Altair Case Studies Asphalt Dryer Optimization: Astec's Energy Saving Solution with Altair EDEM

	Asphalt Dryer Optimization: Astec's Energy Saving Solution with Altair EDEM Altair

Asphalt Dryer Optimization: Astec's Energy Saving Solution with Altair EDEM

Altair

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
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. Read More
About 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. Read More
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. Read More Log in to view content
Contents

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

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.

About 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.

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.

Impact #1	The implementation of the new V Flight design has made Astec's customers more competitive while reducing impact on the environment. The use of EDEM has not only allowed Astec to redesign their drum dryer for better performance, but it has also improved their understanding of aggregate behavior in the drying process. This newfound insight now helps Astec use EDEM to troubleshoot existing dryers in the field, where local aggregate properties can require custom solutions. The virtual environment provided by EDEM has proven to be a valuable tool in Astec's design process, offering a solution where direct observation and measurement were previously impossible.

Impact #1

The implementation of the new V Flight design has made Astec's customers more competitive while reducing impact on the environment. The use of EDEM has not only allowed Astec to redesign their drum dryer for better performance, but it has also improved their understanding of aggregate behavior in the drying process. This newfound insight now helps Astec use EDEM to troubleshoot existing dryers in the field, where local aggregate properties can require custom solutions. The virtual environment provided by EDEM has proven to be a valuable tool in Astec's design process, offering a solution where direct observation and measurement were previously impossible.

Benefit #1	The new V Flight design is more efficient, reducing drying time and fuel consumption.
Benefit #2	The use of EDEM allowed for virtual performance testing, shortening the design cycle.
Benefit #3	The ability to visualize particle flow and analyze particle-particle and particle-equipment interaction in a harsh environment where direct measurement and observation were impossible.

Benefit #1

The new V Flight design is more efficient, reducing drying time and fuel consumption.

Benefit #2

The use of EDEM allowed for virtual performance testing, shortening the design cycle.

Benefit #3

The ability to visualize particle flow and analyze particle-particle and particle-equipment interaction in a harsh environment where direct measurement and observation were impossible.

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Overview

Asphalt Dryer Optimization: Astec's Energy Saving Solution with Altair EDEM

Operational Impact

Quantitative Benefit