Phoenix Industries

Innovations in Asphalt Technologies

 

RAPpro Asphalt Plant

 

 

The RAPpro™ is a hot mix plant specifically designed to efficiently produce high quality HMA utilizing 100% RAP. This plant has a revolutionary multi-tube in-direct heated, continuous flow Patent Pending design. When coupled with PelletRAP™ rubberized binder material used as a RAP rejuvenator and mix modifier extremely durable, high quality mixes are produced.

 

RAPpro Hot Mix Plant

This is not a reconfigured/modified standard type hot mix plant. We’ve truly reinvented the way HMA is produced. The RAPpro’s energy efficient, stainless steel indirect heating and mixing design produces hot mix in an environment free of excess oxygen to help minimize further ageing of the RAP binder, and eliminating blue smoke typically generated by conventional plants when RAP content is too high. By removing the need for a bag house and heated liquid asphalt storage tank the physical and emissions footprint of the RAPpro eases the permitting requirements.

 

Recycling Without Compromising Mix Performance

Each ton of HMA produced with a RAPpro is rubber modified hot mix made with the PelletRAP additive, a unique pelletized material that is transported and stored at ambient temperature. While most rejuvenators just soften the aged binder, PelletRAP modifies it with a high quality PG binder blended and reacted with very fine crumb rubber made from recycled scrap tires and other light end additives specifically designed to revitalize badly oxidized pavement. This higher viscosity rubber modified binder also allows for an increased optimum binder content without drain-down, bleeding or rutting providing an increased film thickness on the aggregate so is more forgiving with variations in the old RAP binder.

  • RAPpro Dirve Motors
  • RAPpro Control System
  • RAPpro Stainless Steel Heating System

The RAPpro Market

Each year approximately 390 million tons of HMA are produced in the U.S. Of that, 125 million tons is used in the commercial/residential (non-agency) secondary market generally referred to as “Contractors Mix”. Much of this has less stringent requirements for work such as base mixes, driveways, parking lots and private commercial & residential development road ways. This contractors mix market is ideal for RAPpro plants. Because of the unique ability of the RAPpro to efficiently produce a high-quality mix from 100% RAP and reclaim the AC value and recycled aggregates, the mix production costs are far less than typical hot plant produced mix. This, along with lower operating and capital cost makes the RAPpro a very attractive option for the secondary HMA market. A RAPpro can also be used as a stand-alone unit, or included in-line of an existing hot plant to pre-dry/heat RAP to help increase production. Additionally, the RAPpro is a great unit for producing cold mix asphalt.  

 

 

The Economics of Using More RAP

100% RAP HMA Production

 

 

Environmentally Friendly

Hot mix produced by a RAPpro plant has the lowest carbon footprint of any asphalt pavement. We refer to it is as double “Green” pavement. By utilizing 100% RAP, this eliminates the need for virgin aggregates, thus saving natural resources and the enormous amounts of energy needed to process and transport this product to a hot mix site. In addition, the asphalt cement (AC) coating the RAP is reused. This greatly lowers the amount of AC that must be refined, transported and stored.

The extremely energy efficient heating system of the RAPpro plant is another big factor in lowering carbon emissions. Its Patented design heats only the hot mix being produced, whereas with a conventional drum mix plant a huge airstream is heated and discharged from the plant into the atmosphere. Also, with a RAPpro plant there is no need to have a heated asphalt cement storage tank. With a typical hot mix plant AC is stored at or above 300°F twenty-four hours a day. This expends a large amount of energy and the heated AC continually releases off-gasses.

By combining the use of 100% recycled asphalt and the energy efficient production process of the RAPpro we are leading the Green Pavement Revolution….

 

 

 

The RAPpro in Action

 

 

Report - Performance Based Design of 100% Recycled Hot-Mix Asphalt 

 

 

Plant - Parts & Service

Our parts and field service personnel are highly trained and have the resources to help our customers get their plants running and keep them running at peak performance.

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