The Gencor Ultraplant

Gencor’s Ultraplant? concept is the most fuel efficient, environmentally clean and lowest maintenance design available to the hot mix industry.  A totally integrated drum concept that allows high production continuous mix with high-volume, high moisture recycle and the optional flexibility of feeding a batch tower, all in a unitized drum design.

Gencor''s Ultraplant? has taken top honors year after year for being the only hot mix plant with a positive volatile capture and recovery system that totally eliminates blue smoke, and asphalt odors from the process and feeds them to the combustion process as fuel.

As a result, Gencor plants have been accepted in the most stringent and environmentally sensitive areas of the country, producing high quality polymer and superpave mixes.

The Gencor Ultraplant? combines simple design with the most advanced control technology and massive heavy construction unmatched in the industry.  Backed by world class product support and training, Gencor Ultraplants provide contractors years of dependable long life with low cost- low maintenance operation for the highest profitability.

The Ultraplant? is available in stationary, skidded and portable configurations with production capacities from 100 to 800 tons per hour.

THE ULTRADRUM

The heart of the Ultraplant? is built around the unique patented counterflow Ultradrum? technology. The innovative Ultradrum? has been proven in 100''s of applications around the globe for producing high quality hot mix without degradation, cleanly and efficiently. Designed with all the heavy-duty features you''ve come to expect from Gencor, the Ultraplant? is without question the heaviest built and most rugged drum mix plant in the industry.

Standard features

Patented adjustable 5-way veiling flights for higher efficiency
Patented combustion T-flights reduce energy costs
Sweeping material inlet flights for even drum loading
Self-cleaning RAP inlet allows up to 50% RAP
Larger drum diameter reduces air velocity & dust carry-out
Friction driven trunnion rolls for lower noise, maintenance, and energy
Positive volatile reclaim system captures and destroys hydrocarbons

Advantages

Patented blue smoke system
Adjustable mixing flights
Total Air Low Nox Combustion

The isolated mixing section is located behind the burner so there is no chance of liquid asphalt coming in contact with the burner flame. This means there is no oxidation of the asphalt, no degradation of the mix, and no asphalt vapors entering the exhaust gas stream. Vapors generated in the mixing section are pulled through the burner by a patented volatile reclaim system and consumed as fuel. There are no odors or blue smoke emissions to pollute the environment. 
  
 
The Genco Ultra II burner is extended well inside the dryer for maximum efficiency and contact with the wet aggregates. There are not refractory chambers or high maintenance combustion ports. The Ultra II is the only burner to use compressed air to atomize each droplet of fuel for optimum fuel efficiency.

THE ULTRADRUM A.R.E. – Advanced Rap Entry

The patented Ultradrum which lead the asphalt industry, now takes the next leap forward with the introduction of Advanced Rap Entry (A.R.E.).

The ARE concept utilizes the gases and convective heat of the combustion zone to preheat and advance the release of internal moisture in the recycle pavement. This advanced release of moisture results in higher production due to a more even and staged release of water vapor in the drying process.

The material process flow starts at the virgin aggregate feed end of the Ultradrum where aggregates are quickly heated to temperature as they approach the burner. While the aggregates approach the combustion zone, the recycled asphalt (having previously been reduced in size) is introduced in the combustion zone, behind the specially designed combustion flighting.

This special flighting allows the RAP material to cascade around the combustion zone absorbing conductive and convective energy.  The heat from this action releases internal moisture before it enters the mixer.  RAP, virgin aggregate and baghouse dust combine in the mixing zone, away from the direct radiant zone.  Asphalt cement (AC) is then added into a thoroughly dried mixture of primary dust, virgin aggregate and RAP to form a fully coated and homogenous mix before exiting the drum.

Any hydrocarbons or steam vapors generated from the mixing process are captured by Gencor''s patented Volatile Reclaim System and returned to the burner as fuel.

Gencor has demonstrated the effectiveness of the new ARE option with some of the largest asphalt producers in the United States.  These plant run applications in excess of 600 tons per hour with as much as 50% recycle (300 tons per hour) of recycled asphalt.

STANDARD A.R.E. FEATURES

Patented adjustable 5-way veiling flights for higher efficiency
Patented A.R.E. combustion flights pre-heat recycle reducing tempertature and energy consumption
Sweeping material inlet flights for even drum loading
Self-cleaning RAP inlet allows up to 50% RAP
Larger drum diameter reduces air velocity & dust carry-out
Friction driven trunnion rolls for lower noise, maintenance, and energy
Positive volatile reclaim system captures and destroys hydrocarbons

SKIDDED ULTRAPLANT FEATURES

Drum erection skids – no foundation required
Screw jack legs
Mounted Primary collector with gravity dust return
Quick disconnect plug wiring

PORTABLE  ULTRAPLANT FEATURES

 Self-erecting Silo (no crane)
Optional Self-erecting ductwork
Hydraulic Drum erection
Drum skids – no foundations
Swing jack legs
Quick disconnect plug wiring