Asphalt in control

N2P Controls have created an asphalt plant automation system to enable plant managers to view analytical data and make informed decisions when running the plant.

Over the years, asphalt plant componentry has largely operated in isolation, adding a layer of complexity to on-site operations.

Integrating the variety of controls in an asphalt plant, from material feeding to loadout, has previously been a challenge and companies have sought to streamline the process.

Automation engineers N2P Controls is one such organisation. The company formed eight years ago after Niki Johnstone joined Blending Systems, a hardware/software company with more than 20 years’ experience in the asphalt industry.

The culmination of four years of research and development saw it launch its next generation Asphalt Plant Control System in 2016. The five-module system enables plant managers to make informed decisions based on analytical data from the plant’s field sensors.

Customers are able to choose exactly which modules they need, all of which connect to CATIE (Cloud Access Total Information Exchange), a cloud based product that stores and displays the plant data.

The MC404 is the first module, controlling what, how much, and when material is added to the mix, to ensure the perfect mix is made. It has built-in algorithms that compensate for different moisture levels, bitumen content, temperatures and other consideration variables to ensure production efficiency.

Niki Johnstone, Sales Manager at N2P Controls, says one of the great features of the MC404 is the feeder setup where managers can choose from a wide range of different feeder types at a click of a button. All the algorithms for a variety of feeders are built into the MC404.

“No matter how many or what type of feeders you have at a plant, this one piece of hardware and software can manage it all,” Mr. Johnstone says.

N2P Controls also offer two different plant control modules. The AC404, suited to continuous plants, and the AC303, suited to batch plants.

“These modules take the materials through the plant, interfacing with the burner controller, drying and then mixing the product before taking it to the hot bins for storage” Mr. Johnstone says.

The LC404 is the fourth module that deals with load-out control. Once the material is in the hot bins, this module controls the dispatch.

“It has a built-in ticketing system. You can input a job’s data and every time you load out the LC404 will record exactly how much has been dispatched to that job.”

Mr. Johnstone says this module is important for increasing safety on site.

“Within the LC404, we have a truck safety option where the hot bins doors are locked until the driver has acknowledged they are under the correct silo. Only then can the silo doors be opened,” he says.

The fifth module is the TC404 which is a controller for the bitumen tanks and their associated valves and pumps. This features built-in safety interlocks to stop tanks being overfilled, incorrectly mixing bitumen, timed heating, and includes automatic operation of valves and pumps.

The newest advancement for N2P Controls is its cloud software CATIE which connects to all of the modules to create an integrated record of data.

CATIE is supplied with a cellular modem so but if power or reception is lost, the software has the ability to store about 30 days of data.

When the modules are installed, N2P Controls engage the plant’s maintenance electrician to ensure familiarity with the control system, its wiring, and how it connects in the field.

Customers are also given full electrical drawings, the hardware coding, any documentation and a commissioning record.

“The big drive with these products is to give asphalt plant managers the opportunity to make data-driven decisions.”