuel use and increased productivity
  • The drag and batcher can be set-up in about 10 minutes
  • Modular design provides added flexibility

Transport Position

(shown with optional hydraulic package)


Voyager 120
KEY FEATURES

Counterflow
Unidrum® Drum

Drag Conveyor
and Batcher

Air Filtration
System

Automated
Control System

Bolt Together
Bins


Voyager 120
PLANT FEATURES


1.) Sloped Bin Walls

The very steep side walls of the bins promote smooth flow of the aggregate and prevent bridging of materials.


2.) Bolt Together Bins

Easily add additional bins to increase capacity (up to four bins maximum) with a bolt together bin design.

3.) Operator's Cab

Operate your plant in a climate controlled cab while using Astec's fully automated PM2 V control system to make your mix. Also available in a stand-alone cab design.


4.) Unidrum® Drum

The 5.5 ft (1.68 meter) counterflow Unidrum drum can produce up to 120 mtph with the addition of 30% recycled material. Astec v-flights come standard and provide greater uniformity of the aggregate veil.


5.) Drag Conveyor and Batcher

The pivoting drag conveyor and batcher attach to the frame during transport. Set the drag in place with a front end loader when it is time to start making mix. For even easier setup, optional hydraulic cylinders are available.


Voyager 120
MORE PLANT FEATURES


6.) Safety Handrails and Ladder

Safety handrails and ladder come pre-installed for added safety and ease of access. Ladders and handrails fold down for transport mode.


7.) Reverse Pulse Baghouse

17,600 CFM reverse pulse baghouse with 175 Aramid bags. Featuring a streamlined design for ultimate portability.


8.) Access Door

A convenient access door is located under the baghouse for easy maintenance access.

9.) Primary Collector

    (not shown in illustration)

The primary collector captures coarse dust as air flows into the baghouse. Since very few coarse particles enter the baghouse, it can collect small fines very efficiently. Removal of coarse fines in the primary collector also reduces wear on the bags.


10.) Recycle Inlet

Recycle inlet allows for producing mix with up to 30% recycled asphalt pavement. Optional recycle bins are offered in one or two bin configurations.


11.) Air Ride Suspension

Air ride suspension provides a smooth ride and allows for fast setup times by raising and lowering the drum into place.


12.) Dust Return System

Common drives throughout the dust return system simplify maintenance in the field. The fixed system results in fast setup times at the job site.


13.) Weigh System

The aggregate weigh system provides accuracy by using a 4-point system that includes an adjustable feed gate, weigh scale, S-type tracking system and gravity take-up.


Voyager 120
UNIDRUM® COUNTER FLOW DRUM

Achieving a quality asphalt pavement requires mixing materials correctly, with consideration given to providing sufficient time for blending. The superheated virgin materials must have adequate mixing time to bring it to temperature. The virgin aggregate, recycled asphalt, additives, baghouse fines, and virgin liquid AC must all be blended thoroughly to ensure everything is well coated and the gradation is uniform. The mixing chamber in the Unidrum mixer is an excellent mechanism to ensure adequate blending to achieve a quality mix.

1.) Material Enters | 2.) Feeder Flights | 3.) V-Flights Flights | 4.) Combustion Flights | 5.) Mixing Flights | 6.) Mix Exits

1.) Feeder Flights

Move material into the drying portion of the drum

Feeder flights guide aggregate as it enters the drum, helping it move efficiently toward the v-flights.

2.) V-Flights

Provide greater uniformity of aggregate veiling through the gas stream during the drying process, across a wide variety of mix designs and tonnage rates.

The v-shaped notch allows material to start pouring out of the flights at the beginning of each revolution. The material in the flight continues to pour out until the rotation is complete. This is what provides an even veil of material. The v-flight is also larger than a traditional flight, allowing it to carry the same amount of aggregate even with the notch.

U.S. Patent No. 9,835,374

3.) Combustion Flights

Prevent aggregate from impinging on the flame, while spreading the material to maximize radiant heat transfer.

The combustion flights are made of stainless steel, which lasts longer than traditional carbon steel. The flights overlap one another, creating a shield that minimizes radiant heat from hitting the drum shell, to keep it from overheating. The overlapping also reduces the opportunity for aggregate to get behind the flights and cause additional drum wear.


4.) Recycle Inlet

A collar around the drum allows entry of recycled asphalt (RAP), additives/filler, and baghouse dust into the mixing chamber, where they are blended with the virgin material.

RAP, recycled asphalt shingles (RAS), baghouse dust, and any additive/fillers enter the mixing chamber directly behind the burner nose, minimizing oxidation of the liquid asphalt from the burner flame and allowing preliminary blending before the virgin liquid asphalt is added.

5.) Liquid Asphalt Inlet

Liquid asphalt is injected after the virgin aggregate, the recycled material, and baghouse dust are mixed. Pre-mixing these materials allows a more even distribution of the liquid asphalt cement.

Liquid asphalt is accurately metered from the storage tanks directly to the liquid asphalt inlet inside the mixing zone.

6.) Mixing Flights

After virgin and recycled materials are combined and brought up to the proper temperature, liquid asphalt is injected. Mixing flights provide increased agitation for improved mix quality.

Unidrum mixing flights are engineered to comb through virgin and recycled materials to provide thorough blending before the mix exits the drum. The mixing flights are reversible to enhance mix coating if necessary.


Voyager 120
Fury™ 35 Burner

Astec's Fury™ burner provides a robust build and simple, accessible construction. Compared to other open-fired designs, the Fury™ burner achieves better emissions and fuel-efficiency by putting 50% more combustion air through the burner.

Model Rated Capacity kW
(with 25% XSA)
Nominal Aggregate Drying Capacity MTPH
(at 5% moisture)
Burner Air Capacity sm3/min Integral BlowerPower kW
PF 35 10,257 109 0.25 30

Above conditions are standard at 75o F (24˚C) at sea level. See detailed capacity, performance sheets for each size for more information and specific flows and pressures. Nominal aggregate drying capacity based on typical exhaust stack temperatures of 240o F (115˚C), 0.2 BTU/Lbm F specific heat in the aggregate. Burner maximum design capacity is 100% of rated capacity. Advertised numbers are achievable in some conditions, but not guaranteed.

Compact Flame Shape

The Fury burner cleanly and efficiently burns oil or gas. Its compact flame makes it easily compatible with the Unidrum dryer/mixer.

No Compressed Air

The Astec designed pre-filming fuel nozzle utilizes the combustion air from the high-pressure blower to atomize fuel. This eliminates the need for compressed air at the burner, and helps increase nozzle life.

Efficiency

Rapidly swirling, high-energy air is the key to the Fury™ burner's efficient combustion. The swirling air and flame are created by the fixed internal spin vanes, high-pressure blower, and high velocity nose.

Better Emissions

The Fury burner is designed to put 50% more combustion air through the burner than competitive designs with the balance of the combustion air drafted in around the burner nose. This means higher combustion quality, better emissions, and higher efficiency combustion throughout the entire firing range, than competitive burners.

Reliability

Each burner is also thoroughly tested before leaving the Astec burner facility to make start-up at your facility as fast as possible. For the most reliable oil light-off, even under cold and harsh conditions, the Fury™ burner is supplied with Astec’s exclusive heat tracing and insulation system on heavy oil burners.


Voyager 120
Plant Controls

PM2 V Continuous Mix Blending Control

  • Store unlimited mix designs on the removable hard drive.
  • Calibrate all scales, pumps and feeders from the application.

The powerful PM2 V system controls and monitors proportional control of aggregate feeders and the blending of asphalt and recycled material. The flexibility of the Programmable Logic Controller (PLC) allows the control system to be easily and cost-effectively upgraded as needs change.

PM2 V Includes: Software, console, personal computer, Windows operating system, removable hard drive, backup hard drive, Ethernet data port, and a UPS power supply in the event of loss of electrical power.