STG 91 successfully completed a comprehensive project for the revitalization, modernization, and automation of an asphalt production plant, with the primary objective of improving productivity, reliability, and process control.
The project included the refurbishment of the existing technological equipment, modernization of key production units, and implementation of a new automated process control system. Upon completion of all project activities, the plant was commissioned and is now operating safely, reliably, and with high production efficiency.
The Challenge
At the beginning of the project, the asphalt plant was operating with aging equipment and limited capabilities for monitoring and controlling production parameters. This resulted in operational difficulties, reduced efficiency, and increased maintenance costs.
The main objective was to restore the functionality of the facility while implementing modern automation and control solutions that would ensure reliable operation and improved production performance.
Scope of Work
During the project, the following activities were carried out:
- Inspection and analysis of the existing equipment;
- Refurbishment of technological units and mechanical systems;
- Repair and calibration of dosing systems;
- Modernization of the electrical infrastructure;
- Design and installation of new control and power panels;
- Implementation of an automated control system;
- Integration of measuring instruments and monitoring sensors;
- Configuration of production recipes and operating modes;
- Testing, calibration, and commissioning.
Automation and Process Control
The core of the project is the newly implemented automation system, which provides:
- Centralized process control through an operator workstation;
- Automatic dosing of aggregates, filler, and bitumen;
- Production recipe management;
- Real-time process monitoring;
- Production data logging and archiving;
- Increased accuracy and consistency of the final product.
The new software interface enables operators to easily monitor all critical process parameters and manage production from a single control point.
Results
Following the successful completion of the project, the asphalt plant now operates with improved efficiency, higher reliability, and significantly better process control.
Key benefits achieved include:
✔ Increased productivity
✔ Reduced downtime and equipment failures
✔ More accurate material dosing
✔ Lower operating and maintenance costs
✔ Improved quality control
