Top Tower: Tomorrow and Beyond

TOP TOWER Gb_5 2013 29-05-2013 14:09 Pagina 1
TOP TOWER
Tomorrow and beyond
MIXING PLANTS
Sustainable road building and energy saving requirements are major

concerns for today’s road builders. Production equipment must be adapted
to suit all types of recycling and modern low-energy mixes, in addition to
incorporating the most recent developments designed to optimise
production costs. These concepts are behind the development of the Fayat
Group’s new generation asphalt plant – Top Tower.
2
TOP TOWER
Brimming with technology
Top Tower is the result of over 50 years’ experience in the development and
construction of hot-mix asphalt plants. It is also the synthesis of an ongoing dialogue
with our clients which has allowed us to incorporate all of their desired
improvements into this plant, resulting in a functional and highly efficient machine.
The entire life cycle of the plant has been re- At each stage, our engineers have focused
engineered and optimised, from the transportation primarily on developing innovative solutions
and assembly of the equipment to its routine designed to enable our clients to produce high-
maintenance, not forgetting production management quality asphalt mixes at the best cost.
and energy consumption.
Contents:
4 Focus
8 Specifications
19 The range
3
Focus
Innovation and sustainable development
Energy savings and the reduction of greenhouse gas emissions are at the heart of the
Top Tower design. All types of recycling and special or warm asphalt production
technologies are also offered.
Environment Energy savings

I the plant innovative design helps to reduce electricity I by positioning the filter above the dryer drum and
and fuel consumption, resulting in significantly redesigning the drying-filtering unit, we have
reduced CO2 emissions optimised the gas and recovered fines circuits
I atmospheric particle emissions comply with the I thanks to the shorter dryer-filter duct, the gases at
latest environmental regulations the dryer mixer outlet lose less heat and the burner
I the mixing tower is designed to incorporate total or consumption is significantly reduced
partial cladding, for even lower particle and dust I the treated fines are collected by gravity into the
emissions and reduced noise hopper positioned under the filter and are stored next
I the plant also has a smaller footprint to the fines weighing hopper, which reduces the
number of augers required and the overall electrical
consumption. These recovered fines are kept in a hot
environment and are reintroduced into the final
mixture at the highest possible temperature
I the screen and hot bins are insulated and cladded in
order to reduce energy losses
TOP TOWER
Special asphalt mixes
The mixer is preconfigured to accept all types of solid additives and fibres in bags or
big-bags and calibrated RAP, without reducing the plant production output.
Special asphalt mixes

Coloured or clear asphalt mixes can be easily
manufactured by adding pigments directly into the mixer
and via a dedicated clear binder line.
Special binders (modified bitumen and bitumen
emulsion) can be injected into the mixer via the
conventional bitumen line or via an additional line. They
are metered using the bitumen weighing hopper
supplied.
Warm-mix asphalt
The production of warm-mix or low-energy asphalt is
possible regardless of the technology used:
I introduction of wet sand into the mixer via the supply
circuit for cold RAP
I addition of zeolite crystals
I addition of liquid additives to the bitumen line in
order to reduce the binder viscosity
I production and injection of foam bitumen
Recycling
The crushed RAP is stored in and supplied from specific
RAP feed bins.
It is introduced into the dryer drum recycling ring and/or
directly into the mixer via a dedicated elevator. It may also
be dried separately in an additional parallel drum.
5
Focus
Transportation, assembly and ergonomics
The plant modular design and factory pre-wiring facilitate transportation and speed
up the assembly of its components.
The ergonomics of the plant have also been redesigned in order to improve user
comfort and safety.
Assembly sequence
Drying-filtering unit
1 Steel foundations (optional) 2 Dryer drum 3 Under-filter hopper,

filter and walkways
Mixing tower
4 Hot-mix asphalt storage 5 Mixing, metering, hot bins 6 Hot-mix elevator, filler silo
and cabin and screen stages and filler elevator
6
TOP TOWER
Improved ergonomics Quick assembly and transfers

I the layout of the plant has been optimised, thus I the plant modular design facilitates the
simplifying the movement of site equipment transportation and assembly of its components
I a spacious cabin offering a perfect view of the plant I the self-supporting steel foundations allow the plant
houses all of the electrical control cabinets to be assembled on a stabilised ground (2.5 kg/cm2),
I the stairs and walkways allow easy access to all for easier transfers
parts of the plant and its peripheral components I all of the tower cable tray is built into the structure
I wide access points allow for ease of movement in and walkways
complete safety I Option: decentralization of power panel control
signals
Easy maintenance
I maintenance operations are facilitated as there are
fewer servicing points
I thanks to our patented system, the screen meshes
can be quickly dismantled and replaced
I drum installation is faster as the rollers are very easy
to adjust
7
Specifications
General operation of the plant
4 6
5
3
2 8
1
1 Storage and metering of virgin aggregates 5 Mixing tower

2 Storage and metering of recycled materials I Hot elevator
3 Drying-filtering unit I Fines elevator
I Dryer drum and recycling ring (mix storage under mixer configuration)
I Under-filter storage silo I Screen
I Filter I Hot aggregate bins
4 Imported filler silo I Metering of components
I Mixer
6 Hot-mix asphalt storage
7 Binder storage tank
8 Control cabin and automation
8
TOP TOWER
Aggregate cold feeders
Storage of materials and recomposition of the gradation curve
Hopper Cold feeder

I basic capacity: 11 m 3
I volumetric metering (accuracy: ± 5%)
I loading width: 3.5 m I output from 6 to 150 T/h
I extension up to 18 m3
I from 1 to 12 hoppers
Options
Features I metering controlled by weight (accuracy: ± 2.5%)
I synchronisation of extractor outputs I antiadhesive coating
I LED indicators showing extractor operation I protective grids
and the need to reload the hopper I steel foundations
I reduced loading height
Specifications
Drying-filtering unit
The filter is now positioned directly over the dryer drum. The flows of gases and
materials have been optimised and the plant smaller footprint facilitates the
movement of site equipment and supply vehicles.
Dryer feeding belt

I reversible belt for easy calibration of the aggregate
metering devices
I a vibrating scalping screen can be fitted at the start
of the feeding belt
High-output counter-flow dryer drum

Design
I robotically arc-welded special steel tube
I shape and layout of the flights are designed to
optimise heat exchanges between combustion gases
and aggregates
I temperature probe for continuous monitoring of the
aggregates at the drum outlet
I aggregate outlet chute protected by a wearing plate
I air space insulation (rockwool insulation available as
an option)
Quick and easy drum position adjustment

I powered by 4 friction drives.
I drum can be adjusted simply by turning the external
adjusting screws, without stopping the drum
Drum E 220 E 250 E 270
Diameter 2,20 m 2,50 m 2,70 m
Lenght 9m 10 m 11 m
Output * 225 t/h 300 t/h 370 t/h

*at 3% moisture content, ΔT = 140°C
10
TOP TOWER
Burner
The burner/dryer unit has been designed with maximum
thermal efficiency in mind: for optimised fuel consumption
and lower CO2 emissions.
Design
I reliable closed total air burner, with a simple design
I automatic start-up and adjustment of the burner and
regulation of heating power according to output
temperature of aggregates
Versatility
I suitable for all types of fuels on the market: diesel,
heavy fuel oil, natural gas and brown coal powder
I mechanical or electronic adjustment of the air/fuel
ratio
Filter and storage hopper

Filter
I the elliptical shape of the aramid fibre bags reduces
the size of the housing while maintaining the same
filtering efficiency
Filter FM 375/400 FM 540 FM 576
Recovered fines storage hopper Filtering area 705 m2/750 m2 970 m2 1280 m2
I as the storage hopper is situated directly underneath Under-filter 25 m3 40 m3 38 m3

storage hopper 70 m3 80 m3
the filter, the fines can be collected via gravity
I the feed auger operates at constant efficiency,
regardless of the quantity of fines stored
11
Specifications
Mixing tower
With larger and more comfortable access points and a new patented quick screen
mesh replacement system, servicing the tower has never been easier. Gravity
metering of bitumen is another of the Top Tower new features.
Hot aggregate elevator

I sealed system for transporting hot aggregates from
the dryer drum to the screen
I self-adjusting chain tension using a counterweight
system
I easy and secure adjustment located at the foot of the
elevator via a lockout key
I totally sealed internal chain tensioning system
I easy to maintain marine-type double chain drive
system (single roller chain available as an option)
Vibrating 5 or 6-size screen

Direct access to the area behind the screen
The lateral position of the by-pass allows easy access to
the screen mesh, in order to facilitate maintenance.
Quick and easy mesh replacement
Easy access to the screen mesh, both from the front and
back. The lower screen mesh are in one or two parts
depending on the model, for quick and easy replacement
using a patented system.
Screen VM 200 VM 240 VM 280 Upgrading

Total area It is very easy to move up from a five to a six-size screen.
27,5/32,6 m2 32/38,4 m2 37/45 m2
(5/6 screen sizes)
Sand screen 6 m2 6,6 m2 8 m2

area Hot aggregate bins
Insulated to minimise heat losses, the hot aggregate bins
Hot aggregate 5 compartments 5 compartments 5 compartments
bins (6 available as (6 available as (6 available as are designed to accommodate one or two bypasses,
an option) an option) an option)
depending on the model.
By-Pass 1 separate 1 separate 1 separate
Hot aggregate 25 ton 25 ton 25 ton

bin storage (60 ton available (60 ton available (80-140 ton as
capacity as an option) as an option) an option)
12
TOP TOWER
Bitumen metering
Design
The bitumen gravity metering system allows you to
change binder types “on the fly” without wasting
materials.
The weighing hopper is mounted on 3 weighing scales for
maximum accuracy.
It is emptied via an electrically-heated butterfly valve and
activated by an electro-pneumatic cylinder.
Safety
The weighing hopper is equipped with a safety level
indicator linked to the cutoff for the metering pump.
Overflow pipes channel any overflow into the mixer.
Metering of aggregates and fines

Aggregates and fines/fillers are both weighed in a
dedicated weighing scale.
Recovered fines/ imported filler elevator

Double, sealed elevator with rubber belt and steel
buckets.
TOP TOWER 3000 TOP TOWER 4000

Weighing Number of Capacity Weighing Number of Capacity
hopper scales hopper bilance
Aggregates 3 2700 / 2900 kg Aggregates 4 3500 / 3600 kg

(direct/screened) (direct /screened)
Fines/fillers 2 410 kg Fines/fillers 3 500 kg
Bitumen 3 225 l Bitumen 3 350 l
13
Specifications
Mixer
This essential part of the Top Tower has been completely redesigned. With its new
shafts, honeycomb paddles and ingenious sealing system, this new-generation mixer
is now even more reliable and efficient.
Mixer
Design
The drive system for the twin-shaft mixer consists of two
motor-reducers which are directly connected to the shafts
and synchronised by splined couplings. The shafts and
paddles have a honeycomb design for optimal mixing.
Versatility
The mixer is ready to accept all types of additives in bags
or big-bags, in addition to recycled materials. It also
features a water vapour disposal system.
All types of modern asphalt mixtures can be produced
(modified bitumen, warm-mix asphalt, etc.).
Safety
Operators are protected by a lockout key system which
prevents access to the interior of the mixer when the plant
is operating.
Reliability
The mixer seals and shaft support bearings are situated
outside the mixer, allowing for easy access and easy
maintenance while offering unrivalled durability, as they
are not in direct contact with the hot mix.
The mixer also benefits from a centralised lubrication
system, which can be automated upon demand.
14
TOP TOWER
Recovered fines and imported

filler circuits
The desing of the new drying-filtering
unit optimises the recovered fines
circuit.
Recovered fines circuit

As the filter is situated immediately above the dryer drum,
the fines descend into the storage hopper via gravity for
collection. As the distance travelled by the recovered fines
has been minimised, they can be added back into the
mixture without losing heat.
Pre-separator
The filter integrated pre-separator collects the largest
fines, which are reintroduced directly at the dryer mixer
outlet.
Recovered fines circuit

I Hot-mix asphalt storage on side
The fines are transported to the weighing scale by an
auger that is directly connected to the under-filter
storage hopper.
I Hot-mix asphalt storage under mixer

Imported fillers
The recovered fines are transported to the buffer
I Hot-mix asphalt storage on side
hopper by a double fines/ filler elevator, and then
The weighing scale is supplied by a feed
transferred to the weighing scale by an auger
auger that is directly connected to the raised
storage silo.
I Hot-mix asphalt storage under mixer

The fillers are transported to the weighing
scale by a double fines/filler elevator.
I Alternative fines/filler circuits may be

designed upon demand in response to specific
configurations.
15
Specifications
Binder storage equipment
The binder storage equipment is designed for loading tanks and supplying
the asphalt plant in complete safety. Featuring vertical or horizontal tanks,
heated electrically or by oil, the equipment on offer is capable of storing all
types of hydrocarbon or synthetic binders.
Vertical, electrically-heated tanks

Specifications
I rockwool-insulated tanks
I heated by a thermostatically-controlled electrical
heating element
I continuous level indicator
I high-level safety indicator to prevent overflow
I purging vent
Single-compartment Dual-compartment
60 m 3
70 m3
La gamma delle3 cisterne verticali elettriche 3
80 m (35 + 35 m )
Thermo-fluid heated tanks

Thermo-fluid heated storage equipment can be supplied
with horizontal or vertical tanks. Horizontal tanks are also
available in mobile versions.
Vertical Horizontal
La gamme 60
desm3citernes thermofluides 50 m3
80 m3
Boilers
Different models of boilers are available, depending upon
the desired heating power. All are equipped with
automatic burners and can use different fuels: light fuel
oil, natural gas and LPG.
Model Heating power

La gamme des
200 chaudières 232 kW
400 465 kW
600 698 kW
800 930 kW
16
TOP TOWER
Asphalt plant management
The new CYBERTONIC control system manages all calibration, production and
maintenance operations. User-friendly and reliable, it guarantees the total
traceability of production parameters.
Ergonomics and safety

I new visual design
I starts up the entire plant in complete safety - each
motor can be controlled with just one click
I easily identifiable alarms
I safety system for temperature monitoring
I monitors the absorption of the main motors
Production management
I easy management of mix formulas and production in
progress
I integrated extractor calibration system
I complete control of the heating of aggregates
I complete management of binder storage tanks
(loading, storage, transfer, etc.)
I management of hot-mix asphalt storage silos
I possible to incorporate a description of materials
used
Data management and traceability

I history of quantities of materials used or produced
according to formulas and production dates
I production data can be exported in Microsoft®
EXCEL© or ACCESS© file formats
I data may be transmitted by ADSL modem
17
Specifications
Hot-mix asphalt storage

Several different capacities and configurations are available to satisfy all
requirements. Thanks to the modular design of the storage silos, up to 3 modules can
be combined, in an in-line or perpendicular configuration.
Design
I truck clearance for under mixer storage: 4 m (4.36 m I electrically-heated and insulated discharge doors
on steel foundations) I high-level indicator in hoppers (continuous level
I rockwool-insulated storage hoppers available as an option)
TOP TOWER 3000

Under mixer storage
Perpendicular version
Loading by shuttle bridge
25 to 320 ton
TOP TOWER 4000

Under mixer storage
Perpendicular version
Loading by shuttle bridge
30 to 580 ton
TOP TOWER 4000

Under mixer storage
In-line version
Loading by shuttle conveyor
25 to 580 ton
TOP TOWER 3000 e

TOP TOWER 4000
Storage on side
Loading by skip
and shuttle bridge
220 to 336 ton
18
TOP TOWER
The range
TOP TOWER 3000 TOP TOWER 3000 P TOP TOWER 4000 TOP TOWER 4000 P
Dryer drum diameter 2,20 m 2,50 m 2,50 m 2,70 m
Mixer capacity 3 ton 3 ton 4 ton 4 ton
Nominal production * 200 t/h 240 t/h 280 t/h 280 t/h**
*3% moisture, ΔT = 140°C
**6% moisture, ΔT = 140°C
Hot mix asphalt storage on side
Hot mix asphalt storage under mixer
19
www.marini.fayat.com
MARINI S.p.A. MARINI CHINA

Via Roma, 50 No 20 Huaxiang Road
48011 Alfonsine (RA) Langfang Economic and
ITALY Technical Development Zone
Tel. + 39 0544 88 111 Hebei 065001
Fax + 39 0544 81 341 CHINA
info@marini.fayat.com Tel. + 86 (0)316 6087001
Fax + 86 (0)316 6087002
MARINI INDIA PRIVATE LIMITED info@marini-china.com
301, Balazee Mall, www.marini-china.com
Opp. IIT Gandhinagar
Motera - Gandhinagar Road, FAYAT BOMAG Rus OOO
Ahmedabad - 380005 Khimki, Klyazma block, h. 1-g
Tel: +91 (0) 79 40194999 141400, RF,
Fax: +91 (0) 79 40194999 Moscow
www.marini.co.in RUSSIA
info@marini.co.in Tel: +7 (0) 495 287 9290,
Fax: +7 (0) 495 287 9291
FAYAT MIDDLE EAST F.Z.E. www.fayat.bomag.ru
Non contractual; please refer to conditions mentioned in the offers. The manufacturer reserves the right to make modifications without any obligation of forewarning 05/2013).
Jafza South FZS1AH03 russia@bomag.com
Jebel Ali Freezone
DUBAI FAYAT. RO s.r.l.
U.A.E. Loc. Timisoara
Tel. + 971 (0)4 88632333 Str. Calea Stan Vidrighin, nr. 18
Fax + 971 (0)4 88632334 Parter-SAD 2
marinime@emirates.net.ae Jud. Timis
Conform CF147730 Timisoara
FAYAT BOMAG POLSKA sp. z.o.o. ROMANIA
Ul. Krzywa 19 Tel / Fax +40 (0)356 439412
60-118 Poznan e-mail info@fayat.ro
POLAND
Tel. + 48 (0)61 853 15 66
Fax + 48 (0)61 855 18 62
m.klosowski@fayat.pl
www.fayat.pl
.
MARINI TÜRKIYE
1214, Sk. No:15 Ostim
Ankara 06370
TURKEY
Tel. +90 (312) 386 33 22
Fax +90 (312) 386 33 23
info@mariniturkiye.com

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TOP TOWER Gb_5 2013 29-05-2013 14:09 Pagina 1

Sustainable road building and energy saving requirements are major

Brimming with technology

Innovation and sustainable development

Environment Energy savings

Special asphalt mixes

Special asphalt mixes

Transportation, assembly and ergonomics

1 Steel foundations (optional) 2 Dryer drum 3 Under-filter hopper,

Improved ergonomics Quick assembly and transfers

General operation of the plant

1 Storage and metering of virgin aggregates 5 Mixing tower

Aggregate cold feeders

Storage of materials and recomposition of the gradation curve

Hopper Cold feeder

Dryer feeding belt

High-output counter-flow dryer drum

Quick and easy drum position adjustment

Drum E 220 E 250 E 270

Diameter 2,20 m 2,50 m 2,70 m

Output * 225 t/h 300 t/h 370 t/h

Filter and storage hopper

I as the storage hopper is situated directly underneath Under-filter 25 m3 40 m3 38 m3

Hot aggregate elevator

Vibrating 5 or 6-size screen

Screen VM 200 VM 240 VM 280 Upgrading

Sand screen 6 m2 6,6 m2 8 m2

Hot aggregate 25 ton 25 ton 25 ton

Metering of aggregates and fines

Recovered fines/ imported filler elevator

TOP TOWER 3000 TOP TOWER 4000

Aggregates 3 2700 / 2900 kg Aggregates 4 3500 / 3600 kg

Fines/fillers 2 410 kg Fines/fillers 3 500 kg

Bitumen 3 225 l Bitumen 3 350 l

Recovered fines and imported

Recovered fines circuit

Recovered fines circuit

I Hot-mix asphalt storage under mixer

I Hot-mix asphalt storage under mixer

I Alternative fines/filler circuits may be

Binder storage equipment

Vertical, electrically-heated tanks

Thermo-fluid heated tanks

Model Heating power

Asphalt plant management

Ergonomics and safety

Data management and traceability

Hot-mix asphalt storage

TOP TOWER 3000

TOP TOWER 4000

TOP TOWER 4000

TOP TOWER 3000 e

220 to 336 ton

Hot mix asphalt storage on side

Hot mix asphalt storage under mixer

MARINI S.p.A. MARINI CHINA

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