The RF City Star: an economical, mass-produced solution designed with operators’ needs in mind


Continuous solutions are renowned for their compatibility with mobile applications and are recommended for high-rate recycling.
The TSM (Dryer Drum Mixer)-type parallel flow solution is the flagship of the road and motorway-building industry and also allows for very high production outputs: 500 T/h or even 600 T/h for the TSM 28. On the other hand, the average recycling rate is limited to 25% or 30% in exceptional situations, such as for draining asphalts.
Nevertheless, Retroflux machines represent the sole alternative to 50% recycling and as a consequence, they are undergoing significant development. The two RF 500s in operation for Colas in northern Picardy and Eurovia’s major projects division are an example of this strategy. RF 400 hypermobile machines will also be brought into operation during 2007.
This trend of using versatile, high-rate plants is a recent phenomenon resulting from sustainable development policies becoming part of everyday practice.
Furthermore, a large number of operators have chosen this method for their fixed plants. This is an interesting market trend which, although not new, had somewhat fallen out of favour.

 

 



 


 

There is no such thing as a universal, perfectly adapted solution. Individual operators have to choose the most appropriate method for their needs according to their environmental and operating constraints.

The types of products and formulae, the importance of recycled materials and special products all have an influence on the decision. (See FOR N° 11, a special edition on hot-mix asphalts).

 

 

 We have observed several significant trends.

1.     The RF 200 machines, with production outputs of 220 T/h at 2% moisture content, or 150 T/h at 5%, are a particularly suitable solution for fixed plants of the mass-production type.  The RF City Star set up in continuous mode can obtain particularly attractive production costs, while offering extreme flexibility in the choice of formulations, using virgin or recycled materials. The optimum choice consists of equipping the machine with a battery of 7 to 8 feed bins, one or more of which is reserved for recycled materials, and also with several types of bitumen: 3 to 4 for the plants mentioned. Long-duration storage solutions, organised around 3 x 80-tonne facilities, help to increase the flexibility of operations and save energy. This type of modern, environmentally-friendly machine is also chosen where environmental concerns are of paramount importance, as shown by the cladding. These plants are designed like genuine factories and keep emissions and pollution to an absolute minimum.
2.     RF continuous plants make it easy to produce low-energy asphalts. TSM dryer drum mixer plants such as the RF are well suited to the production of low-energy asphalts, regardless of specific company processes, and comply with the new market requirements.


As a conclusion, batch-mix and continuous techniques coexist on the market. Criteria, choices and recommendations for hot-mix asphalts have been presented in publications such as the SETRA (Department of Technical Studies for Roads and Motorways) Guide. However, the manufacturing plants share the common characteristics of cladding and their mass-produced design.

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