Benninghoven granulator – turn old road surfaces into black gold

Recycling technologies are making inroads all over the world. This is chiefly due to the fact that the earth's resources are limited – and so that costs can be reduced. In road construction in particular, the advantages are obvious: When renovating and upgrading roads, cold milling machines remove asphalt base layers or these are broken up. This raw material is also known as “black gold”. This is taken care of by the recycling technologies from BENNINGHOVEN – in particular the MBRG 2000 granulator. The mobile plant separates asphalt up to a slab size of 1.8 m edge length into its individual components, without destroying the original grain structure. This gentle crushing technology is the perfect precondition for nearly 100% re-use of reclaimed asphalt.

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Another significant benefit of this technology is the substantially reduced generation of dust and fine particles – a decisive advantage which prevents clogging up of the transport paths and the parallel drum as far as possible. This ensures that the efficiency of the parallel drum is not significantly impaired, preventing it from even breaking down due to fine particles.

To achieve these results, Benninghoven has opted for a total of three crushing levels. In a one-person operation, the granulator is loaded with reclaimed asphalt via a wheel loader. During the first crushing stage, the plant breaks the asphalt slabs into smaller pieces via rammers, and presses them down onto the milling shaft. During the upwards motion, the rammers prevent bridge formation in the hopper. The milling shaft, featuring wear protection and special drill bits, achieves an output of 0 70 mm in the second crushing stage. Before the crushed material is conveyed to the screen, the MBRG 2000 removes any contained iron parts via a magnetic separator. After fractioning trough the screen, the oversize aggregate from crushing stage 3 is fed to the secondary granulator. The result of this stage is variable – analogous to the screen used – and is fed back to the screen through the oversize aggregate return.

Low wear, operating and follow-up costs ensure maximum efficiency. This is also supported by the direct loading with a wheel loader, since only one person is required, which means low personnel costs. The granulator is available as a stationary or mobile model, with the mobile version ready for operation in 30 minutes.

The system is operated via a touch panel display and features a user-friendly and clear structure. An integrated, self-regulating control system even enables temporary independent plant operation. This does not require the constant presence of an operator, which minimises operating costs significantly. For process optimisation, the frequency converter technology integrates a continuously adjustable speed control for the milling shaft. This continuous, self-regulating material feed ensures maximum throughput. A radio remote control can be optionally integrated.